Nexen WEB CONTROL TCD 030 User manual

1FORM NO. L-20166-F-0304
Open Loop Tension Controller
TCD 030
FORMNO.L-20166-F-0304
WEB CONTROL PRODUCTS
User Manual

2FORM NO. L-20166-F-0304
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, Minnesota 55127
ISO 9001 Certified
Copyright 2000 Nexen Group, Inc.
Readthismanualcarefullybeforeinstallationandoperation.
Follow Nexen's instructions and integrate this unit into your system with care.
This unit should beinstalled,operatedandmaintained by qualified personnel ONLY.
Improper installation can damage your system or cause injury or death.
Comply with all applicable codes.
WARNING

3FORM NO. L-20166-F-0304
TABLEOFCONTENTS
Introduction----------------------------------------------------------------------------------------------------------------------------------------4
Installation ---------------------------------------------------------------------------------------------------------------------------------------- 5
Electrical Connections -----------------------------------------------------------------------------------------------------------------------7
Calibration -----------------------------------------------------------------------------------------------------------------------------------------8
Operation ------------------------------------------------------------------------------------------------------------------------------------------9
Specifications----------------------------------------------------------------------------------------------------------------------------------10
Parts List -----------------------------------------------------------------------------------------------------------------------------------------10
Mounting Dimensions-----------------------------------------------------------------------------------------------------------------------11
Warranties---------------------------------------------------------------------------------------------------------------------------------------12

4FORM NO. L-20166-F-0304
INTRODUCTION
Read this manual carefully, making full use of its explanations and instructions. The “Know How” of safe, continuous,
trouble-free operation depends on the degree of your understanding of the system and your willingness to keep all
components in proper operating condition. Pay particular attention to all NOTES, CAUTIONS, and WARNINGS to avoid
the risk of personal injury or property damage. It is important to understand that these NOTES, CAUTIONS, and
WARNINGS are not exhaustive. Nexen cannot possibly know or evaluate all conceivable methods in which service may
be performed, or the possible hazardous consequences of each method. Accordingly, anyone who uses a procedure
that is not recommended by Nexen must first satisfy themselves that neither their safety or the safety of the product will
be jeopardized by the service method selected.
Nexen’s TCD 030 tension control system has been
designed to maintain constant tension in a web at the
unwind or rewind position. TCD 030 is a total non-
contact type system, composed of the TCD 030, a
Proximity Switch, and Output Amplifier.
The Output Amplifier can be an EN40 type Electro-
Pneumatic Converter to convert the 4-20mA output of the
TCD 030 into a variable air pressure for control of an air
operated clutch or brake. The Output Amplifier may also
be an electrical power supply (i.e., Nexen’s MPB Power
Supply) to follow 0-10V output from TCD 030 and
modulate output to an electrical brake or clutch.
In automatic operation, the operator enters the initial roll
radius (full roll for an unwind, core for wind up), web
thickness, and tension set point. The Tension Controller
calculates the correct output to the Output Amplifier
based upon the set point and radius. As the roll builds
up on a wind up, the Tension Controller adds one web
thickness to the roll radius every time the Proximity Switch
indicates one revolution. On an unwind, it subtracts one
thickness for each revolution.

5FORM NO. L-20166-F-0304
100V
V
110V
V
200V
V
220V
AC
C
SELECT
UW, SW2, W
Voltage Jumper Wire
m, SW1, m
FIGURE 2
FIGURE 1
INSTALLATION
PREPARATION
1. Remove two Phillips head screws from top cover and
remove the cover.
2. Set Voltage Jumper Wire to correspond to AC
Voltage supplied to TCD 030. Select from 100, 110,
200, or 220VAC (See Figure 1).
3. On the metric model, set SW1 for "m"or "µ". This
determines the value of numbers entered in the "t" or
Thickness Rotary Switch located on the front panel.
The selection of "m"indicates the values will be
0.01-9.99 millimeters. The selection µ resets the
values on the "t"Switch to the range of 1-999
microns (µm). On the Inch model, set SW1 Switch
to µ.(See Figure 2).
4. Set SW2 to Wfor wind up clutch control or UW for
unwind control (See Figure 2).
5. Replace the top cover and reinstall the two Phillips
head screws.
POSITIONING
The TCD 030 is designed for easy panel mounting. Refer
to MOUNTING DIMENSIONS for dimensions, hole sizes,
and panel cut out dimensions (See Figure 7).
NOTE: The TCD 030 is an electronic component and
should be mounted in a shock and vibration free area
which has an ambient temperature of more than 32oF
[0oC] and less than 122oF [50oC]

6FORM NO. L-20166-F-0304
FIGURE 3
0.20
[5] MIN.
2
[51] MIN
0.40
[10] MAX
Proximity
Switch
FIGURE 4
PROXIMITY SWITCH MOUNTING
1. The Proximity Switch senses a customer supplied
ferrous metal (iron or steel) target. The minimum gap
between the Proximity Switch and the target is 0.20
inches [5 mm] and maximum gap is 0.40 inches [10
mm]. The target must be of sufficient mass to trigger
the Proximity Switch and may be mounted to the roll
shaft or any other mechanical component which
rotates at the same speed as the roll shaft, brake,
rotor, etc. (See Figure 3).
2. Mount Proximity Switch to a non-rotating member
using mounting bracket provided (See Figure 15,
Page 10).
NOTE: The Proximity Switch must be mounted in
such a position as to maintain the correct gap as
defined in Step 1.

7FORM NO. L-20166-F-0304
1
2
3
4
5
6
7
8
9
10
11
12
13
14
+
-
15
+
4 to 20V
-
+12V
SIG
COM.
Control
Output
Remote
START
(Momentary Contact)
STOP
(Maintained Contact)
Proximity
Switch
Brown
Black
Blue
Power
Supply
EN40
Electric
Clutch or
Brake
Air
Clutch or
Brake
+
0 to 10V
-
+
-
Power Supply
AC100, 110, 200, 220V
50/60 Hz
ELECTRICALCONNECTIONS
All wiring must be shielded or run through
conduit. Wire runs are to be no more than
300 feet. Connect all wires to terminal strip
on back panel of TCD 030 (See Figure 4).
The Remote Start Switch is optional, customer provided,
and momentary contact. A Remote Start Switch is built
into the TCD 030 front panel.
The optional Stop Switch is also customer provided with
maintained contact. Use with the unwind brake only.
For the Proximity Switch, use Horton Part Number
912068.
Wire the Proximity Switch to Terminals 5, 6, and 7.
1. Positive voltage wire (Brown) to Terminal 5.
2. Signal wire (Black) to Terminal 6.
3. Common wire (Blue) to Terminal 7.
FIGURE 5
Terminals 9 and 10 provide a 0-10V control signal for
output to a remote power supply to control an electric
clutch or brake.
Terminals 11 and 12 provide a 4-20mA signal which is
used to control an EN40 Electro-Pneumatic Converter
when a pneumatic control signal is needed for an air
brake or clutch.
Observe polarity when connecting the EN40
to the TCD 030.
Connect AC power rated 100, 200, or 220VAC, at 50 or
60 Hz, single phase to Terminals 13 and 14, with ground
to Terminal 15.
NOTE: Be sure Voltage Jumper Wire is connected for
correct voltage (See INSTALLATION).

8FORM NO. L-20166-F-0304
CALIBRATION
"r" Radius
Rotary Switch
"t" Thickness
Rotary Switch
Set Point Knob
Mode Switch
Gain Knob
Bias Knob
Start Switch
Stop
Potentiometer
Power
Switch
Power
Light
PG
Signal
Indicator
FIGURE 6
Output
Meter
1. Set Mode Switch to AUTO (See Figure 5).
The optional, customer supplied Stop Switch is used
with an unwind brake to increase brake torque during a
stop, to prevent coasting, and web spillage.
The additional braking effort is adjustable from one to
three times the running torque with the STOP
Potentiometer located on the TCD 030 front panel. Stop
torque is maintained as long as the Stop Switch is held in
the closed position.
NOTE: The Stop Switch in not used for clutch
control of a wind up.
2. Perform initial set up.
This operation must be performed when first placing
TCD 030 into service. It calibrates the TCD 030 to
deliver 100 percent output when the wind up or unwind
roll is at maximum radius and the Set Point Knob is at
maximum.
a. Rotate GAIN Knob counterclockwise for
minimum setting (See Figure 5).
b. Rotate BIAS Knob to mid-position setting
(See Figure 5).
c. Determine the maximum roll radius to be run
on the machine.
d. Select (in inches or millimeters) the maximum
roll radius on the "r"Radius Rotary Switch.
e. Rotate the Set Point Knob clockwise to
maximum.
f. Press the Start Switch (either the built in
start switch or the remote switch).
NOTE: The Start Switch is a momentary contact
switch; therefore, it will not stay depressed.
g. Adjust GAIN Knob so that the Output Meter
indicates 100 percent.
NOTE: 100 percent can not be achieved
with a maximum roll radius of 7
inches [180 millimeters] or less.
This completes calibration of the TCD 030. If the
maximum roll radius to be run on the machine increases,
the TCD 030 must be recalibrated. If 100 percent output
is desired at a smaller radius, the TCD 030 must also be
recalibrated to that size.

9FORM NO. L-20166-F-0304
OPERATION
MANUALOPERATION
1. Set Mode Switch to MAN (See Figure 6).
2. Set Point Knob controls Output from 0-100 percent
(rotate clockwise to increase and counterclockwise
to decrease).
NOTE: 0-100 percent is equal to 0-10VDC or 4-20mA,
depending on which output terminals have been
selected.
UNWIND BRAKE CONTROL
1. Set Mode Switch to AUTO (See Figure 6).
2. Dial full roll radius into the "r"Radius Rotary Switch.
This value is expressed in inches or millimeters.
3. Dial web thickness into the "t"Thickness Rotary
Switch. This value expressed in inches or millimeters.
NOTE: If the m position was selected, the "t" value is
expressed as 1-999 microns (m meters).
The Inch model of the TCD 030 is calibrated to
acceptthickness settings of 0.0005-0.0999 inches.
The Metric model can be calibrated to accept
thickness settings of 0.01-9.99 mm or 1-999 microns
(SeeINSTALLATION).
Power
Switch
Power
Light
PG
Signal
Indicator
Output
Meter
FIGURE 7
"r" Radius
Rotary Switch
"t" Thickness
Rotary Switch
Set Point Knob
Mode Switch
Gain Knob
Bias Knob
Start Switch
Stop
Potentiometer
4. Rotate Set Point Knob counterclockwise to minimum
setting.
5. Set GAIN Knob to calibration position as determined
in CALIBRATION.
6. Set the BIAS Knob to middle position (straight up).
7. Start the machine.
8. Press the Start Switch (either built in switch on TCD
030 front panel or the remote switch) (See
ELECTRICAL CONNECTIONS).
9. Rotate Set Point Knob clockwise until desired web
tension is reached.
10. Observe operation of the first roll.
a. If tension is correct at the beginning of the un-
wind and becomes slack as the radius
decreases, rotate the Bias Knob clockwise to
raise the tension back up to the desired level.
b. If tension becomes greater as the roll
decreases in radius, rotate the Bias Knob
counterclockwise until tension drops to the
desired level.
11. When roll is depleted, press and hold the Stop
Button until unwind roll has stopped.
12. Dial the roll radius of the next roll into the "r" Switch,
also change the "t"value if the web is a different
thickness.

10FORM NO. L-20166-F-0304
PARTS LIST
Main PC Board..............................................................................3085
Power Supply PC Board............................................................3086
Digital Switch.................................................................................3088
Output Meter.................................................................................3089
Potentiometer................................................................................3090
WIND UP CLUTCH CONTROL
1. Set Mode Switch to AUTO.
2. Dial the core radius into the "r"Radius Rotary
Switch. This value is expressed in inches or
millimeters.
3. Dial the web thickness into the "t"Thickness Rotary
Switch. This value is expressed in inches or
millimeters.
NOTE: If the "µ"position was selected, the "t" value
is expressed as 1-999 microns (µ meters).
4. Rotate Set Point Knob counterclockwise (minimum
setting).
5. Rotate Gain Knob to calibrated position as
determined in CALIBRATION.
6. Rotate Bias Knob to middle position (straight up).
7. Start the machine.
8. Press the Start Switch, either the built in switch on
TCD 030 front panel or the remote switch (See
ELECTRICAL CONNECTIONS).
9. Rotate Set Point Knob clockwise until the desired
web tension is reached.
10. Observe operation of the first roll.
a. If tension at the core is correct, but tends to
become slack, rotate the BIAS Knob
clockwise.
b. If the tension is correct at the core but
becomes tighter as the radius increases,
rotate the GAIN Knob counterclockwise.
11. Core radius value "r"must be changed if a new core
size is used.
12. Web thickness value "t"must be changed when a
new web of different thickness is run.
13. Taper tension can be achieved by slightly decreasing
the "t"value or BIAS Knob setting.
SPECIFICATIONS
TCD 030
Control Output.......................................................................0-10VDC
4-20mA
Constant Rating (Start and Stop Switches)..............DC15V, 30mA
Input................................................. “0”.......0-1VDC (10mA)
“1”...................10-12VDC
12VSystemRectangular Wave; One pulse
per revolution of the wind or unwind roll.
AC Power..................................................100, 110, 200, 220VAC
Power Consumption......................................................................5VA
Ambient Temperature..................................32o-120oF (0o-50o C)
Weight.................................................................3.75 Lbs. [1.7 kg]
Fuse............................................................................... 0.2A, 250V
PROXIMITY SWITCH
Supply Voltage..................................................................10-30VDC
PowerConsumption..................................................................<10mA
OutputSignal.........................................................“0”...<1VDC(10mA)
“1”.............>10VDC
Frequency Response..............................................................>50 Hz

11 FORM NO. L-20166-F-0304
MOUNTING DIMENSIONS
FIGURE 8

12FORM NO. L-20166-F-0304
WARRANTIES
Warranties
Nexen warrants that the Products will be free from any defects in material or workmanship for a period of 12 months
from the date of shipment. NEXEN MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND ALL IMPLIED
WARRANTIES, INCLUDING WITHOUT LIMITATION, IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED. This warranty applies only if (a) the Product
has been installed, used and maintained in accordance with any applicable Nexen installation or maintenance manual
for the Product; (b) the alleged defect is not attributable to normal wear and tear; (c) the Product has not been altered,
misused or used for purposes other than those for which it was intended; and (d) Buyer has given written notice of the
alleged defect to Nexen, and delivered the allegedly defective Product to Nexen, within one year of the date of
shipment.
Exclusive Remedy
The exclusive remedy of the Buyer for any breach of the warranties set out above will be, at the sole discretion of Nexen,
a repair or replacement with new, serviceably used or reconditioned Product, or issuance of credit in the amount of the
purchase price paid to Nexen by the Buyer for the Products.
Limitation of Nexen’s Liability
TO THE EXTENT PERMITTED BY LAW NEXEN SHALL HAVE NO LIABILITY TO BUYER OR ANY OTHER PERSON
FOR INCIDENTAL DAMAGES, SPECIAL DAMAGES, CONSEQUENTIAL DAMAGES OR OTHER DAMAGES OF
ANY KIND OR NATURE WHATSOEVER, WHETHER ARISING OUT OF BREACH OF WARRANTY OR OTHER
BREACH OF CONTRACT, NEGLIGENCE OR OTHER TORT, OR OTHERWISE, EVEN IF NEXEN SHALL HAVE
BEEN ADVISED OF THE POSSIBILITY OR LIKELIHOOD OF SUCH POTENTIAL LOSS OR DAMAGE. For all of
the purposes hereof, the term “consequential damages” shall include lost profits, penalties, delay images, liquidated
damages or other damages and liabilities which Buyer shall be obligated to pay or which Buyer may incur based upon,
related to or arising out of its contracts with its customers or other third parties. In no event shall Nexen be liable for
any amount of damages in excess of amounts paid by Buyer for Products or services as to which a breach of contract
has been determined to exist. The parties expressly agree that the price for the Products and the services was
determined in consideration of the limitation on damages set forth herein and such limitation has been specifically
bargained for and constitutes an agreed allocation of risk which shall survive the determination of any court of
competent jurisdiction that any remedy herein fails of its essential purpose.
Limitation of Damages
In no event shall Nexen be liable for any consequential, indirect, incidental, or special damages of any nature whatso-
ever, including without limitation, lost profits arising from the sale or use of the Products.
Warranty Claim Procedures
To make a claim under this warranty, the claimant must give written notice of the alleged defect to whom the Product
was purchased from and deliver the Product to same within one year of the date on which the alleged defect first
became apparent.
Nexen Group, Inc.
560 Oak Grove Parkway
Vadnais Heights, MN 55127
800.843.7445
Fax: [phone]
www.nexengroup.com
ISO 9001 Certified