Nexen WEB CONTROL TC250 User manual

(i)
TC250, TC450, and TC650
FORM NO. L-20184-A-0501
WEB CONTROL PRODUCTS
User Manual

(ii)
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.
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.
WARNING

(iii)
TABLE OF CONTENTS
Introduction---------------------------------------------------------------------------------------------------------------------------------------- 1
Controller Operation-------------------------------------------------------------------------------------------------------------------------- 2
Installation ----------------------------------------------------------------------------------------------------------------------------------------- 3
Control Panels ----------------------------------------------------------------------------------------------------------------------------------- 4
Electrical Connections------------------------------------------------------------------------------------------------------------------------ 8
Configuration ------------------------------------------------------------------------------------------------------------------------------------- 9
Calibration ---------------------------------------------------------------------------------------------------------------------------------------12
Test Run ------------------------------------------------------------------------------------------------------------------------------------------15
Maintenance and Testing ------------------------------------------------------------------------------------------------------------------18
Troubleshooting--------------------------------------------------------------------------------------------------------------------------------21
Replacement Parts --------------------------------------------------------------------------------------------------------------------------- 25
Tension Sensor Specifications-----------------------------------------------------------------------------------------------------------25
Warranties --------------------------------------------------------------------------------------------------------------------------------------- 26

1FORM NO. L-20184-A-0501
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.
The 50 Series Tension Controllers use digital logic to
maintain constant tension. Digital logic is used, rather
than the more conventional analog, to allow trim
adjustment of many control factors.
These Controllers receive an input signal from a tension
sensor and compare it with a desired or ‘set’ tension
level. The difference between the sensed and set signals
is called deviation. These controllers reduce the deviation
to zero by increasing or decreasing their output signal.
The sensed input signal is generated by two Nexen-
Nireco MB Tension Sensors. Sensing narrow webs, or
wire may be done with one Nexen-Nireco Tension
Sensor. Two Sensors are normally used to provide
sensing at both ends of a sensor roll. This eliminates any
error caused by a difference in tension from one side of
the web to the other.
The output signal of the tension control depends on the
model number. TC250 has a 4—20mA output. This
signal is used with the Nexen-Nireco Electro-Pneumatic
Convertor. It varies its output air pressure in direct
relation to the variable input signal from the TC250. This
output air pressure can be used to actuate a pneumatic
clutch, brake, or motor.
Output from TC650 is 24VDC (0—6A). This signal is
compatible with 24V electro-magnetic clutches, and
brakes.
TC450 provides a 0—10VDC output signal to interface
with variable speed motors.

2FORM NO. L-20184-A-0501
CONTROLLER OPERATION
Automatic control operation can be broken down into three parts (See Fig. 1).
FIGURE 1
THE LOGIC SECTION
The logic section drives the deviation to zero by perfor-
ming the following actions:
1. Proportional (P) control prevents overshooting when
the error is removed by integral control.
2. Integral (I) control determines if there is a deviation,
and acts to increase or decrease the output, to
correct the deviation.
3. For use with winding or unwinding controls, there is
also a Derivative (D) control available. This
maintains a constant loop gain as the wind or
unwind roll constantly changes diameter.
4. Inertia compensation also can be programmed in for
acceleration, deceleration, or both.
No. 1
Tension
Sensor
No. 2
Tension
Sensor
No. 1
Amplifier
No. 2
Amplifier
+
+
Tension Indicator
Amplifier
Section
PI
Control
Section
PI
Control
Action
Exponential
Operation
+
-
Current
Amplification
Auto
Man
Output
Percent
Indicator
Actuator
Set
Point
Manual
Control
THE SIGNAL ADDER SECTION
The signal adder section receives the input signal from
each MB Tension Sensor. These signals are 0—400 mV.
Each signal is amplified, and the amplified signals are
added. The added signal (0—10VDC) is displayed at the
tension indicator on the front panel of the controller, as a
total tension reading. The tension being sensed by either
sensor also may be indicated on this indicator by using
the selector switch located inside the controller door.
The added signal is then compared to the ‘Target’ value,
which is set with the Set Point Pot located on the front
panel of the controller. Any difference (deviation)
between the added signal and set point is transmitted to
the logic section.
5. Taper Tension control also can be programmed, in
both forward and reverse modes; and based upon
internal calculations, or an external roll diameter
signal.
6. An initial output during acceleration, can be set and
timed. This ‘Start’ signal can be a fixed value, or
vary as the roll diameter changes. The ‘Start’
function can be timed to last up to ten seconds after
the machine starts.
7. For unwinding application there is also a ‘Stop’
function, which allows the output to be increased
during a machine stop, to counteract roll inertia and
prevent run-on, slack web, or web spillage. The
‘Stop’ function also can be timed for up to ten
seconds.

3FORM NO. L-20184-A-0501
THE OUTPUT AMPLIFIER
The output amplifier receives the signal from the PI
section and amplifies it to the correct output signal level.
This output level is shown on the indicator located on the
front panel.
INSTALLATION
This unit is an electronic instrument and
should not be mounted where it will be
subjected to shock, vibration, excessive heat,
or moisture.
The controller can be shelf or floor mounted using the
mounting feet installed on the controller.
FIGURE 2
Mounting Dimensions
1. For wall mounting, remove mounting feet from the
controller base, then remove the rubber pads, and
reinstall the mounting feet in the rear mounting holes
on the sides of the controller.
2. For panel mounting, the same feet may be used as
above, only installed in the forward mounting holes
on the sides of the controller.
NOTE: The controller may be mounted at any angle.
POWER
AUTO START STOP POWER
AUTO
10.63
[270]
9.06
[230]
6.97
[177]
6.18
[157]
9.45
[240]
0.79
[20]
5.98
[152]
0.87
[22]
5.91
[150]
5.12
[130]
ON
OUTPUT
OUTPUT
MAN
ON
TENSION CONTROLLER
MODEL TC XXX
LB %

4FORM NO. L-20184-A-0501
AUTO START STOP POWER
OUTPUT
AUTO MAN
%
LB
TENSION CONTROLLER
MODEL TC450
OUTPUT POWER
ON ON
CONTROL PANELS
Tension
Indicator
AUTO
START
STOP
POWER
Mode Switch
Output Switch Power Switch
Output Indicator
Tension Set
Point Pot
Manual
Control Pot
FIGURE 3
Operational Status
Indicator Lights
FRONT PANEL (See Fig. 3)
1. TENSION INDICATOR (7 segments, 4 digits, with
decimal)
Displays actual web tension in pounds of total
tension.
2. OUTPUT INDICATOR (7 segments, 2 digits)
Displays controller output, as a percentage of total
capacity. Reads 0 to 99 percent. No display when
Output Switch is set to "OFF".
3. OPERATIONAL STATUS INDICATOR LAMPS
Shows operation status of the controller as follows:
a. POWER
Lights when the Power Switch is ON.
NOTE: The following lamps are used only
when the ‘MODE’ Switch located
on the front panel is set to ‘AUTO’.
When the switch is set to ‘MAN’,
all lamps except the POWER lamp
go off.
b. AUTO
Shows automatic operation status. The
output is being varied to maintain a
constant tension value at the set point.
c. START
Shows ready to start status. A stall torque
output is being delivered before the
automatic operation begins.
d. STOP
Indicates stop status. An increased
"STOP" level output is being delivered, to
eliminate slackening of web tension when
the machine is stopped.
5. MODE SWITCH
Selects Automatic or Manual Operation Mode.
6. TENSION SET POINT POT
Used when the Mode Switch is set to ‘AUTO’. Sets
the desired tension value. One graduation on the
pot equals 10 percent of the full scale value of the
Tension Indicator.

5FORM NO. L-20184-A-0501
7. MANUALCONTROLPOT
Sets output manually during operation in the Manual
Mode. It is used for setting the ‘START’ output
value during operation in the Automatic Mode.
8. OUTPUT SWITCH
Allows the output to be totally disconnected from
the controlled unit, when set to the ‘OFF’ position.
Normally set to the ‘ON’ position.
9. POWER SWITCH
Controls power to the Tension Controller. Power
Lamp illuminates when the Power Switch is set to
the ‘ON’ position.
FIGURE 4
INSIDE CONTROL PANEL (Side Face) (See Fig. 4)
Left Hand Side
1. DEC. T
DECeleration Timer (0 to 10 seconds).
2. DEC. L
Inertia compensation Level for DECeleration.
3. ACE. T
ACCeleration Timer (0 to 10 seconds).
4. ACE. L
Inertia compensation Level for ACCeleration.
5. DDW
Broken line deviation width (0 to 10% of full scale).
6. DDG
Broken line gain (variable from x 0 to x 1.0).
7. PAS. T
Not used.
8. PAS. L
Not used.
9. STOP/MIN
Sets MINimum ‘STOP’ output value (0 to 30%).
Prevent Stop output from dropping too low.
Right Hand Side
10. NO. 1 ZERO
Calibration pot for tension sensor.
11. NO. 2 ZERO
Calibration pot for tension sensor.
12. NO. 1 SPAN
Calibration pot for tension sensor.
13. NO. 2 SPAN
Calibration pot for tension sensor.
14 READ OUT SELECTOR
Selector switch to indicate the tension value at No. 1
Sensor, No. 2 Sensor, or the total tension on the
tension indicator.
0DEC. T
10
0DEC. L
10
0
0
0
0
0
0
00
0
0
0
0
0
0
0
0
ACE. T
ACE. L
DDW
DDG
PAS. T
PAS. L
STOP
MIN START
TIMER
STOP
TIMER
FILTER
STOP
TA PER
ZERO. L
I. GAIN
10
10 10
10
10
10
10
10
10 10
10
10
10
10
10
10
0NO. 1
ZERO
10
0NO. 2
ZERO
10
0NO. 1
SPAN
NO. 1
SPAN
NO.2
TOTAL
P. GAIN
NO.1
10

6FORM NO. L-20184-A-0501
15. P. GAIN
Proportional GAIN Pot.
16. I. GAIN
Integral GAIN Pot.
17. FILTER
Filter
18. START/TIMER
START/TIMER Pot, times duration of ‘START’ cycle.
19. STOP
STOP Pot. controls output during ‘STOP’ cycle.
20. STOP/TIMER
Sets duration of the 'STOP' cycle (0 to 10 seconds).
21. TAPER
Sets taper rate for taper tension control.
22. ZERO. L
ZERO-tension Level (0 to 30% of full scale).
INSIDE CONTROL PANEL (Top Face) (See Fig. 5)
1. FP 1, 2, 3, & 4
Check Pins
2. OT. FS
Not used
3. OT. BIAS
Not used
4. EST. FS
External Signal Trim Pot, (Full Scale), used to trim the
signal from an external analog diameter source.
5. D. MIN
MINimum Diameter pot, used to trim the signal from
an external analog diameter source.
6. TAP. FS
TAPer circuit trim pot (Full Scale), used to trim the
signal from an external analog diameter source.
7. DIA. FS
DIAmeter trim pot (Full Scale), used to trim the signal
from an external analog diameter source.
FIGURE 5
FP 4 COM
FP 3
FP 2
FP 1
OT. FS
OT. BIAS
EST. FS
D. MIN
TAP. FS
DIA. FS
0
10
10
10
10
10
10
0
0
0
0
0

7FORM NO. L-20184-A-0501
FIGURE 6
CONFIGURATION SWITCHES (Main PC Board "A")
(See Fig. 6)
1. SW1
Rotary switch for setting the second digit of the Full
Scale Range of the Tension Indicator.
2. SW2
Rotary switch for setting the first digit of the Full
Scale Range of the Tension Indicator.
3. SW3-1 and -2
Dip switches used to set the decimal point position
on the Tension Indicator.
4. SW3-3 and -4
Dip switches used to define the taper tension mode.
5. SW3-5
Dip switch used to determine controller correction
logic
6. SW3-6
Dip switch used to select use of an external analog
diameter signal.
7. SW3-7
Dip switch activates Zero Tension circuitry (web
break detection).
8. SW3-8
Dip Switch determines control basis for Start Level
output.
9. SW4-1
Sip switch enables/disables derivation calculation in
the control logic.
10. SW4-2
Dip switch selects either internal or external origin for
Set Point Signal.
11. SW4-3, -4, -5, & -6
Dip switches to determine the use of inertia
compensation during acceleration/deceleration, and
the basis for the correction.
12. SW5-1
Dip switch allows instant transition to Stop Level
output or a gradual transition.
13. Sw5-2, -3, & -4
Dip switches which are not used. Must always be
set to "OFF".
Configuration
switches on
the main board
Cover
SW4
SW5
SW2
SW1 SW3

8FORM NO. L-20184-A-0501
ELECTRICAL CONNECTIONS
FIGURE 7 FIGURE 8
NOTE: Always set the Power Supply Selector to the
power supply voltage used before making
electrical connections. (Power supply is factory
set to 240VAC.) Do not use a power voltage
that is greater than plus or minus 10%. (See
Fig. 8)
CAUTION
The sensor signal line and the control
signal line of the Controller and related
equipment use weak electrical signals.
To prevent signal interference and cross-
talk, arrange wiring as far from strong
electrical circuits as possible, or shield
the signal lines, or run signal in conduit.
Use crimp style terminals with insula-
tion for connecting wires to the terminal
block. Use 3mm screws for external
connections.
1. Use cable provided with the MB Tension Sensor to
connect sensors to the Controller. (See Fig. 7).
NOTE: Reverse GREEN and YELLOW wire when
using MB-11, and MB-25 with reverse wrap.
For single sensor operation, connect as
normal for sensor No. 1, and provide a jum-
per wire to short terminals No. 1, and No. 5.
2. Wire External Set Point Pot (if used) using Terminals
10, 17, and 18 (See Fig. 7).
3. Control Output at Terminals 11, and 12 varies
according to the model: TC-250 output is 4—20
milliamps, TC-450 output is 0—10 VDC, and TC-650
output is 0—24VDC.
4. The Tension Readout Signal varies with the Tension
Indicator reading, where 0 to 10VDC is equal to 0 to
Maximum full scale readout.
5. If an external analog signal is used, it is wired to
Terminals 21, and 25.
6. External contacts wired to Terminals 21 through 25
must be electrically isolated or use dry contacts to
prevent ground loops.
a. The Auto Relay closes to begin the Start
Time. When the Start Time elapses, the
Controller begins Automatic Control. When
the Auto Relay opens, the Automatic Control
ends, and the Stop Time begins. After the
Stop Time elapses, the Controller returns to
the Start output, and is ready to Restart.
b. The Memory Relay causes the memory to
store the output value present at the time the
relay closes. This relay should be timed to
make contact just as the Auto Relay is
opened and must remain open until after the
Controller returns to Start Status.
c. The Deceleration Relay enables the
deceleration circuitry. The deceleration
circuit remains enabled as long as the
Deceleration Relay is held closed.
}
}
}
}
}
{
{
Tension
Sensor
No. 1
Tension
Sensor
No. 2
GN
YL
RD
BK
GN
YL
RD
BK
WH
Controller
External Set Point
Power Supply (10V)
Control Output
Tension Readout
0 to 10V
Contact Input
External set point input
0to10V
Analog diameter
Input 0 to 10V
Auto
Memory
Decele.
Accele.
Zero tension
relay output
Ground
Power
Supply
+ 15V
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
+
_
+
_
+
_
+
+
_
External Set Point Pot
10
17
18

9FORM NO. L-20184-A-0501
d. The Acceleration Relay enables the
acceleration circuitry. The acceleration
circuit remains enabled as long as the
Acceleration Relay is held closed.
6. The Zero Tension Relay is rated at 30VDC, 0.2A; or
250VAC, 0.2A.
CONFIGURATION
SET FULL SCALE VALUE FOR THE SYSTEM (SW3-1
and -2)
1. Using Switches SW3-1, and SW3-2, set decimal
position(See Table 1).
2. Using Switch SW2, set the first significant digit of
the Full Scale Value (Any value 1through 9) .
3. Using Switch SW1, set the second significant digit
of the Full Scale Value (Any value 1 through 9) .
NOTE: Zero adjustment and span adjustment
cannot be made if a full scale value is set
that deviates greatly from the ratings of the
tension sensors. Set the full scale at, or
around the rated value of the tension sensor.
EXAMPLE 1:
Set the switches as follows if the full scale is
set to 25.0 pounds.
SW2: Set to 2.
SW1: Set to 5.
SW3-1: Set to OFF
SW3-2: Set to ON
EXAMPLE 2:
Set the switches as follows if the full scale is
set to 120 pounds.
SW2: Set to 1
SW1: Set to 2
SW3-1: Set to ON
SW3-2: Set to OFF
7. Connect AC Power at 100, 110, 120, 200, 220, or
240VAC, either 50 or 60 Hertz, to Terminals 29, and
30, with Earth Ground to Terminal 28.
Jumper wire must be properly positioned for
power supplied.
1
1
1
1
2
2
2
2
ON
ON
ON
ON
SW3-1, 2
OFF
OFF
OFF
OFF
0.10 to 9.90
1.0 to 99.0
10 to 990
100 to 1000
FULL SCALE
TABLE 1

10FORM NO. L-20184-A-0501
SET TAPER TENSION MODE (See Table 2)
1. Select desired mode from the following:
a. Internal Forward Mode
Used to apply a taper tension signal to a
winding clutch. Taper rate is based upon
internal calculations, and the position of the
Taper Tension Pot. This is the standard
Taper Tension Mode. When Taper Tension
is not desired, use the Internal Forward
Mode, and set the Taper Pot to “0”.
b. Internal Reverse Mode
Used to apply a reversed taper signal to an
unwind brake on a single zone machine,
such as a slitter. Taper rate is based upon
internal calculations and the position of the
Taper Tension Pot.
c. Forward/Diameter Mode
Used to apply a taper tension signal to a
winding clutch. Taper rate is based upon an
TABLE 2
OFF
ON
OFF
ON
OFF
ON
OFF
ON
SW3-4
OFF
OFF
ON
SW3-3
SW3
OFF
Internal
Reverse
Forward
Diameter
Internal
Forward
SET CONTROL DIRECTION (SW3-5)
Forward Control is the “Normal” direction; when tension
is too low the output increases, and vice versa. Reverse
Control is used to control devices (motor or clutch) that
are located before the web reaches the sensors. With
Reverse Control, the output increases when tension is
too high, and decreases when the tension is too low.
external analog roll diameter signal, and the
position of the Taper Tension Pot.
d. In all three Modes, the “0” position on the
Taper Pot yields no taper, taper rate
increases as the pot is rotated toward “10”.
2. Set Switches SW3-3, and SW3-4 to conform to the
Taper Mode selected above.
Set Control Direction with Switch SW3-5, “ON” for
Forward Control, and “OFF” for Reverse Control
SET EXTERNAL ANALOG DIAMETER INPUT (SW3-6)
An external analog diameter signal, in the range of 0 to
10VDC, can be used for Taper Tension or Stop Cycle
controls.
SET ZERO TENSION RELAY SWITCH (SW3-7)
A normally open relay at Terminals 26 and 27 closes
when tension falls below the value set with the Zero
Tension Pot.
Switch “SW3-7” controls this relay. Set it to “OFF” if the
Zero Tension Relay is not needed, or when performing
the Zero Calibration during the load cell calibration
procedure.
If an external diameter input is to be used, set Switch
“SW3-6” to “ON”. If no external diameter signal is to be
used, set the Switch to “OFF”.
Set Switch “SW3-7” to “ON” when the Zero Tension
Relay is needed, after the zeroing phase of load cell
calibration has been completed. Set the Switch to “OFF”
if the Zero Tension Relay is not needed.

11 FORM NO. L-20184-A-0501
SET START LEVEL MODE (SW3-8)
The output delivered during the Start phase of the
Automatic Control Mode is called the Start Level. Start
Level can be controlled in one of three ways.
In standard configuration, the Start Level is set with the
Manual Pot on the front panel. The Start Level can be
adjusted any time the Controller is in Start Mode and the
Start Status lamp is “ON”.
The Start Level can also be varied based upon an input
from an external analog diameter signal (see “Set
External Analog Diameter Input” above). In this mode the
Start Level varies as the roll diameter changes, this is
called the Variable Mode. The Manual Pot is used to set
the Start Level output at the maximum roll diameter, and
the external analog diameter signal is used to decrease
the output at smaller diameters.
ENABLE CONSTANT LOOP GAIN (SW4-1)
A derivative logic circuit is provided to maintain a
constant gain in the control loop as the roll diameter
changes on winding or unwinding operations. This circuit
is not need, and can be counterproductive, on internal
drives, such as nip rolls or s-wrap drives.
The Start Level can also be based upon the output at
the end of the previous Automatic operation. This is
called the Memory Mode. The output at the time the
Memory Relay is closed across Terminals 22 and 25 is
held in memory as long as contact is maintained. This
memorized value is multiplied by the setting on the
Manual Pot to determine the Start Level. The “0” to “10”
of the pot is equivalent to a “0” to “1” multiplier. Thus, if
the desired Start Level is 50 percent of the previous
output, set the Manual Pot at position “5”.
To use the Variable Mode, set Switch “SW3-8” to “ON”.
Set the Switch to “OFF” for Memory Mode, or for
standard configuration.
To enable the derivative logic circuit, set Switch “SW4-1”
to “ON”. To disable the circuit, set the Switch to “OFF”.
INERTIA COMPENSATION MODE
(SW4-3,-4,-5, and -6) (Unwind Brake Control)
During acceleration and deceleration of high speed
machines, tension in the web will often momentarily
decrease as the machine transitions from acceleration to
steady state speed, or from steady state speed to
deceleration.
The controller provides an inertia compensation circuit to
correct this problem. The inertia compensation circuit
increases the Tension Set Point during the final phase of
acceleration and during the initial phase of deceleration.
This artificially raised set point causes the output to
increase during the transition phase, thus eliminating the
drop off in tension.
There are three methods of controlling the inertia
compensation circuit:
SET POINT SELECTION (SW4-2)
TheSetPoint,ordesiredtensionlevel,isnormallysetwiththeAuto
Set Point Pot on the front panel. The Set Point can also be set
with a remote signal received at Terminals 17 and 18.
To use the Auto Set Point Pot, set Switch SW4-2 to “ON”. To
follow a remote signal, set the Switch to “OFF”.
1. The Set Point Method is simplest, and requires no
external diameter signal. The Set Point can be
increased between 0 and 50 percent with the “ACE.
L” pot during acceleration, or the “DEC. L” pot during
deceleration. This increased Set Point value
continues for a period of time as determined by the
“ACE. T” pot for acceleration or the “DEC. T” pot for
deceleration, both pots have a time duration of 0 to
10 seconds. This timing is initiated by a momentary
contact closure at Terminals 24 and 25 for
acceleration, and Terminals 23 and 25 for
deceleration.
2. The Set Point/Diameter Method is also based upon
the Set Point value but is modulated as the roll
changes in diameter. The “ACE. L” and “DEC. L”
pots set the maximum increase value during
acceleration and deceleration, this amount of

12FORM NO. L-20184-A-0501
STOP LEVEL FILTER (SW5-1) (Unwind Brake Control)
At times it is desirable to increase the output of the
controller from normal to the higher level dictated by the
Stop Pot, on a filtered curve rather than an immediate
change. On slower machines this can prevent over
tensioning during the transition from steady state running
to the Stop Level output.
To achieve this filtered increase to the Stop level, set
TABLE 3increase is only available at Full Roll Diameter. As the roll
diameter decreases, the amount of Set Point increase
also decreases, in direct proportion. The time duration of
the increased Set Point value is controlled by the relay
that is applied to Terminals 24 and 25 for acceleration,
and Terminals 23 and 25 for deceleration.
3. There is also the Output/Diameter Method which
acts directly upon the controller output. Here the output
can be increased by as much as 100 percent at the Full
Roll Diameter tapering off to no increase at the core. The
percent of increase available at the Full Roll Diameter is
controlled with the “ACE. L” pot for acceleration, and the
“DEC. L” pot for deceleration.
Set the desired type of inertia compensation for
acceleration with Switches SW4-3 and SW4-4. Set the
desired type of inertia compensation for deceleration with
Switches SW4-5 and SW4-6. Refer to Table 3 for
Switch settings.
123456
ON
OFF
SW4
Inertia Compensation Mode (deceleration)
56
34
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
No Compensation
Set Point Method
Set Point/Diameter Method
Output/Diameter Method
Inertia Compensation Mode (acceleration)
No Compensation
Set Point Method
Set Point/Diameter Method
Output/Diameter Method
CALIBRATION
The number of items to be calibrated depends upon the configuration of the controller. The minimum calibration,
necessary for all configurations, requires setting the Full Scale Tension Value of the controller, Zero Adjustment of the
Tension Sensors, and Span Adjustment of the Tension Sensors. Other calibration steps must be performed as
necessitated by the use of various optional functions selected during configuration of the controller.
Switch SW5-1 to “ON. For normal, immediate, increase
to the Stop level, set Switch SW5-1 to “OFF”.
NOTE: Switches SW5-2, SW5-3, and SW5-4 must
always be set to “OFF”.
FULL SCALE TENSION SETTING
The position of the decimal point and full scale value of
the Tension Indicator (also the whole system) is set with
Switches SW1, SW2, SW3-1, and SW3-2 (See
CALIBRATION, Set Full Scale Value for the System).
NOTE: Adjustment of Zero and Span can be impossible
if the Full Scale Value of the Tension Indicator is
greatly different from the tension measurement
capacity of the Tension Sensors. Calculate the
maximum tension measurement capacity of the
Tension Sensors, based on the web angle over
the sensing roller and the force capacity (See
TENSION SENSOR SPECIFICATIONS) for the
model Tension Sensor being used.

13 FORM NO. L-20184-A-0501
ZERO ADJUSTMENT ( See Fig. 9)
1. Set Power Switch to “ON”.
2. Make sure Sensor Roll is mounted to “MB” Sensors
as described in “MB Sensor Manual, L-20127.
3. Make sure the web has been removed, and no other
objects are sitting or leaning on Sensor Roll.
4. Set Switch SW3-7 to "OFF".
5. Set Selector Switch to “1”.
6. Adjust “No. 1 Zero” pot until Tension Indicator
displays “0”.
7. Set Selector Switch to “2”.
8. Adjust “No. 2 Zero” pot until Tension Indicator
displays “0”.
9. Set Selector Switch to “TOTAL”, Tension Indicator
should still display “0”.
10. Set Switch SW3-7 to "ON" if Zero Tension Circuit is
needed.
NOTE: Tension Indicator will not display negative
numbers, therefore be careful when
adjusting Zero Pot to prevent overshooting.
FIGURE 9
SPAN ADJUSTMENT
1. Thread a rope or narrow web over the Sensor Roll in
the normal web path. Secure one end of the rope.
Insure that the rope is at the center of the Sensor roll.
Hang a known weight (within the Full Scale range of
the system) on the other end of the rope (See Fig. 10).
2. Set Selector Switch to “No. 1”.
3. Adjust “No. 1 Span” pot until the Tension Indicator
displays one half the known weight applied to the
rope.
4. Set the Selector Switch to “No. 2”.
5. Adjust “No. 2 Span” pot until the Tension Indicator
displays one half the known weight applied to the
rope.
FIGURE 10
0DEC. T
10
0DEC. L
10
0
0
0
0
0
0
00
0
0
0
0
0
0
0
0
ACE. T
ACE. L
DDW
DDG
PAS . T
PAS . L
STOP
MIN START
TIMER
START
TIMER
FILTER
STOP
TAP ER
ZERO. L
I. GAIN
10
10 10
10
10
10
10
10
10 10
10
10
10
10
10
10
0NO. 1
ZERO
10
0NO. 2
ZERO
10
0NO. 1
SPAN
NO. 1
SPAN
NO.2
TOTAL
P. GAIN
NO.1
10
0
10
0NO. 1
ZERO
10
0NO. 2
ZERO
10
0NO. 1
SPAN
NO. 1
SPAN
NO.2
TOTAL
NO.1
10
Inside Control Board
(Side Face)

14FORM NO. L-20184-A-0501
CALIBRATION USING ONLY ONE SENSOR
1. Make sure that Sensor is wired correctly (See
ELECTRICAL CONNECTIONS, step 3), and that the
Jumper Wire is placed between Terminals 1and 5.
2. Perform Zero Adjustment (See CALIBRATION, Zero
Adjustment) for “No. 1 Zero”. It is not necessary to
perform “No. 2 Zero”.
3. Perform Span Adjustment (See CALIBRATION,
Span Adjustment, Step 1).
4. Set Selector Switch to "TOTAL".
5. Adjust "No. 1 Span" pot until the Tension Indicator
displays the known weight.
CALIBRATION OF THE ANALOG DIAMETER INPUT
NOTE: This Calibration must be performed if an Analog
Diameter Input signal is being applied at
Terminals 19 and 20
1. Set Switch SW3-6 to “ON”, to enable the analog
input circuitry.
2. Set Analog Diameter Input Signal at the maximum
diameter value (approximately 10V).
3. Adjust “DIA.FS” pot so that voltage measured
between “CP2” and “CP4” is 5VDC (See
MAINTENANCE AND TESTING, Testing, for
location of "CP2" through "CP4" on the Display
Board).
NOTE: It is not necessary to perform "No. 2 Span".
NOTE: This completes the basic calibration of the
Tension Controller. The following calibration
techniques are necessary only if special
functions have been selected during
configuration. All of these calibration
techniques are performed using the Pots,
and Check Pins (CP) located on the Top
Face of the Inside Control Panel (See
CONTROL PANELS, Inside Control Panel,
Fig. 5).
CALIBRATION OF THE EXTERNAL SET POINT
NOTE: If an External Set Point signal is being applied to
Terminals 17 and 18, the following calibrations
must be performed.
1. Set Switch SW4-2 to “OFF”. to enable the external
set point circuitry.
4. Set Analog Diameter Input Signal to the core
diameter value.
5. Adjust “D. MIN” pot so that voltage measured
between “CP3” and “CP4” is 0VDC.
6. Set Analog Diameter Input Signal at the maximum
diameter value.
7. Adjust “TAP. FS” pot so that voltage measured
between “CP3” and “CP4” is 5VDC.
2. Set the External Set Point signal to its maximum value
(approximately 10VDC).
3. See MAINTENANCE AND TESTING, Testing, for
location of "CP1" and "CP4" on the Display Board.
4. Adjust “EST. FS” pot so that voltage between “CP1”
and “CP4” is 5VDC.

15 FORM NO. L-20184-A-0501
TEST RUN
After completing the Configuration and Calibration, a Test Run should be performed. Make the Test Run with the lowest tension web to
beusedinnormaloperation. Thelowerthetensionintheweb,themoresensitiveitwillbetosystemstability. Ifsatisfactorycontrolisachieved
with a low tension web, there should be no problem with high tension webs.
NOTE: Prior to making the Test Run, check the following:
1. Ensure that no wires, cables, or air lines are in contact with the web, or rotating parts of the machine
2. Check that all rotaing parts of the machine move freely, that there is no mechanical binding, or excess
rotational friction.
3. Recheck all electrical connections.
4. Make sure Voltage Select Jumper is set to the correct AC supply voltage level (See "Electrical
Connections, Fig. 8).
5. If using the TC250 with the EN-40 Electro-Pneumatic Converter, make sure air system is correctly installed
(See Manual L-20127)
AUTOMATIC MODE, START STATUS
NOTE: If the Controller is in Start Status; the output is
the Start Level. The Start Status Lamp comes
“ON”.
1. In standard configuration, Start Level is controllable
with the Manual Pot.
2. The Start Level can be varied in the Variable Mode,
based upon an external analog diameter signal.
AUTOMATIC MODE, AUTOMATIC STATUS
NOTE: When the Start Time has elapsed, the Automatic
Mode will progress into its Automatic Status.
The Automatic Status Lamp comes “ON”.
1. While the Controller is in Automatic Status, the
actual tension in the web, as measured by the
Tension Sensors, is constantly compared to the
Tension Set Point as defined by the Auto Pot on the
front panel.
POWER ON
NOTE: When the Power is “ON”, the Tension Indicator
on the front panel displays the actual web
tension, as measured by the Tension Sensors.
1. When the power is turned “ON”, the Automatic or
Manual Mode is activated, depending on the
position of the Mode Switch.
2. Output Switch "ON". This switch must be turned
"ON" to provide an output at the Output Terminals,
and to provide a signal to the Output Indicator.
3. In Manual Mode; all Status Lamps except Power
Lamp are “OFF”. The output of the Controller is
varied with the Manual Pot.
4. In Automatic Model; one of the Status Lamps will be
“ON”, depending on the status of the Auto Relay
connected to Terminals 21 and 25 (See
ELECTRICAL CONNECTIONS, Step 6, a.).
3. Start Level can also be the memorized previous
automatic control level in the Memory Mode.
4. Refer to CONFIGURATION, Set Start Level Mode,
for Variable or Memory Mode.
5. When the Relay Contacts connected to Terminals
21 and 25 are closed, the time set on the Start
Timer begins.
2. If actual tension is not equal to the Set Point tension,
the Controller will vary its output to the clutch, brake,
or drive it controls, to cause the actual tension to
become equal to the set point.
3. The Set Point tension can be adjusted any time, while
controlling in the Automatic Mode, output will change
to follow the new set point.

16FORM NO. L-20184-A-0501
4. Response speed, or sensitivity, of the Controller can
be adjusted with the Gain Controls. Gain should
always be adjusted while the web is moving at
normal processing speeds, as increases in response
speed can be accompanied by a decrease in control
stability.
Control instability, or hunting, occurs when the output
of the Controller will not “settle down”, and the
reading on the Tension Indicator wanders. Four
common causes for hunting are:
a. Incorrect gain adjustment of the Tension
Controller.
b. Excess brake, clutch, or drive capacity.
c. Eccentricity of the unwind roll.
d. Excessive mechanical friction in the machine
components.
Decreasing the Proportional Gain adjustment can
help with all these problems. With Items b, c, and d,
if hunting cannot be eliminated with the gain controls,
correction of the mechanical problem is required.
5. Proportional Gain is controlled with the “P. GAIN”
pot on the side panel. Set the Proportional Gain to
position “5” as a starting value. Increase the gain
toward “10” if the Controller is reacting too slowly to
maintain constant tension. Decrease the gain toward
“0” if the controller is overreacting and correcting too
fast to maintain stability.
6. Integral Gain is controlled with the “I. GAIN” pot on
the side panel. Set the Integral Gain to position “5”
as a starting value. The “I. GAIN” pot is generally set
at the same value as the “P. GAIN” pot. Response
speed is increased by advancing the pot toward
“10”, and decreased by retarding toward “0”.
7. On high speed machines, during the transition from
acceleration to steady state running, and from steady
state running to deceleration, the inertia of the
unwind roll can cause a temporary decrease in
tension. Most this problem can be corrected through
use of the Inertia Compensation Circuitry (See
CONTROL PANELS, Configuration Switches).
Any residual instability or tension lag can be
corrected with the Deviation Detection Circuit. This
circuit senses large scale deviations between actual
and set point tension, then increases the correction
rate to remove the deviation faster.
8. The magnitude of deviation that will enable the
Deviation Detection Circuit is controlled with the
“DDW” pot on the side panel. The movement of the
pot from 0 to 10 varies the trigger point from 0 to 10
percent of Full Scale on the Tension Indicator.
EXAMPLE:
If “DDW” is set for “5”, a deviation of more
than 5 percent of Full Scale between actual
and set point tension will activate the
Deviation Detection Circuit.
Set the “DDW” pot to position “5” as a
starting value.
9. The increase in Proportional Gain caused by the
activation of the Deviation Detection Circuit is
controlled with the “DDG” pot.
The starting value for the “DDG” pot is 10
(maximum). To set a desired increase rate, set the
“DDG” pot for the inverse of the desired
magnification of the Proportional Gain.
EXAMPLE:
To apply a Proportional Gain that is twice
the normal Proportional Gain, whenever the
Deviation becomes more than 5 percent of
Full Scale.
a. Set “DDW” to graduation “5” (sets the
trigger point at 5 percent).
b. Set “DDG” to graduation “5” (the
inverse of 2 is 5).
10. The “Filter” pot located on the side panel controls
minor, low frequency fluctuations in tension which
cause constant changes in the Tension Indicator
reading. Set the “Filter” pot to “5” as a starting level.
To increase the suppression of the transient
readings, advance the pot toward “10”, to increase
the Tension Indicator sensitivity, decrease the setting
toward “0”.

17 FORM NO. L-20184-A-0501
AUTOMATIC MODE, STOP STATUS
When the relay contacts connected to Terminals 21 and
25 are opened, the Controller enters its Stop Status. The
Stop Status Lamp comes “ON”.
1. The output of the Controller increases to the Stop
Level as determined by the “Stop” pot on the side
panel. The Stop Level is based upon the output of
the Controller at the time the relay contacts are
opened. The Stop Pot controls the amount of
increased output needed to decelerate the unwind
roll to zero speed, without causing slackness in the
web tension.
2. The “0” to “10” span of the Stop Pot controls the
multiple applied to the output. The multiple varies in
a range of 1 times output (at “0”), to 3 times output
(at “10”). Set the Stop Pot to decelerate the web
smoothly, without losing tension. Too much output
increase will raise the tension level above the desired
level. A position of "3" (about 1.5 times increase) is
a good starting value.
3. The Stop Timer Pot determines the length of time the
Stop Level output is applied to the brake. The “0” to
“10” span of the Stop Timer Pot is equal to 0 to 10
seconds.
4. For midprocess control or wind up control, the Stop
and Stop Timer Pots are always set to “0”.
5. When the time on the Stop Timer Pot has elapsed,
the Stop Status Lamp will go “OUT”, and the Start
Status Lamp will come “ON”, indicating the
Controller is ready to begin the cycle again.
PROBLEMS DURING TEST RUN
Most problems are the result of incorrect installation of
the components, or miswiring. Recheck the following
points:
1. Is the Tension Sensor correctly sized for both the
tension induced load, and the tare weight of the
sensing roller and bearings? (See TENSION
SENSOR SPECIFICATIONS).
2. Are Tension Sensors installed correctly? (Refer to
Maintenance Manual L-20127)
3. Is the brake, clutch, or drive being controlled sized
correctly? (Refer to Manufacturers Specifications)
4. Are external electrical connections correct? (See
ELECTRICAL CONNECTIONS).
5. Is the relay contact needed for control of the
Automatic Mode wired to the Controller, and
correctly timed? (See ELECTRICAL CONNEC-
TIONS, Step 6).
6. Is the Power Supply Jumper set to the correct
terminals for the AC power being provided? (See
ELECTRICAL CONNECTIONS).
PROBLEM: Impossible to Achieve Zero Adjustment
1. Is the Tare Weight (The combined weight of the
sensing roller and bearings) too great for the Tension
Sensor being used? (See TENSION SENSOR
SPECIFICATIONS).
2. The Tension Sensor will not return to a display of “0”
when all force is removed. The Tension Sensor is not
mounted to a flat surface, or a side loading force has
been applied to the Sensors. Check mounting
instructions in Maintenance Manual L-20127
provided with the Sensors)
3. Disconnect the cables from the Tension Sensors,
and from Terminals 1 through 8. Check voltage at
Terminals 3 and 4, and at Terminals 7 and 8. Correct
voltage is approximately 6VDC, fluctuating. If the
voltage varies radically, from 6VDC, the Controller is
defective.
4. Short across Terminals 1 and 2, and across
Terminals 5 and 6. Attempt to achieve Zero
Adjustment. If adjustment can be made, the Tension
Sensor is defective. If the adjustment cannot be
made, or if the Zero Adjustment Pot is near the high
or low limit of its range, the Controller is defective.
5. Reconnect cables to the Tension Sensor and to
Terminals 1 through 8.