Montalvo X-3000ce-N User manual

Version 1.0 Pub. date: 9/23/02 v2
PID Web Tension Controller
INSTALLATION AND OPERATION INSTRUCTIONS
X-3000ce-N

9/23/02 3
Table of Contents
1 General Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
2 Technical Data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
2.1 X-3000ce-uw-N Electrical - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
2.2 X-3000ce-uw-N Mechanical - - - - - - - - - - - - - - - - - - - - - - - - - - 9
3 lnstallation and Setup - - - - - - - - - - - - - - - - - - - - - - - - - 11
3.1 Mechanical Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
3.2 Electrical Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
3.3 Quick Setup Guide - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
3.4 Complete Wiring Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - 26
3.5 Terminal Blocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28
3.6 Basic Wiring Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
3.7 Digital Input: Standard Functions - - - - - - - - - - - - - - - - - - - - - 33
3.8 Analog Signals: Standard Functions. - - - - - - - - - - - - - - - - - - 41
3.9 Input and Output: Special Functions - - - - - - - - - - - - - - - - - - 42
3.10 Digital Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43
3.11 Trim Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46
3.12 PID Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47
3.13 Operation of the Controller Menu - - - - - - - - - - - - - - - - - - - - - 48
3.14 Menu Tree - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50
3.15 Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 51
3.16 Hardware Adjustment and LEDs - - - - - - - - - - - - - - - - - - - - - 52
4 Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
4.1 Tension Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
4.2 Tuning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54
4.3 Regulation Parameter, Gain, Ratio - - - - - - - - - - - - - - - - - - - - 55
5 Operating the X-3000ce-N - - - - - - - - - - - - - - - - - - - - - - 56
6 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58

9/23/02 5
1 General Description
The Montalvo X-3000ce-N analog controller provides precise automatic control of
web tension. The X-3000ce-N is used in a closed loop that includes a load cell roll, a
motor, and a motor controller.
To properly set up and operate the X-3000ce-N and to take advantage of all its
available features, it is important to have a general understanding of the controller
and its place in the tensioning system (please refer to the diagram on the following
page). The control outputs of 4 to 20 mA and 0 to 10 volts DC enable the X-3000ce-N
to interface with a variety of variable speed drives to control web tensioning motors.
Load Cell Function
Two load cells (also called transducers) are normally used. The signals from the load
cells are summed together to indicate total web tension across the entire web. Each
load cell contains two strain gauges connected in a series. The two load cells are
connected so that the four strain gauges form a Wheatstone bridge configuration
supplied with + 2.5 VDC. The web tension transfers a force to the load cell roll,
changing the resistance values in the bridge. The resulting voltage change is
amplified and calibrated to display actual web tension.
Motor Controller and Motor Function
The motor controller converts the 0 to 10 volt signal from the X-3000ce-N into the
output appropriate to regulating the speed of the nip motor. The nip motor tracks the
line speed of the main drive motor.
Auto Mode Function (Closed Loop)
In auto mode, the speed of the NIP motor follows line speed. The signal from the load
cells is calibrated to display the actual web tension. When this signal is compared to
the desired tension (or setpoint), the regulator automatically trims the line speed until
the setpoint and actual tension are equal. Because the web itself is part of the
feedback loop, the X-3000ce-N can quickly compensate for changes in speed, and for
other factors that affect tension during the process.

6 9/23/02
1 General Description
Manual Mode Function (Open Loop)
There is no tension regulation in the manual mode. The speed of the NIP motor
follows the actual line speed plus or minus the amount of manual trim that has been
selected.
Load cell
X3000ce-N controller
Motor
Motor
Controller
Line speed Nip Speed
Type : X3000-ce-UW SN:3 455
Suppl y voltage: 115/230V 60/50Hz
Suppl ycurrent: <0.5A
TRIM %
0
50
20 80
100%
0
MANUAL/
AUTO
AUTO
0
60 60
+100-100
MANUAL
TRIM %
40
60
Nip Roller
PR018.dsf

9/23/02 7
General Function and Standard Operation
1. Manual Trim% Supplies a trim level (+/-) to the line speed when the controller is running in manual.
2. Auto setpoint In auto mode, the controller automatically regulates output so that actual tension
reaches the tension setpoint (appears on a scale of 0 to 100% on the meter).
3. Actual tension Displays actual tension on a scale of 0 to 100%.
4. Actual trim output
Indicates regulated trim output. Trim output (+/-) corrects the line speed so that actual
tension reaches the tension setpoint. Trim output appears as -100 to 100% on the
analog meter.
5. Manual / Auto switch Switches between manual and auto mode.
6. Green power LED Indicates that unit is on.
OPTIONS
7. Taper% The percentage of tension reduction at full diameter. (Use if controller runs as a
surface rewinder.) (See section 3.13.)
8. Material 1/2 Switches between material 1 and 2.
9. Calibration Low/High Switches between different tension scales.
OPTION:
-Taper %
-Material 1 / 2
-Cal. low/high
TRIM %
0
-50
+50
50
20 80
100%0
MANUAL/
AUTO
AUTO
0
60 60
+100
-100
MANUAL
TRIM %
MATERIAL
SELECT
50
20 80
100%
0
12
TAPER %
LOW/
HIGH
345
26
40
20
60
80
1
8 9
7
IL123.dsf

8 9/23/02
2 Technical Data
2 Technical Data
2.1 X-3000ce-N Electrical
AC Input 115 or 230 VAC +10% (ENG 60204) 48 to 62 Hz
Fuse Size (fuse not installed by factory)
115 V-160 mA T (slow-blowing type) Ø5 x 20 mm
230 V-80 mA T (slow-blowing type) Ø5 x 20 mm
(Both types are supplied)
Overvoltage Category
II (IEC 664)
2 kV in 1 minimum primary to secondary
Pollution Degree 2
Material Fire Classification 94V0
Maximum Power Consumption 12 VA
Maximum Fuse Input 10A
Noise Immunity EN 50082-2 industrial
Noise Emission EN 50081-1
Load Cell Supply ±2.5 VDC ±5%
Load Cell Input 0 to ±250m VDC
Zero Range (tare) 100% of load cell rating [max. 500mVDC (+/- 250 mVDC)]
Calibration Range Gain -11 to 480
Temperature Range
0 to 50° C (32 to 122° F) operating
-10 to 80° C (14 to 176° F) storage
Degree of Protection IP 54 / IP 10 for non-cabinet version
Regulator Outputs
0 to 10 VDC
Maximum load - 5 mA
4 - 20 mA / 0-20 mA
R
L
= 0 to 1000 Ω
Meter Outputs
0 to 100 µA
R
O
= 100 K Ω
0 to 10 VDC
Maximum load - 5 mA
Analog Input Voltage
0 to 10 VDC
R
I
= 100K Ω
Digital Input Voltage
15 to 30 VDC
R
I
= 10K Ω
Digital Output Voltage
24 VDC ±15
Current max 100 mA
Total Imax for all 4 outputs: 250mA
(If internal power supply is used).
Standards Designed to meet UL 508 and EN 60204

2.2 X-3000ce-N Mechanical
9/23/02 9
2.2 X-3000ce-N Mechanical
Dimensions (L x W x H) (Cabinet version) 330 x 260 x 163 mm (12.99" x 10.24" x 6.42")
Weight (Cabinet version) 4.7 kgs (10.38 lbs.)
Dimensions L x W x H (Non-cabinet version) 160 x 160 x 55 mm (6.3" x 6.3" x 2.36")
Weight (Non-cabinet version) 1 kg (2.2 lbs.)
Cabinet version Non-cabinet version
Typ e: X3000-ce-UW SN: 3455
Supply v olt age: 115/230V 60 / 50Hz
Supplycurrent: < 0.5A
TRIM%
0
50
20 80
100%0
MANUAL/
AUTO
AUTO
0
60 60
+100-100
MANUAL
TRIM%
40
60
IL121.dsf
R1 R2 R3 R4 R5 R6
Enter
-
+
Back Space
Down
Up
DI 6
DI 5
DI 4
DI 3
DI 2
DI 1
DI 7
DI 8
0
0
DO 4
DO 1
DO 2
DO 3
1234567891011121314151617181920212223242526272829
444546474849505152535455565758
L N PE
TENSION 0 %
Type :X-3000-N
Serial no : 960034
Voltage : 115V /230V AC
Current : <200 mA
220
110
30 31 32 33 34 35 36 37 38 39 40 41 4 2 43
11 12 13 14
IL126.dsf

3 Installation and Setup
9/23/02 11
3 Installation and Setup
3.1 Mechanical Installation
IL076.dsf
160 mm
160 mm
1234567891011121314151617181920212223242526272829
3031323334353637383940414243444546474849505152535455565758
148 mm
120 mm
55 mm
PEL N
R1 R2 R3 R4 R5 R6
Enter
-
+
Back Space
Down
Up
DO 4
DO 3
DO 2
DO 1
DI 8
DI 7
DI 6
DI 5
DI 4
DI 3
DI 2
DI 1
0
0
PE
230
115
TENSION 0%
L N
Type : X-3000ce-UW
Voltage : 115 / 230 V AC
Current : <200 mA
S. nr. : 3000
10 mm

12 9/23/02
3 Installation and Setup
3.1.1 Cabinet
The X-3000ce-N controller cabinet should be mounted in a dry place, away from any
source of heat. The mounting surface should be free of any excessive vibration. If
possible, the controller should be mounted at eye level and in a location accessible to
the operator.
Enclosure with doors open
Note: Plastic latch to hold door open
18.00" (457)
8.25"
(210)
10.23"
(260)
11.81 (300)
12.99" (330)
6.43" (163) 0.39" (10)
Space for mounting
bracket
6.82" (173)
Type:X3000-ce-UW SN:3455
Suppl y v ol t ag e: 115/230V 60/50Hz
Suppl ycurrent: <0.5A
TR IM %
0
50
20 80
100%0
MANUAL/
AUTO
AUTO
0
60 60
+10 0-100
MANUAL
TR IM %
40
60
IL125.dsf
Avoid mounting the
controller cabinet close to
drive controllers or any
other equipment that
produces large amounts
of EMI.

3.1 Mechanical Installation
9/23/02 13
3.1.2 X-3000ce-N Cabinet
Fig. 1
18°
18°
Fig. 2
20°
45°
Fig. 3 Fig. 4 IL037.dsf
Cutout dimensions: 320 x 250 mm

14 9/23/02
3 Installation and Setup
3.2 Electrical Installation
Warning: Electrical installation must be done by skilled personnel. Wiring must
meet all applicable codes and standards.
Refer to appropriate wiring and terminal descriptions for external connections.
Be sure that the voltage selector on the regulator PCB is in the correct position for the
voltage supplied.
Select the PCB fuse size according to the input voltage selected. The maximum
external fuse on the input is 10 A.
Note: 0VDC and PE are internally connected.
Note: Double-check accuracy of all wiring connections before applying power to the
controller. Damage caused by improper wiring is not covered under warranty.
EMC Requirements
Connect protective ground wire to terminal marked PE. Ground wires should be as
short as possible. Connect PE, mounting plate, and cabinet to a common ground.
Use only shielded cable for all external connections. For analog signals, terminate
shield at controller end; for digital signals, terminate shield at both ends. For cabinet
versions, connect shield to the cabinet at the point where the cable enters, whether to
a buss bar or to the connector housing. Keep the shield as short as possible (not to
exceed 10 mm or 0.4 inches). For best results, clamp the uninsulated shield directly
to the buss bar with the strain reliefs provided.
Keep signal cables away from supply cables or any wires that conduct high current.
For best noise immunity, run signal cables close to the machine frame, mounting
plates, or other grounded structures.
Safety Information
The following safety symbols appear in this manual.
Caution Electrical Hazard
Failure to follow installation
and setup instructions in
this manual may result in
equipment damage or
personal injury.
Failure to follow wiring
instructions in this manual
may result in equipment
damage, personal injury, or
death.

3.3 Quick Setup Guide
9/23/02 15
3.3 Quick Setup Guide
3.3.1 Introduction
The controller system will typically include the following components:
• 1 X-3000ce-N
• 1 motor controller
• 1 motor
• 2 load cells
Note: If the system includes other equipment, please refer to the appropriate
sections of the manual.
3.3.2 Mechanical Installation
1. Mechanical Installation
Mount all components on the machine.
The Quick Setup
Guide is intended to
help get the system up
and running in a short
period of time.
To maximize system
performance, please
read the entire
manual.
- Line speed.
- Start and stop
signal from
main cabinet
115/230 Vac
Power supply
X-3000ce-N
Load Cell 1 Load Cell 2
Motor
Controller
Type:X 30 00-ce - U W SN:3 455
Supplyvoltag e: 115 / 230 V 60/50Hz
Supplycurrent: <0. 5 A
TRIM%
0
50
20 80
100%0
MANU AL /
AUTO
AUT O
0
60 60
+100-100
MANU AL
TRIM %
40
60
PR032.dsf

16 9/23/02
3 Installation and Setup
3.3.3 Electrical Installation
1. Line speed signal
Connect cable from X-3000ce-N controller to the source of the line speed signal (see
diagram below):
Linespeed X3000-ce-N
0 - 10 VDC
Tension
+
Setpoint
Output
0 - 10 VDC
0 - 100%
0 - 100%
x
Trim
R6
0 - 10 VDC
X
(max. 20 VDC)
WD099.dsf
Cable from X-3000ce-N
to line speed signal
R1 R2 R3 R4 R5 R6
Enter
-
+
Back Space
Down
Up
DO 4
DO 3
DO 2
DO 1
DI 8
DI 7
DI 6
DI 5
DI 4
DI 3
DI 2
DI 1
0
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 6 1 7 18 19 20 2 12 22 3 24 25 26 27 2 8 29
44 45 46 47 4 849 50 51 52 53 54 55 56 57 58
L N PE
TENSION 45 %
Type : X/D-3000
Serial no : 960034
Voltage : 115V/ 230V A C
C u rr e n t : <2 0 0 mA
22 0
11 0
30 31 32 3 3 3 4 3 5 36 37 38 3 9 40 41 42 4 3
11 12 13 14
535455565758
0 - 10 VDC
Line speed
-
+
signal
WD100.dsf

3.3 Quick Setup Guide
9/23/02 17
2. Regulated output to motor controller
Connect NIP motor controller to X-3000ce-N, according to the diagram below:
3. Load Cells
Plug cables into load cells and connect cables to the controller (see diagram below).
Note: the above diagram shows the connection for the T-series only. If another type
of load cell is used, refer to Section 3.6, "Basic Wiring Instructions‚" p. 29.
4. Connection of start/stop signal from machine main panel:
Connect cable between the start relay of the NIP motor controller and X-3000ce-N.
The signal must come from a relay with the following function:
a) The relay must:
• energize when NIP motor controller starts running or moving
• de-energize when stop is pressed or when NIP motor controller comes to
a complete stop (zero speed signal).
15 16 17
0 V
4 -20 mA
0 -10 V
Cable from X-3000ce-N
to motor controller
Regulated
output:
R1 R2 R3 R4 R5 R6
Enter
-
+
BackSpace
Down
Up
DO4
DO3
DO2
DO1
DI 8
DI 7
DI 6
DI 5
DI 4
DI 3
DI 2
DI 1
0
0
1 2 3 4 5 6 7 8 9 10 11 1 2 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
44 45 46 47 484 9 50 5 1 52 53 54 55 56 57 5 8
L N PE
TENSION 45 %
Type : X/D-3000
Serial no: 960034
Voltage : 115V/230VAC
Current : <200m A
220
110
30 31 32 33 3 4 3 5 36 37 38 39
40 41 42 43
11 12 13 14
Motor
Motor
Controller
0 - 10 VDC
-
+
WD101.dsf
LOAD CELL 1
CABLE
0VDC
+2.5V
-2.5V
-INPUT
*RED
*WHITE
*BLACK
LOAD CELL 2
CABLE
0VDC
-2.5V
+2.5V
+INPUT
Connection for T-Series
40 41 42 43
11 12 13 14
40414243444546
11121314151617
*RED
*WHITE
*BLACK
*Colors refer to standard cables supplied by Montalvo
R1 R2 R3 R4 R5 R6
Enter
-
+
Back Sp ace
Down
Up
DO4
DO3
DO2
DO1
DI 8
DI 7
DI 6
DI 5
DI 4
DI 3
DI 2
DI 1
0
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 1516 17 1819 20 212223 2425 2627 2829
44 4 546 47 48 49 50 51 52 53 54 55 56 57 58
L N PE
TENSION 45 %
Type : X/D-3000
Serial no: 9 60034
Voltage : 115V/230V AC
Current : <200 mA
220
110
30 31 32 33 34 35 36 37 38 39 40 41 42 43
11 12 13 14
WD121.dsf

18 9/23/02
3 Installation and Setup
b) From this relay use the closing function (NC). The relay contact must be open
at stop and closed at start of operation (see wiring diagram below):
5. Connection of supply voltage to the X-3000ce-N controller
Connect cable between machine main panel and X-3000ce-N controller.
Select a supply voltage (230/115 VAC) that is turned on when the power to the
machine main panel is turned on. Then:
a) Turn off machine main panel.
b) Connect cable in the machine main panel.
c) Remove fuse from the fuse holder on the printed circuit board (PCB) if fuse
is already installed.
START
STOP
K100
K100
+24V
DI5
Start /
1 2 3 4 5 6 7 8 9 10
30 31 32 33 34 35 36 37 38 39
K100
11 (COM)
13 (NO)
START
NIP MOTOR
CONTROLLER
WD118.dsf

3.3 Quick Setup Guide
9/23/02 19
d) Connect cable in the X-3000ce-N (see diagram below).
e) Turn on machine main panel again.
f) Using voltmeter, check connection of terminal points L, N and PE before
inserting fuse.
g) Turn machine off.
h) Insert correct fuse and turn machine on.
L N PE
L N PE
220
230
115
10 MM Max.
R1 R2 R3 R4 R5 R6
Enter
-
+
BackSpace
Down
Up
DO 4
DO 3
DO 2
DO 1
DI 8
DI 7
DI 6
DI 5
DI 4
DI 3
DI 2
DI 1
0
0
1234567891011121314151617181920212223242526272829
444546474849505152535455565758
L N PE
Type : xxxxxxxxxx
Serial no : xxxxxxxx
Voltage : xxxxxxxxx
Current : xxxxxxx
230
115
30 31 32 33 34 35 36 37 38 39 40 41 42 43
11 12 13 14
Voltage Switch ( In 230 v Position )
Fuse Holder
FUSE SIZE:
115V -160mA T (slow blowing type) Dia. 5 - 20 mm
230V - 80 mA T (slow blowing type) Dia. 5- 20 mm
WD022.dsf

20 9/23/02
3 Installation and Setup
3.3.4 Web Tension Adjustment
1. Check that load cells are mounted and oriented properly. Refer to the load cell
installation instructions.
2. Before applying power, check that tension meter is mechanically zeroed. If not,
adjust the small screw below the meter scale until the meter reads zero.
3. Apply power to the controller and let it warm up for at least 10 minutes.
4. With web removed and no tension applied to the sensing roller, adjust
potentiometer R1 until analog tension meter reads zero. (If non-cabinet version is
used, see digital display: tension should read 0%.) If value is below zero, turn R1
clockwise; if above, turn counterclockwise.
Note: R1 and R2 are 25-turn potentiometers, so many rotations may be required.
5. Thread a rope over the center of the tension-sensing roller following the exact path
of the web. Make sure the rope extends at least one roller before and one roller
after the sensing roller. Make sure the rope does not pass over any dead bars or
non-freewheeling rollers. Fasten one end of the rope securely.
6. Attach a weight of known value to the other end of the rope. For best results, the
weight should be at least 25% of the analog meter's full-scale value. A tension
value below 0% with the weight hung indicates that the signal from the load cells
is reversed. In the event of such a reversal, switch wires 12 & 14 and 41 & 43 on
the terminal block. To eliminate friction, rotate rollers in the direction of the weight.
For cabinet and non-
cabinet versions of
the controller, see
section 2.2, p. 9.
MANUAL
MANUAL/
AUT O
AUTO
TENSION
OFF / ON
LOW /
HIGH
TAPE
R
20 80
50
20 80
50
20
50
OUTPU T
IL004.dsf
R1 R2 R3 R4 R5 R6
+
Back Spac eUp
DO 4
DO 3
DO 2
DO 1
0
0
Load cell
IL005.dsf