Renova isomatic User manual

Renova S.r.l. –via Pompeo Mariani 16 –20128 Milano Italy –tel: [phone] –fax: [phone]
www.renova-srl.it –email: [email protected]
isomatic
tension control system
user manual

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© Copyright Renova Srl, 2013. All rights reserved.
MANISOENA4V0817

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index
introduction ……………………………………………………...……….……………….…….……
page 4
support ……………………………………………..….….………………..….…..…….………………
page 4
general warnings …………………………………………..….………...…………………....……
page 4
warning and safety aspects ……………………………………..……….….………….………
page 5
installation of the tension control system .….……………………………………………
page 5
Installation drawings ………….…………….……………………..…………..….…
page 5
tension control system –isomatic .………………………….…………..….….…….….…
page 6
control unit …………………..………………….……..………………….…………….……………
page 7
keyboard .………………………………………………………………..………………..
page 7
menu page .………………………..…………………………………….….…….……..
page 8
operating modes …………………………………………………..……………………..……….….
page 8
manual (stop mode) ……………………………….…………………....…….……..
page 8
system calibration .…….…………..………….……………………….…….……….
page 9
automatic …………………………………………..…..………………………………….
parameter setup ………………………………….…………………………………………………..
page 10
page 11
list of parameters ………………………………………………………..……..………….…………
page 12
remote interactions of a single unit …………………..……………………………………..
page 18
Multiple remote control (max 31 units) …..………………………………….
page 19
connections …..…………………………………………………………………………………………
page 20
technical specs ………..………………………………………………………………………………
page 22
drawings ………………….………………………………………………………………………………
page 23
declaration of conformity ………….……………………………………………………………
parameters and defaults ……………………………………..………………………………….
page 25
page 26

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introduction
Dear customer,
Thank you for purchasing Renova’s isomatic control system.
Renova’s produts are designed in compliance to the highest quality and functional standards.
We are sure your new tension control system isomatic fully meets your expectations.
This user manual describes the steps to proper use the tension control system isomatic.
Please, read carefully this user manual before using the isomatic tension control system.
support
Our technical department is on hand to help you and offer the right solution to overcome any problems.
Renova is also present in the world market with a detailed sales network.
In case of need please contact us at suppo[email protected]. We will be happy to directly help you or address you to
the right Renova’s representative.
general warnings
CAREFULLY READ THE INSTRUCTIONS AND WARNINGS IN THIS MANUAL AND KEEP THEM FOR FURTHER REFERENCE
FOR ENTIRE PRODUCT LIFE. THEY SUPPLY IMPORTANT INSTRUCTIONS REGARDING OPERATIONS AND SAFETY FOR
INSTALLING, USING AND MAINTAINING THE PRODUCT.
PLEASE TAKE THE TIME TO READ AND UNDERSTAND THE SAFE PRECAUTIONS TO BE RESPECTED FOR A SAFE AND
PROPER USE OF THIS PRODUCT.
THIS COMPONENT IS DESIGN TO BE INCORPORATED IN A MACHINE AND IT CAN’T WORK INDIPENDENTLY. THE USE
OF THIS COMPONTENT IS FORBIDDEN IF THE USE ON THE MACHINE ISN’T IN COMPLIANCE WITH THE LAW.

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warnings and safety aspects
The control system has been designed in compliance to CE regulations. Additionally, the tension control system
isomatic is designed to work in harsh industrial environments.
Before proceed to the installation and during the utilization of the system, check the following points:
Danger: Disconnect all the power connections before installing the system and remember to provide a
solid ground connection.
Danger: Never open the cover of the tension control’s electronic parts when the power is switched on or
when the system is working. Do not manage or disassembly the system.
Danger: Do not touch the electrical connections with wet hands
Do not use the control system in a potentially explosive environment. Use this system only in fire-proof
and explosion-proof environments.
Danger: use only the power and connection cables supplied together with the system. Please, replace the
eventual damaged cable immediately.
Danger: use power cable that can deliver the required amount of current.
Attention: in case of incorrect operations due to EMC interferences, separate the power cables from the
signal cables.
Attention: do not install the system in a position subjected to conductive powder or to corrosive gases. Do
not expose the system to high temperature, wind, vibrations and environments subjected to bad weather.
Attention: Renova is not responsible for any damage caused by repair, modifications or tampering of the
system, done by a third party and not authorized by Renova.
Attention: the above-mentioned directives are subjected to changes without prior notice.
installation of the tension control system
SUPPLIED MATERIAL
The isomatic tension control system includes:
-1x LCD user interface with keyboard ( dim. 124x104x65mm –cut-out 90x90mm )
-1x or 2x load cells
-1x brake for tension correction with connection cables (optional)
-1x power supply box with connection cables (optional)
INSTALLATION DRAWINGS
The mechanical dimensions are reported on drawing isomatic/mechanical dimensions, 41M052E
The electrical connections are reported on drawings isomatic/electrical connections, 42E004E

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tension control system - isomatic
The isomatic is an automatic control system of the web tension. The system is studied for various application fields
where measurement and control of tension of unwinding / rewinding reels are required.
Typical application areas include control of the tension of moving materials in printing and converting machines.
By programming the relevant parameters, the system can be adapted to various applications.
Thanks to the advanced programming features a wide range of optional functions and operations can be performed.
The system is designed for uninterrupted operations in harsh factory environments, with features for quick job setup.
The isomatic system is made of a display unit connected to one or two load cells, which assess the web tension.
Alternatively, it is also possible to check the web tension by means of a potentiometer. The display unit can
communicate with magnetic powder brakes, with electrovalves to control pneumatic brakes or with drivers to control
motors.
The display unit isomatic can also communicate with a remote computer using and optional serial link.
The display unit is fitted with an alphanumeric LCD display and a programming keyboard.
The display unit is connected through cable connections to the other parts of the system.
Load cells are designed to control the tension of rewinding and unwinding machines. They are fixed at the end of the
cylinder and detect the power applied to the cylinder during rewinding and unwinding process.

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control unit
The control unit has small dimensions, it is light and easy to use. The LCD alphanumeric display shows the program
values, the current operating conditions, the error messages and the values measured by isomatic.
Figure 1 - display and keyboard
KEYBOARD
Used to confirm the selection.
Used to cancel an operation or to exit from menu pages.
,
Used to change parameter values, scroll between parameters and to drive the actuator
manually.
Used to activate the Manual mode.
Used to activate the Automatic mode.

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MENU PAGES
To select the various menus use the and keys (arrow keys). Once the desired menu has been selected, press
OK to enter the menu. After entering a menu, the display visualizes the parameters related to the selected menu. To
change a parameter value or scroll among parameters press the and keys and the OK key to confirm.
The tension control system ISOMATIC can operate in three different modes:
Manual Mode: this mode allows the manual control of the reel tension. The display shows the measured
tension level. The tension of the web can be modified manually using the keyboard. On certain conditions an
alarm indicator is activated.
Automatic Mode: this mode measures the error and regulates the braking using a PID automatic control
algorithm. The display shows the measured web position error and, on certain conditions, an alarm indicator
is activated.
Setting Mode: this mode allows to set the values of the parameters that determine the behaviour of the
ISOMATIC. It allows to set the parameters of the system (like the ones used by the PID algorithm to control
the system).
operating modes
MANUAL (STOP MODE)
By Manual mode the user can manually correct the tension of the web. In Manual mode, the system visualizes the
following data (the figure is an example):
By pressing the and keys (arrow keys) it is possible to modify the tension of the reel thus correcting the current

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value.
By pressing Esc it returns to the menu from which it entered in Manual mode.
In case an alarm is active, the acknowledgement (shutdown) of the alarm occurs by simultaneously pressing the OK
and Esc keys.
In manual mode are also available some quick procedures to perform operations that might be done in other ways
(but with a greater number of steps). These quick procedures include:
- Set point setting for the tension: by pressing the OK key with the key it sets the value of the measured tension
as set point value.
SYSTEM CALIBRATION
Through the calibration procedures the references for the desired tension measurements are provided to the system.
It is worth noting that the calibration procedures are independent from your system of units adopted: the values
entered by the user during the calibration procedures are handled by the system only as numbers, without any
reference to their physical meaning (in other words, the calibration procedure is the same whether the tension is
expressed in Kg, Pounds or whatever). Since the calibration is done on two points for any measured size you need to
have at your disposal some known conditions of:
-low tension (no material is on the roller with load cells)
-high tension (a weight of known value is tied to the roller with load cells)
Due to these constraints and the fact that calibration is critical in relation to measured values, the tension control is
released from the factory with a default calibration to be modified after the installation on the machine.
Important: to avoid losing the calibration values, before proceeding to a new calibration take note of the values of
parameters TXL, TYL, TXH, TYH (see paragraph concerning the setting mode Parameters hereinafter in this manual).
Low calibration
1) Do not lean anything on the roller with load cells
2) Press simultaneously OK, Esc and keys
High calibration
1) Tie a weight of known value to the roller with load cells
2) Press simultaneously OK, Esc and keys
3) Tension high calibration: press and keys to decrease or increase the numeric value displayed; press
OK key to confirm the figure that is going to be changed. When the last figure of high calibration is confirmed,
the controller automatically goes to the visualization of the measured tension and set point.
Sum up of the functions of keys in Manual mode:
Decrease the tension in the machine

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Increase the tension in the machine
Esc
Return to menu page
OK + Esc
Alarm acknowledgement
OK +
Setting of tension set point
OK + Esc +
Low calibration
OK + Esc +
High calibration
+
Setting of tension to SPS value (SPS=Set point in Manual mode)
AUTOMATIC
By selecting the automatic mode the system automatically corrects the current tension trying to get it to the setpoint
values. In Automatic mode the controller modulates the output to the brake according to the PID parameters set. (See
Picture 3).
The display looks like the following picture:
By pressing or keys (arrow keys) it is possible to change the tension set point.
By pressing Esc it returns to the menu from which it entered in Automatic mode.
In case an alarm is active, the acknowledgement (shutdown) of the alarm occurs by simultaneously pressing the OK
and Esc keys.
The algorithm for the automatic control of the tension is a PID algorithm. The basic concepts of the control algorithm
can be understood looking at the following drawings (Dwg. 3 and 4):

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The difference between the measured value and the set point (desired value) determines the required correction
(required output). The correction value depends on the output value required:
Summary of the functions of the keys in Automatic mode:
Decrease the tension set point
Increase the tension set point
Esc
Return to menu page
OK + Esc
Alarm acknowledgement
parameter setup
The device parameters determine the system behaviour. They are numeric values used to program and configure the
ISOMATIC system. The parameters values should be checked for each specific application. It is advised to write down
the programmed parameter values after installing the system. Programming of these parameters requires a good
knowledge of the system functionality and of the meaning of every single parameter.
The parameters have default values but they can be changed by an enabled operator.

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By default the system is not password protected. If the password feature is enabled, the operator needs to enter the
correct password to change the parameters.
Once the parameter programming mode has been entered, the display appears like the following picture:
The displayed parameter is selected by pressing the and keys. By pressing the OK key the cursor moves to the
value field. Each digit of the value field can be changed using the and keys and confirmed by the OK key. When
all digits have been changed (or confirmed), the OK key takes the cursor back to the parameter name field. To cancel
the changes press the Esc key.
To quit from parameter setup press Esc key.
list of parameters
GKP –Proportional gain
Usage: Proportional gain factor in automatic mode.
Description: This gain factor is used to calculate the proportional part of the correction needed to compensate
the measured error.
Range: 0 … 32767
Default: 100
GKD –Derivative gain
Usage: Derivative gain factor in automatic mode.
Description: This gain factor is used to calculate the derivative part of the correction needed to compensate
the measured error.
Range: 0 … 32767
Default: 0
GKI –Integrative gain
Usage: Integrative gain factor in automatic mode.
Description: This gain factor is used to calculate the integrative part of the correction needed to compensate
the measured error.
Range: 0 … 32767
Default: 0
GIL –Integrative limit
Usage: Maximum limit of the integrative part of the correction.

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Description: This value is used to limit the integrative part of the correction needed to compensate the
measured error.
Range: 0 … 32767
Default: 0
GKF –Tracking diameter gain
Usage: tracking diameter gain factor
Description: This gain factor is used to calculate the correction in relation to the diameter of coil.
Range: 0 … 255
Default: 0
ACC –Acceleration
Usage: Acceleration of correction motor
Description: This value sets the acceleration of the brake or motor in automatic mode.
Range: 0 … 999
Default: 10
DEC –Deceleration
Usage: Deceleration of correction motor.
Description: This value defines the deceleration of the brake or motor in automatic mode.
Range: 0 … 999
Default: 10
VMI –Minimum correction speed
Usage: Minimum correction speed.
Description: This field specifies the minimum speed to apply to the correction motor. It permits to eliminate
the inertia of the correction motor.
Range: 0 … 127
Default: 10
VMA - Maximum correction speed
Usage: Maximum correction speed.
Description: This field specifies the maximum speed to apply to the correction motor. It permits to eliminate
the over correction of the error.
Range: 0 … 127
Default: 127
TYP –Type of sensor
Usage: Shows the type of sensor used
Description: This parameter allows to select the sensor you are using.

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Valore
Descrizione
0
Load cell
1
Dancer roll (potentiometer)
2
Ultrasonic sensor (detector diameter)
Range: 0 … 2
Default: 0
SPA –Set point in automatic mode
Usage: Set the desired value of tension (tension setpoint).
Description: This parameter stores the value of the desired tension.
Range: 0 … 199,9
Default: 10,0
SPB –Set point dancer roll
Usage: Set the potentiometer setting.
Description: This parameter stores the default value of the potentiometer (dancer roll).
Range: 0 … 100%
Default: 20
SPS –Set point in stop mode
Usage: Set the default value of the command output in stop mode.
Description: This parameter stores the default value of the command output in stop mode.
Range: 0 … 199
Default: 20,0
SPF –Set point diameter
Usage: Defines the percentage of braking
Description: This parameter stores the percentage of braking for a specific diameter of coil.
Range: 0 … 100
Default: 50 %
SPE –Set point in emergency mode
Usage: Set the default value of the command output in emergency mode.
Description: This parameter stores the default value of the command output in emergency mode.
Range: 0 … 100
Default: 40

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TXL –Tension X-Lo
Usage: The operator MUST NOT change the value of this parameter (this parameter is set by the logic
part after a low calibration procedure of the load cell).
Description:
Range: 0 … 2047
Default: 1024
TYL –Tension Y-Lo
Usage: The operator MUST NOT change the value of this parameter (this parameter is set by the logic
part after a low calibration procedure of the load cell).
Description:
Range: 0,0 … 199,9
Default: 0,0
TXH –Tension X-Hi
Usage: The operator MUST NOT change the value of this parameter (this parameter is set by the logic
part after a high calibration procedure of the load cell).
Description:
Range: 0 … 2047
Default: 1984
TYH –Tension Y-Hi
Usage: The operator MUST NOT change the value of this parameter (this parameter is set by the logic
part after a high calibration procedure of the load cell).
Description:
Range: 0,0 … 199,9
Default: 50,0
DXL -Diameter X-Lo
Usage: The operator MUST NOT change the value of this parameter (this parameter is set by the logic
part after a low calibration procedure of diameter sensor of coil).
Description:
Range: 0 … 2047
Default: 0
DYL –Diameter Y-Lo
Usage: The operator MUST NOT change the value of this parameter (this parameter is set by the logic
part after a low calibration procedure of diameter sensor of coil).
Description:
Range: 0,0 … 3,999
Default: 0

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DXH –Diameter X-Hi
Usage: The operator MUST NOT change the value of this parameter (this parameter is set by the logic
part after a high calibration procedure of diameter sensor of coil).
Description:
Range: 0 … 2047
Default: 2047
DYH –Diameter Y-Hi
Usage: The operator MUST NOT change the value of this parameter (this parameter is set by the logic
part after a high calibration procedure of diameter sensor of coil).
Description:
Range: 0,0 … 3,999
Default: 1,000
ALR –Alarm level
Usage: Maximum level of tension tolerated
Description: This parameter allows to set a maximum level measurable beyond which the system will enter
the alarm mode.
Range: 0 … 199,9
Default: 199,9
DIS –Average display
Usage: Displays the average of the display.
Description: This parameter makes the average of the indication noted on the display
Range: 0..8
Default: 4
DIG –Digits number
Usage: Change the position of comma within the tension display digits
Description: This parameter allows to move the position of comma to calibrate the load cell with any unit of
measurement of weight.
Range: 0..3
Default: 1
INP –Selection of input signals
Usage: Allow to select input signals.
Description: This parameter selects the input signal applied to inputs Di4-Di3-Di2-Di1. This value is made of 3
figures, each figure specifies the input signal of the respective pin in the connector CN102.

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Value
Signal (enable +24Vdc)
0
Inactive
1
Emergency (rapid braking)
2
Free brake (brake at zero)
3
Selection Auto/Man (enable automatic)
Range: 0000 … 3333
Default: 0000
OUT –Selection of output signals
Usage: Allow to select output signals.
Description: This parameter selects the output signal applied to outputs Do2-Do1. This value is made of 3
figures, each figure specifies the output signal of the respective pin in connector CN102.
Value
Signal (enable +24Vdc)
0
Inactive
1
Active
2
Alarm Out
Range: 00 … 22
Default: 02
ADR –Address
Usage: RS-485 serial line address.
Description: This parameter sets the address of the tension system to communicate with a serial device.
Different addresses permit to install many devices on the same line.
Note: Protected parameter, press Esc during the start up screen to enable the changes.
Range: 0...31
Default: 0
INI –Initial screen
Usage: Set the screen to be displayed at power up.
Description: Define the screen displayed at system power up.
Note: Protected parameter for remote function (INI = 9), press Esc during the start up screen to
enable the changes.
Range: 0 … 9
0 = Main menu
1 = Program
4 = Setup
7 = Stop mode
8 = Automatic mode

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9 = Remote Display
Default: 0
LNG –Language
Usage: Language of menu.
Description: This field sets the preferred language in the text menu.
Range: 0 … 3
0 = Italian
1 = English
2 = French
3 = Spanish
Default: 1
PWD –Password
Usage: To protect the setting of parameters.
Description: When this parameter is set to a value (different to zero), the operator is asked a (fixed) password
to enter to parameters. Value 0 means no password required.
Range: 0 … 32767
Default: 0
TXT –Text on initialisation
Usage: Text shown on the initialisation screen.
Description: This parameter lets the operator to enter a specific string of characters to be shown during the
system initialisation screen.
Range: Fourteen characters
Default: “Renova.it”
remote interactions of a single unit
The RS-485 serial communication allows to control a second unit ISOMATIC from a remote location, using another
ISOMATIC.
By connecting a Isomatic to another Isomatic, the device can operate like an additional user interface. Let’ s explain
this application by an example. Let’ s consider a Isomatic, called “1”, connected to load cells and brake; consider then
another Isomatic, called “2”, to be used as a remote interface. By setting the INI parameter of the Isomatic “2” to 9
(INI = 9) and connecting the two devices like on the following figure, it is possible to use the keyboard and the display
of the Isomatic “2” like if they were the keyboard and the display of the Isomatic “1” (in other words, the user can use
either the keyboard and the display of the Isomatic “1” or “2”).
Note: in this type of application the Isomatic “2” works only like a clone of the Isomatic “1”. Example: if the GKP
parameter is changed from the Isomatic “2”, the parameter that is actually changed is the GKP parameter stored into
the Isomatic “1”.

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Note: to have back the Isomatic “2” working as a tension control system (and not like a remote display), it is necessary
to set INI = 0. To enter in local parameters (of “Isomatic 9000 number 2”) it is necessary to press the Esc key during
the initialization phase (welcome screen).
MULTIPLE REMOTE CONTROL (MAX 31 UNITS)
To work with remote control, it is necessary to link all the units with a RS-485 net (CN 105) and to connect one
external switch (button) to the terminals 1 and 2 of the CN 102 of the command unit.
To work like Isomatic command unit it’s necessary to set the following parameters:
INI = 9 (Remote display)
ADR = 1…31 (Max number of external units)
INP = 1 (External button enabled)
To enter local parameter press ESC during the start up screen.
To work like Isomatic remote slave unit it is necessary to set the following parameters:
INI = 0…8 (according to the desired starting screen)
ADR = 1…31 (for each connected Isomatic a different sequence number must be entered).
By pressing the external contact of the command unit it can be selected the element to control. Alternatively the

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master unit can control all of the remote units. By pressing the external contact the Isomatic will show the following
menu screen:
By setting 0 on the master unit all of the remote devices are controlled at the same time.
By setting the corresponding remote unit number (ADR of each unit) on the master unit, the selected device is
controlled independently.
connections
Pin
Name
Description
1
Commad
Powder Brake command (output)
2
Commad
Powder Brake command (output)
3
AO1
Analog Output1 (0-10V)
4
AO2
Analog Output2 (0-10V)
5
0 Vdc
0 Vdc
Connector CN100 (Motor)
Remote display
Connect = <…>