Nexen RSTC1000 User manual

FORM NO. L-21204-D-0418
Tension Controller
RSTC1000
WEB CONTROL PRODUCTS
User Manual

FORM NO. L-21204-D-0419 2
In accordance with Nexen’s established policy of constant product improvement, the specifications contained in this
manual are subject to change without notice. Technical data listed in this manual are based on the latest information
available at the time of printing and are also subject to change without notice.
Technical Support: 800-843-7445
[phone]
www.nexengroup.com
Nexen Group, Inc.
560 Oak Grove Parkway
Vadnais Heights, MN 55127
Copyright 2018 Nexen Group, Inc.
Read this manual carefully before installation and operation.
Follow Nexen’s instructions and integrate this unit into your system with care.
This unit should be installed, operated and maintained by qualified personnel ONLY.
Improper installation can damage your system or cause injury or death.
Comply with all applicable codes.
DANGER
Manufacturers’ Declaration
In accordance with the CE machine directive 98/37/EC, Appendix II B
We hereby declare that the pneumatic/mechanical components described in this manual as well as their indi-
vidual components are intended, in the configuration in which they have been supplied, to be integrated into
a machine.
They must not be put into service until the machinery into which it is to be incorporated has been declared in
conformity with the provisions of the Directive mentioned above or its amendments.
All Nexen products are designed in accordance with the manufacturing directives for pneumatic systems ac-
cording to EN 983.
ISO 9001 Certified

3FORM NO. L-21204-D-0419
Copyright 2018 Nexen Group, Inc.
Table of Contents
Introduction ----------------------------------------------------------------------------------------------------------------------------------------4
Wiring Installation Guidelines --------------------------------------------------------------------------------------------------5
Installation -----------------------------------------------------------------------------------------------------------------------------6
Electrical Connections------------------------------------------------------------------------------------------------------------7
Network Connections -----------------------------------------------------------------------------------------------------10
Input/Output Descriptions -----------------------------------------------------------------------------------------------11
Setup --------------------------------------------------------------------------------------------------------------------------------- 13
RSTC to PC USB Communications ---------------------------------------------------------------------------------13
Display Window--------------------------------------------------------------------------------------------------------------13
Setup Window----------------------------------------------------------------------------------------------------------------13
Torque Actuator --------------------------------------------------------------------------------------------------------------14
Tension Zone ------------------------------------------------------------------------------------------------------------------14
Alarms ---------------------------------------------------------------------------------------------------------------------------15
Web ------------------------------------------------------------------------------------------------------------------------------15
Outputs -------------------------------------------------------------------------------------------------------------------------15
Signal Calibration-----------------------------------------------------------------------------------------------------------------16
Tension Signal Calibration------------------------------------------------------------------------------------------------16
Diameter Signal Calibration----------------------------------------------------------------------------------------------17
Run/Stop Signal Selection-----------------------------------------------------------------------------------------------17
Tuning ------------------------------------------------------------------------------------------------------------------------------- 19
RSTC Tuning Window -----------------------------------------------------------------------------------------------------19
Tuning Procedure------------------------------------------------------------------------------------------------------------19
Setpoint -------------------------------------------------------------------------------------------------------------------------20
Advanced-----------------------------------------------------------------------------------------------------------------------20
Taper Tension -----------------------------------------------------------------------------------------------------------------20
Network Port Setup -------------------------------------------------------------------------------------------------------------21
Operation----------------------------------------------------------------------------------------------------------------------------21
Manual Control ---------------------------------------------------------------------------------------------------------------21
Unwind Application ---------------------------------------------------------------------------------------------------------22
Splicing Unwind Application --------------------------------------------------------------------------------------------22
Wind Application ------------------------------------------------------------------------------------------------------------23
Splicing Wind Application------------------------------------------------------------------------------------------------23
Spring Disengaged Clutch-----------------------------------------------------------------------------------------------24
Mid-Process Application--------------------------------------------------------------------------------------------------24
Diagnostics --------------------------------------------------------------------------------------------------------------------24
Specifications----------------------------------------------------------------------------------------------------------------------25
Part Numbers ----------------------------------------------------------------------------------------------------------------------25
Troubleshooting -------------------------------------------------------------------------------------------------------------------26
Service Instructions--------------------------------------------------------------------------------------------------------------27
Appendix-----------------------------------------------------------------------------------------------------------------------------27
Warranty -----------------------------------------------------------------------------------------------------------------------------28

FORM NO. L-21204-D-0419 4
INTRODUCTION
Nexen RSTC Tension Controllers are used to control web tension, relying on load cell based tension sensors to measure
web tension. As a part of a tension control system, the RSTC measures the web’s tension and corrects tension errors
by sending a signal to change the torque output of brakes, clutches, and motor drive systems. The RSTC automatically
adapts to changes in inertia and torque as roll diameters change. This ensures constant/stable tension at all times and
allows for faster accelerations and decelerations for a more productive web machine. The RSTC does not require a
diameter sensor for constant tension applications and can adapt to spliced rolls of different diameters automatically
without readjustment.
Applications for the RSTC include unwinding, mid process, constant tension winding, and taper tension winding.
RSTC1000 SYSTEM
The RSTC1000 Tension Control System includes three components: the RSTC1000, RSTC Operator Panel (ROP), and
RSTC Communications Software. The RSTC1000 tension controller can be used as a slave on a Modbus RTU network.
Because of this capability, many Human Machine Interfaces (HMIs) and Programmable Logic Controllers (PLCs) can
communicate directly with it. Web machines that already have a compatible HMI control panel do not require the ROP.
The Communications Software features setup, tuning and diagnostics functions and is available from the Nexen website:
www.nexengroup.com.
MOUNTING
The RSTC is designed to mount inside the machine’s control cabinet alongside other controllers, PLCs, relays, etc. Small
size and its DIN rail mounting capability make installation fast and easy. Pluggable connectors simplify wiring as they can
be removed for convenient access to terminals. Only requiring a commonly available 24 VDC supply, the RSTC requires
no hazardous voltages.
Figure 1

5FORM NO. L-21204-D-0419
WIRING INSTALLATION GUIDELINES
This product is designed to minimize the effects of ElectroMagnetic Interference (EMI) on its operation, but as
with any electronic device, proper installation and wiring methods are necessary to ensure proper operation. By
doing so, the interference from external effects such as electrical line spikes, electrical noise, static electricity, etc.
will be minimized. The following methods outline wiring installation guidelines to protect your system:
• All input and output signal and sensor cables must
be shielded with the shields tied to earth ground at
one end. In case of very high frequency (MHz range)
electrical noise, both ends of the shield need to be
tied to earth ground.
• Keep cable length and unshielded leads as short as
possible. Think of them as antennae for noise.
• Use power line filters to suppress interference on
the AC voltage lines that power the unit.
• Place a resistor-capacitor network (snubber) across
inductive coils such as relays and solenoids in order
to stop electrical interference at the source (See
Figure 2).
• Isolate signal and sensor cables from cables
carrying AC voltages, power for high current loads
or relays and solenoids. Either relocate the signal
and sensor cables away from other cables or use
grounded metal conduits to shield them. This will
reduce the potential for noise interference between
the signal and sensor cables and the other noisy
cables.
Figure 2
For environments that experience high levels of static electricity follow these additional guidelines:
• Remove the static charge from material carrying it.
In the case of webs that carry static charges, there
are static charge removal products available such as
static bars and ionized blowers.
• Ensure that sensors and machine frames are
grounded to earth through a low impedance path.
• Wrap grounding tinsel around sensors and cables
that are close to the source of the static electricity
and ground the tinsel to earth.
• Tie all signal and sensor cable shields directly
to earth ground without passing through the
electronic device. This will help prevent high voltage
interference from coupling into other circuits within
the device.
Relay
R
C
Snubber
Snubber applied across relay coil

FORM NO. L-21204-D-0419 6
INSTALLATION
Figure 3
Mount the RSTC within a user-supplied enclosure, typically
the machine’s controls cabinet. The RSTC can be mounted
on 35 mm DIN rail or panel mounted (Refer to Figure 3).
CAUTION
Mount the RSTC in a shock and vibration free
area with an ambient temperature of less
than 140°F [60 C] and more than 32°F [0 C].
149.0
[5.87]
110.3
[4.34]
13.9
[0.55]
13.9
[0.55]
35.0
[1.38]
75.0
[2.95]
134.1
[5.28]
7. 4
[0.29]
7. 4
[0.29]
1.1
[0.04] 2X
60.2
[2.37]
R2.2
[0.09]
4X

7FORM NO. L-21204-D-0419
ELECTRICAL CONNECTIONS
Figure 4 Electrical Connections
* Power cable must be less than 10 m [390 in].
** There are two terminals that require a low impedance connection
to earth ground.
† For improved signal integrity in noisy environments, tie cable
shields directly to Earth Ground.
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
Control Signal Shield & Earth Ground** †
Control Signal Common
Splice B Input
Splice A Input
Run/Stop Input
Signal Shield †
Common
Remote Tension Setpoint Input
+12 VDC Excitation
Common
Diameter Sensor Input
+24 VDC Excitation
Load Cell Shield †
Excitation Common
+6 VDC Excitation
–Sensor Signal
+Sensor Signal
Excitation Common
+6 VDC Excitation
–Sensor Signal
+Sensor Signal
+24 VDC
Common
Earth Ground**
Alarm 1 Out
Alarm 2 Out
Alarm Common
† Alarm Shield
0-10 VDC
Output Common
4–20 mA
Output Common
† Signal Shield
0–10 VDC
Output Common
4–20 mA
Output Common
† Signal Shield
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
RSTC
USB
Control
Inputs
Power
Input*
Control
Output B
Control
Output A
Load
Cell 1
Load
Cell 2
Power Indicator
Reset
Network Port and
Indicators

FORM NO. L-21204-D-0419 8
FIGURE 5 Alarm Output Connections
Alarm Out
RSTC
RSTC
To PL C Input
VDC Common
VDC* (See Specifications for
maximum voltage.)
R(See Note.)
User Supplied
User Supplied
NOTE: The minimum value of resistor (R) is 7 x VDC.
VDC Common
VDC*
(See Specifications for
maximum voltage.)
(See Note.)
User Supplied
User Supplied
R
External Indicator
VDC Common
VDC *
(See Specifications for
maximum voltage.)
(See Notes.)
User Supplied
User Supplied
External
Coil
1N4002
Alarm Output Tied to External Indicator
Alarm Output Tied to PLC Input.
Alarm Output Tied to External Inductive Coil
Alarm
Common
Alarm Out
Alarm
Common
RSTC
Alarm Out
Alarm
Common
NOTE: The minimum value of Resistor (R) is equal to VDC divided by the maximum
current limit of the Indicator. Maximum current limit of the indicator must be less
than the current limit of the alarm output (See Specifications for maximum current).
NOTE: Be sure the current requirement of the External Coil does not exceed the
capability of the alarm output (See Specifications for maximum current.
Any inductive load such as relay coil must have a 1N4002, or equivalent, diode
across it as shown.
* To isolate the Alarm Output signals use power
supply that is separate from the RSTC power supply.

9FORM NO. L-21204-D-0419
CFL or Single Full Bridge Strain Gauge Load Cell
24 25 26 27 28 29 30 31 32 33 34
No. 2
Sensor
No. 1
Sensor
BRWGBRWG
Dual MB Single MB
24 25 26 27 28 29 30 31 32 33 34
Sensor
BRWG
Cable
Shield
Add
Sensor 2
RBW
SW Sensor Colors
–Vex+VexVsig
24 25 26 27 28 29 30 31 32 33 34
Sensor 1
BRW
Cable
Shield
Add
Jumpers
SW Sensor Colors
–Vex+VexVsig
SW or Half Bridge Strain Guage Load Cell
24 25 26 27 28 29 30 31 32 33 34
Sensor
BRWG
Cable
Shield
Add
CFL Sensor Colors
–Vex+Vex–Vsig+Vsig
Figure 6 Control Input Signals
NOTE: To isolate the Control Input Signals, use a power
supply that is separate from the RSTC power supply.
Figure 8 Load Cell Connections
40 41 42 43 44 45 46
Cable Shields
+12 to + 24 VDC
DC Common
Run/Stop
Splice A
Splice B
32 33 34 35 36 37 38 39
1–5 kΩ
Potentiometer
NOTE: Potentiometer can be replaced with analog
voltage signal by connecting analog signal (0-12V
maximum) to terminal 37 and signal common to
terminal 38.
Figure 7 Remote Tension Setpoint

FORM NO. L-21204-D-0419 10
NETWORK CONNECTIONS
Modbus RS485 Port: This port is for communicating with
the RSTC1000 using the Modbus RTU protocol over a
2-wire or 4-wire RS485 physical layer (Refer to Figure 10).
Communication Indicator: Yellow indicator, visible
through top cover, will illuminate whenever the RSTC1000
communicates over the RS485 port.
Communication Error Indicator: Red indicator, visible
through top cover, will illuminate whenever the RSTC1000
detects an error with a received message.
Figure 10 Modbus RS485 Connections
DC Common
TxB+
TxA–
RxB+
RxA–
1
2
3
4
5
6
DC Common
RxB+
RxA–
TxB+
TxA–
LTR
RSTC1000
PLC or HMI
Four Wire RS485 Connections
LTR
DC Common
TxB+
TxA–
RxB+
RxA–
1
2
3
4
5
6
DC Common
Non-Inverted Tx/Rx
Inverted Tx / Rx
RSTC1000
PLC or HMI
Two Wire RS485 Connections
+24 VDC
DC Common
TxB+
TxA–
RxB+
RxA–
1
2
3
4
5
6
Red
Black
White (RxB+)
Yellow (RxA–)
Blue (TxB+)
Orange (TxA–)
RSTCROP
ROP - RSTC
LTR
Termination resistors added externally
- Recommend 150 Ω, 0.5 W
LTR = User supplied line termination resistor
Cable Recommendation:
- Shielded
- 24 awg is always sufficient
- 4 wire system, 1000 m (9600 baud)
- 2 wire system, 500 m (9600 baud)
Figure 9 RSTC1000
RSTC1000
USB
RS485
Power Indicator
Reset
Communication Error
Indicator
Communication Indicator