Re T-two User manual

.ENG.
T-two
Tension control with load cells or dancer roll
USER’S MANUAL

Re S.p.A. T-two –standard model
Rev. 05/15 I
Contents
Warnings ...................................................................................................................................................1
Detailed description of the application ...................................................................................................2
Interface.....................................................................................................................................................3
Remote control of the states by PLC ......................................................................................................4
Setting up the regulator............................................................................................................................5
Regulator set-up and parameters menu (P.1) ...................................................................................5
Detailed description of the regulator set-up and parameters menu (P.1) ............................................7
Function 1 –Torque in STOP state (%)............................................................................................7
Function 3 –“Proportional” regulator in AUTO state.........................................................................7
Function 4 –“Integral” regulator in AUTO state ................................................................................7
Function 5 –“Derivative” regulator in AUTO state ............................................................................7
Function 6 –ACC delay state ...........................................................................................................8
Function 7 –“Proportional” regulator in ACC state ...........................................................................8
Function 8 –“Integral” regulator in ACC state...................................................................................8
Function 9 –“Derivative” regulator in ACC state...............................................................................8
Function 11 –DEC delay state .........................................................................................................8
Function 12 –“Proportional” regulator in DEC state .........................................................................8
Function 13 –“Integral” regulator in DEC state.................................................................................9
Function 14 –“Derivative” regulator in DEC state.............................................................................9
Function 16 –“Proportional” regulator in STOP state .......................................................................9
Function 17 –“Derivative” regulator in STOP state ..........................................................................9
Function 18 –Tension (kg)/Position (%) setpoint .............................................................................9
Function 19 –Torque in EMERGENCY state (%).............................................................................9
Function 32 –Dancer roll air pressure (%) .......................................................................................10
Function 33 –Tension/Position alarms mode...................................................................................10
Function 34 –Tension/Position alarm 1 threshold............................................................................11
Function 35 –Tension/Position alarm 2 threshold............................................................................11
Function 36 –Tension/Position reading filter....................................................................................11
Function 37 –Position of the decimal point ......................................................................................11
Function 38 –Remote SETPOINT acquisition..................................................................................12
Function 39 –Remote SETPOINT filter............................................................................................12
Function 40 –Remote acquisition of the DANCER ROLL AIR PRESSURE.....................................12
Function 41 –Remote DANCER ROLL AIR PRESSURE filter.........................................................12
Function 48 –Retain in STOP mode the last torque value used in AUTO mode..............................12
Function 97 –Entering the “Admin”password...................................................................................12
Function 98 –Saving the “Admin” password ....................................................................................13
Guarantees ................................................................................................................................................14

Re S.p.A. T-two –standard model
Rev. 05/15 1/14
Warnings
The present manual is for device fitters and operators. It provides indications on the intended use of the
device, technical specifications and instructions for installation, adjustment and use.
This manual is an integral part of the device and must be kept until the device is decommissioned. It
reflects the technical state of the device at the time of its sale.
The plant builder may include the present manual in the documentation for plant use.
Re S.p.A. reserves the right to update its production and/or manuals without updating products already
sold and previous manuals.
Since the device forms part of a plant, the plant builder is responsible for ensuring that all parts comply
with the laws in force in the country in which it is installed.
The device must be fitted and adjusted by qualified technical personnel.
It may be moved manually.
Information about device recovery
-In European Union member states
The device falls within the electrical and electronic equipment category, which must be disposed of
not amongst undifferentiated urban waste, but through separate collection. Therefore, at the end of
the device’s lifetime, it must be disposed of in conformity with the European standards adopted in the
member state in which it was installed.
WEEE (Waste Electrical and Electronic Equipment) may be intended for individual, collective or
mixed collection and recovery systems at designated centres (for more information contact the
relevant local authorities) or may be returned to the distributor when a new item of equipment is
purchased. This eliminates or reduces potentially negative effects on the environment deriving from
improper use of the equipment or parts of it.
For correct waste management, the relevant authorities promote the reduction of final waste disposal
by means of re-use, recycling and other forms of recovery to obtain raw materials from waste.
In the event of illegal disposal of WEEE, offenders will be punished in accordance with the sanctions
established by the member state in which it was installed.
-In non-EU countries
Recovery and final disposal of the device must be carried out in conformity with the standards in
force in the country in which it was installed. It may be advisable to take into account the information
provided regarding European Union member states.
The device bears a clear, visible and indelible indication allowing identification of the
manufacturer and the separate collection symbol (symbol on side).
This symbol, showing a wheelie bin with a cross through it, unequivocally indicates that
the device was released after 13.08.2005 and that it must be subject to separate
collection.

Re S.p.A. T-two –standard model
Rev. 05/15 2/14
Detailed description of the application
The following is a functional block diagram of the T-two device application:
The T-two regulator uses an automatic tension control system for torque regulated winding/unwinding
systems fitted with load cells or dancer rolls. The torque, which is transferred to the reel via a brake
(pneumatic or electro-magnetic) or clutch, is regulated by the PID algorithm in order to maintain the
tension applied to the material (or the position of the dancer roll) constant at the setpoint. The setpoint is
set-up locally using function F.18 (if F.38 = OFF) or remotely (if F.38 = On), using a potentiometer or an
analogue signal from the PLC, for example.
When the dedicated digital input is activated, causing the regulator to switch from the STOP to the
AUTO state, the regulation begins to apply a torque value that may be either the value set-up using
function F.1 (if F.48 = OFF) or the last value that was applied in AUTO mode (if F.48 = On). If the
STOPAUTO state transition occurs after the instrument has been set to the ZERO state in order to
change the reel, the regulator will restart at the torque value set-up in F.1, irrespective of the F.48
setting; this also happens if the instrument is disconnected from its power supply.
The regulator monitors the tension (or the position of the dancer roll) continuously and if any of the
alarm limits are exceeded the corresponding digital outputs on the T-two unit are activated; this enables
external devices, such as the PLC, to detect any fault conditions.
T-two is equipped with an auxiliary analogue output that can be used to control an external display
device or, when using a dancer roll to regulate the tension, the transducer that regulates the air
pressure in the dancer roll piston; this pressure value may be set-up locally using function F.32 (if F.40
= OFF) or remotely (if F.40 = On), for example by converting the analogue signal from a potentiometer
of the PLC.
P.I.D.
SETPOINT
AUTO/STOP
TENSION / POSITION ALARM 1
TENSION / POSITION ALARM 2
ALARMS
MANAGEMENT
F.33
DANCER ROLL
AIR PRESSURE
BRAKE / CLUTCH
LOAD CELLS / DANCER ROLL
(optional) TORQUE
ZERO
ACC
DEC
EMERGENCY
DANCER ROLL
AIR TRANSDUCER
or
REMOTE TENSION
DISPLAY
(optional)
PRESSURE
or TENSION
F.18
F.32

Re S.p.A. T-two –standard model
Rev. 05/15 3/14
Interface
The T-two unit features two separate configuration menus: The first menu is identified by the initials
P.0 and includes all the functions necessary for setting up the device hardware, whereas the second,
which is identified by the initials P.1, can be used to set-up the tension regulator operating
parameters.
When the user selects a menu without accessing it, the display indicates some useful additional
information about the selected menu. To select the menu, press and hold the key for
approximately 3 seconds the letter P. Appears on the display, followed by the menu identification
number; press the +/ –keys to scroll to the desired menu, then press to select it and continue
pressing to access the functions menu.
Information indicated on the display
The following table lists the information that may appear on the display, depending on which menu
has been selected.
Key pressed
Menu P. 0
Menu P. 1
None
Firmware Version
Tension (kg)/Position (%)
+
-
Setpoint
–
-
PID regulator state *
+and –
-
-
and +
Current (A) supplied by AO3
-
* For a list of the states, see the table on page 4
Programming keypad
Red, 3-figure display

Re S.p.A. T-two –standard model
Rev. 05/15 4/14
Remote control of the states by PLC
The T-two unit is equipped with four digital inputs that are used to control the state of the regulator.
For a detailed description of the operating logic used to activate these inputs (closure of a 24Vdc
contact) see the paragraph Remote control of states by PLC in the unit installation manual.
It is important to note that the EMERGENCY remote command is a “virtual” function only and does not
correspond to any of the physical inputs and is activated only if both the ACC and DEC remote contacts
are active, as illustrated in diagram 1 below.
By using the ACC (F.6) and DEC (F.11) state delays it is possible use a different set of parameters, for
a predetermined period, in order to optimise the way the system reacts to the during the start and stop
phase transients using nothing more than the AUTO/STOP remote command.
Diagram 1: AUTO/STOP and REEL SELECTION command functions
Regulator states
Display indication
State
Description
-S-
STOP
Machine stationary
-AU
AUTO
Machine operating at working speed
-AC
ACC
Machine in acceleration phase
-d-
DEC
Machine in deceleration phase
-0-
ZERO
Machine stationary + Reel released
-E-
EMERGENCY
Machine in rapid stop phase
AUTO/STOP
DEC
T-two STATE
ACC
STOP ACC AUTO STOPEMERGENCY

Re S.p.A. T-two –standard model
Rev. 05/15 5/14
Setting up the regulator
The following is a brief summary of the functions that are available for setting up the tension regulator.
For a complete description, consult Detailed description of the regulator set-up and parameters menu
(P.1) on page 7.
To access the set-up environment press and hold the for approximately 3 seconds. The letter P.
Appears on the display, followed by the menu identification number. Press the +/ –keys to scroll to
the regulator set-up and parameters menu “P.1”. Press and hold the key again to access the menu.
The display indicates the letter F. followed by the number that identifies the first available function.
Use the +/ –keys to scroll through the list of programming functions.
To modify the parameters associated with each individual function, select the desired function, then
press the key: The display indicates the current parameter value. Use the +/ –to set the desired
value, then press the key to confirm.
To save the new settings, select the first function in the menu and press the –key, or select the last
function and press the +key, after approx. 3 seconds the unit will exit the menu and the data will be
saved.
Regulator set-up and parameters menu (P.1)
Function
ID
Description
Parameter name
Range
Factory
value
F.1
Torque in STOP state (%)
STOP_OUT
0.0÷99.9
10.0
F.3
“Proportional” regulator in AUTO state
AUTO_P
0.0÷99.9
2.0
F.4
“Integral” regulator in AUTO state
AUTO_I
0.00÷9.99
0.80
F.5
“Derivative” regulator in AUTO state
AUTO_D
0.00÷9.99
0.00
F.6
ACC delay state(s)
ACC_TIME
0÷100
0
F.7
“Proportional” regulator in ACC state
ACC_P
0.0÷99.9
2.5
F.8
“Integral” regulator in ACC state
ACC_I
0.00÷9.99
0.40
F.9
“Derivative” regulator in ACC state
ACC_D
0.00÷9.99
0.00
F.11
DEC delay state(s)
DEC_TIME
0÷100
0
F.12
“Proportional” regulator in DEC state
DEC_P
0.0÷99.9
2.5
F.13
“Integral” regulator in DEC state
DEC_I
0.00÷9.99
0.40
F.14
“Derivative” regulator in DEC state
DEC_D
0.00÷9.99
0.00
F.16
“Proportional” regulator in STOP state
STOP_P
0.0÷99.9
0.0
F.17
“Derivative” regulator in STOP state
STOP_D
0.00÷9.99
0.00
F.18
Setpoint (Tension/Position)
SETPOINT
0÷FS
25
F.19
Torque in EMERGENCY state (%)
EMERGENCY_OUT
0.0÷99.9
60.0
F.32
Dancer roll air pressure (%)
DANCER_PRESSURE
0.0÷99.9
0.0
F.33
Tension/position alarm modes
ALARMS_MODE
OFF
A-b
b-A
A-A
b-b
b-A

Re S.p.A. T-two –standard model
Rev. 05/15 6/14
F.34
Tension/position alarm 1 threshold
ALARM1_THRESHOLD
0÷FS
5
F.35
Tension/position alarm 2 threshold
ALARM2_THRESHOLD
0÷FS
45
F.36
Tension/position reading filter
TENSPOS_FILTER
0÷100
80
F.37
Decimal point position
DECIMAL_PLACES
0
0.1
0.02
0
F.38
Remote setpoint acquisition
SETPOINT_ACQ_MODE
OFF/On
OFF
F.39
Remote setpoint filter
SETPOINT_FILTER
0÷100
80
F.40
Remote dancer roll air pressure
acquisition
PRESSURE_ACQ_MODE
OFF/On
OFF
F.41
Remote dancer roll air pressure filter
PRESSURE_FILTER
0÷100
80
F.48
Enable/disable last torque value used
in AUTO mode to be retained in STOP
mode
USE_LASTAUTOINT_STOP
OFF/On
On
F.97
Enter “Admin” password
-
0÷999
0
F.98
Save “Admin” password
PASSWORD_LEV2
0÷999
0

Re S.p.A. T-two –standard model
Rev. 05/15 7/14
Detailed description of the regulator set-up and parameters
menu (P.1)
The functions preceded by this symbol are valid for applications with dancer rolls only.
The functions preceded by this symbol are valid for applications with load cells only.
Function 1 –Torque in STOP state (%)
You can use this function to set-up the percentage of torque applied to the reel when the machine is
stationary (STOP).
Press to access the function, the display indicates the corresponding value.
Press +/ –to set-up the desired torque value, expressed as a percentage.
Press to confirm.
Function 3 –“Proportional” regulator in AUTO state
This parameter, together with the integral and derivative parameters, acts on the regulation when the
machine is operating at the working speed (AUTO state). Increase the value of the proportional
parameter to increase the system response speed so that it reaches the setpoint value more rapidly. If
the speed is too high the system could become unstable, resulting in excessive tension (setpoint
exceeded) and harmful oscillations.
Press to access the function, the display indicates the corresponding value.
Press +/ –to set-up the desired value.
Press to confirm.
Function 4 –“Integral” regulator in AUTO state
This parameter, together with the proportional and derivative parameters, acts on the regulation when
the machine is operating at the working speed (AUTO state). Decrease the value of the integral
parameter to increase the speed at which the regulator corrects the error at the working speed, so that it
reaches the setpoint value more rapidly. If the integral parameter value is set too low the system could
become unstable, causing the tension to oscillate continuously around the setpoint value, without ever
reaching a stable state.
Press to access the function, the display indicates the corresponding value.
Press +/ –to set-up the desired value.
Press to confirm.
Function 5 –“Derivative” regulator in AUTO state
This parameter, together with the proportional and integral parameters, acts on the regulation when the
machine is operating at the working speed (AUTO state). Increase the value of the derivative parameter
to improve the capacity of the regulator to predict the error trend and compensate for sudden variations
in the tension; it is also capable of damping the undesired effects caused by a high proportional value. If
the derivative parameter value is set too high the system may become highly sensitive, reacting to even
the smallest variations at the input (interference) and resulting in harmful oscillations.
Press to access the function, the display indicates the corresponding value.
Press +/ –to set-up the desired value.
Press to confirm.