Operating e

Instructions
Web tension controller DC 600.
Assembly and commissioning
Controller type 1, motor drive
1. Safety 2
2. Input/ouput functions 3
2.1 Analog inputs 3
2.2 Digital inputs 4
2.3 Analog outputs 5
2.4 Digital outputs 6
2.5 Controller status table 7
3. Operator panel RT 4101 7
4. Assembly 9
5. Installation 10
6. Commissioning 11
6.1 Setup editor 11
6.2 Setup mode 11
6.3 Commissioning sequence 13
6.4 Setting controller type 13
6.5 Setting parameters 13
6.6 Parameter listing 14
6.7 Parameter description 19
6.8 Calibrating the measuring amplifier 32
6.9 Synchronising drives 32
6.10 Optimising controller 37
7. Special functions 39
8. Operation 41
9. Error code 42
10. Control diagram 44

BEA--221853-E-02
Web tension controller DC 600.

Explanation of symbols ➜ = jobs to be performed

= important information and instructions

= text sections due particular attention to assure the safe

operation of web tension controllers DC 6000, DC 6001.

1. Safety
1.1 Intended usage The controller may only be used to control web tension.
The controller is built to state-of-the-art technology.
The controller should only be used
- in perfect technical condition,
- for use as intended, in accordance with the operating instructions.
Work relating to the operation, production gearing, conversion or ad-
justment of the web tension controller as well as its inspection,
maintenance and repair may be performed by trained personnel only.

1.2 Operating manual Please keep this manual in a safe place, accessible to personnel at
all times.

1.3 Safety instructions Never reach into rotating rollers with your hand or tools.

Never touch the edges of running webs.

Never touch live cables.

1.4 Assembly and installation When installing controller DC 600. you must observe the locally appli-
cable and professional safety and accident prevention requirements
(e.g VDE 0100, EN 294, EN 349, IEC )
Electrical components must be adequately protected.
Please ensure that:
- electrical components without enclosures are protected according
to the locally applicable safety regulations, e.g. VDE 0100,
- when running electrical cables that the insulation is not damaged
and the cables correctly secured and protected,
- signal lines are run separately from heavy current-carrying leads.

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 Web tension controller DC 600.

Please refer to the connection diagram for the exact terminal assign-
2. Input/ouput ments.
functions Free, unassigned analog inputs must be grounded.
2.1 Analog inputs The analog inputs are works set as voltage inputs. On re-
quest, E+L can also supply current inputs (conversion volta-
ge to current may only be performed ex works).

Analog inputs
Input Terminal Terminal X 10 Signal connected
DC 6000 DC 6001
+ - + -
1 24c 26c 7 8 F-target external
or
F-actual external
or
7 8 Start diameter
2 22a 24a 3 4 N-batch actual
or
3 4 D-batch actual
3 26a 28a 5 6 V-web target

F-target external
Using this analog input an analog voltage of 0 to 10 V DC (or 0 to
20 mA) may be preset and stored for the tension set point. 10 V is
the equivalent of the maximum web tension (Parameter .24.).
The external target value is accepted by the controller when the ap-
propriate digital input is high and the value of the external set point is
stored on the negative edge.
Set point adjustment from the operator panel is blocked as long as
the digital input is high.

F-actual external
This input allows one to enter an actual tension value in the form of
an analog voltage of 0 to 10 V DC (or 0 to 20 mA) - e.g. a previously
established web tension. 10 V corresponds to the maximum web ten-
sion (Parameter .24.).
The external actual value is only effective as long as the digital input
for the actual value is high.

Start diameter (for diameter calculation only)

This analog input is used to input the start diameter in the form of an
analog voltage of 0 to 10 V DC (or 0 to 20 mA).
The start diameter is accepted on the positive edge of the digital in-
put and stored on the negative edge.

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Web tension controller DC 600.

N-batch actual
This analog input is used to input the batch speed in the form of an
analog voltage of 0 to10 V DC. 10 V DC is the equivalent of the maxi-
mum batch speed (Parameter .28.)
The actual batch speed is only used for diameter calculation, in
conjunction with a set line speed signal.

D-batch actual
This analog input is used to enter the batch diameter directly in the
form of analog voltage of 0 to 10 V DC (Parameter .30. and .31.).

Line speed V-web target

This analog input is used to enter the processing speed in the form of
an analog voltage of 0 to 10 V DC. 10 V DC is the equivalent of the
maximum speed. (Parameter .26.).
The set line speed signal is required for batch diameter calculation
and to control the speed of traction rollers in a multidrive configurati-
on.

2.2 Digital inputs Digital inputs are to be used as appropriate to the application.
Please refer to the connection diagram attached for terminal as-
+ 24 V DC external signments.
(logic "0" -5 V to +3 V DC)

Digital inputs
Input Input Terminal Terminal X 1 Function
DC 6000 DC 6001
DE 0 6c 3 Not assigned
DE 1 8a 4 Automatic
DE 2 8c 5 Synchronous mode
DE 3 10a 6 F-target accepted
DE 4 10c 7 Start diameter accepted
Reference potential
(DC 6000 terminal 6a, DE 5 12a 8 F-actual accepted
DC 6001 terminal 2) DE 6 12c 9 Batch change
Digital input - 6a 2 digital reference potential

It is possible to invert single or all digital inputs. See special

functions section.

Automatic Automatic
(green) The tension controller is switched on via the digital input "automatic".
The indicator lights up green. The web tension is now controlled in
accordance with the preset value.

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 Web tension controller DC 600.

Synchronous mode
- multidrive configuration: if the synchronous mode digital input is
high, the set external line speed signal is switched automatically to
the analog output "actuator signal V, N" (∆V = 0).
- batch drive: when the synchronour mode digital input is high, in
automatic mode when calculating the diameter, the external set
line speed signal is divided by the start diameter and switched to
the analog actuator signal (V, N) as the set batch N:
Set line speed V
Set batch N =
Start diameter
When entering the diameter by sensor, the external set line speed
signal is divided by the actual diameter and switched to the analog
actuator output signal (V, N) as the set batch N:
Set batch N = Set line speed V
Actual diameter

F-target accepted
When this digital input is high, the analog set web tension is enabled.

Start diameter accepted

When this digital input is high, the analog set batch start diameter is
enabled and stored.

F-actual accepted
When this digital input is high, the analog set actual web tension value
is enabled.

Batch change
If this digital input is high, pres the "start diameter" button (or min.
start diameter parameter) to actuate the preset diameter for web
tension control. A batch change is only possible when "automatic" is
switched off.

2.3 Analog outputs Please refer to the attached connection diagram for the exact terminal
assignments.
The analog output for the actuator signal (V, N)" is works set as a
voltage output. On request, E+L can also supply it as a current out-
put (voltage - current conversion may only be performed ex works).

Analog outputs
Output Terminal Terminal X 11 Signal connected Voltage / current
DC 6000 DC 6001
1 28c 30c 2 3 Actuating signal (V, N) Uoutput 0 bis ±10 V DC
Ioutput 0 (4) to 20 mA optional
2 32a 32c 5 4 Monitor output (D actual or F actual) Uoutput 0 to 10 V DC

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Web tension controller DC 600.

Actuating signal (V, N)

The acuating signal is either in the form of a speed signal for a mul-
tidrive configuration or a rotational speed signal (reel) for the follow-
up drive (Parameter .40.).

Monitor output
The monitor output is used for measuring purposes or the graphic
representation of the actual value of the batch diameter or web tensi-
on. It is available in 8 bit resolution. Due to circuit-related reasons,
the zero point can waver by 5 % to 6 % (Parameter .35.).

2.4 Digital outputs Please refer to the attached connection diagram for the installation
terminal assignments.
+24 V DC external
(DC 6000 terminal 4c; Digital outputs
DC 6001 X 2 terminal 2)
Output Terminal Terminal X 2 Function
DC 6000 DC 6001
DA 0 14a 3 Not assigned
Output
(Imax = 500 mA) DA 1 14c 4 Not assigned
DA 2 16a 5 Not assigned
DA 3 16c 6 F-actual limit value
DA 4 18a 7 N-batch actual limit value
DA 5 18c 8 V-web target limit value
Digital output DA 6 20a 9 System operational
- 4c 2 +24 V DC external

F-actual limit value

If the actual web tension limit value is less than the lower limit, out-
put 3 becomes logic 1.

N-batch actual limit value

If the actual batch speed limit value is less than the lower limit, output
4 becomes logic 1.

V-web target limit value

If the set line speed limit value is less than the lower limit, output 5 be-
comes logic 1.

System operational
Output 6 indicates that the controller is operational.
Output: logic 1 = system operational
logic 0 = error; controller malfunction
The type of error is indicated in parameter . .5. by an error code (see
error code section).
Output 6 may also be used as an error indicator for the following con-
trols.

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 Web tension controller DC 600.

2.5 Controller status table 0 = off

1 = on
X = don't care
= switch with leading edge

Controller state Digital inputs Keys on the operator panel

Synchronous mode

Synchronous mode
in service mode

Batch change
Automatic

Automatic

Manual
Controller off 0 0 0 0 0 0
Controller off 0 0 X 0 0
Controller on 1 0 X X X 0
Controller on 0 0 X 0 0
Synchronous mode 1 1 X X X 0
Synchronous mode X X X X X
Batch change 0 X 1 X X X

Operator panel RT 4101 is used to enter all control parameters and

3. Operator panel operating modes.
RT 4101

Operating voltage display

Lights up when operating voltage present.

Automatic Automatic
(green) When automatic mode is enabled by the digital input of the same
name, the indicator lights up. The web tension is controlled in accor-
dance with the preset values.
The "automatic" key only selects the automatic function directly in
service mode (expanded setup, parameter .4.1.).

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Web tension controller DC 600.

Manual mode Manual

(green) The controller may only be switched off in service mode via the "manu-
al" key. The "0 V" actuator signal is then supplied at the controller out-
put. The indicator is illuminated in manual mode.

Synchronous Synchronous mode

mode This key may only be used in service mode (expanded setup, parame-
ter .4.1.) to select synchronous mode. The indicator on the automatic
key flashes.

Line 1: F-target, parameter number, Digital display

diameter When you actuate the F-target key, the web tension target value is dis-
played in the first line of the digital display and in the second line the
-8.8.8.8.8. web tension actual value.
If the diameter key is pressed, the first line indicates the start diameter
and the second line the actual batch diameter. If the material-specific
-8 8 8 8 8
parameter record is pressed, the number of the last parameter setting
Line 2: F-actual, parameter value, is indicated.
diameter In setup mode, the first line indicates the parameter number and in the
second line the parameter value is indicated.
The digital display shows the preset values with comma (decimal
point) and sign.

F-target F-target
(green) Press key "F-target" and the "Up/Down" key to set the desired web
tension target value. The indicator lights up when this function is selec-
ted.
Press the "F-target" key...
- once, the LED lights up, the display is selected.
- twice, the LED flashes, change the F-target value.
- three times, the LED lights up, the F set point is stored.

Diameter Diameter
(green) Press the diameter key and the "Up/Down" key to set the start diame-
ter.
Press the "diameter" key...
- once, the LED lights up, the display is selected.
- twice, the LED flashes, change diameter.
- three times, the LED lights up, store diameter.

Material-specific Material-specific parameter record

parameter record (green) Press this key and the "Up/Down" key to select one of eight different
material-specific parameter records.
Press the "material-specific parameter record" key...
- once, the LED lights up, the display is selected.
- twice, the LED flashes, set the number of the material-specific pa-
rameter record (0-7).
- three times, the LED lights up, the parameter record is adopted.
The LED will flash if you try to set an invalid parameter record.

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 Web tension controller DC 600.

Select setup mode Setup

Press the setup and additionally the "Increase value" keys to enter
+ setup mode, the green LED on the setup key flashes (always press
the setup key first).
Setup In setup mode you can:
(green)
- change various parameters
- reset all factory settings automatically (see commissioning sec-
tion)

Down key
Use this key to reduce the value indicated on the digital display (set
value, parameter number or diameter etc.).

Up key
Use this key to increase the value indicated on the digital display.

Please observe the relevant safety regulations!

4. Assembly
The length of the connection cable between the load cells and
controller DC 600. should not exceed 50 m and should be conti-
nuous.
➜ Mount the DC 6000 controller 19" sub-assembly (28 TE, 3 HE,
160 mm deep) in a module rack or control console.
➜ Mount the DC 6001 as near as possible to the load cells for field
implementation.

4.1 Load cells ➜ See load cell description PD 21, 22, 23, 25.

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Web tension controller DC 600.

Please observe the locally applicable and professional safety

5. Installation and accident prevention regulations.
The DC 600. modules are already interconnected. Only the power
supply, the inputs and outputs, and where appropriate, the CAN bus
require connecting.
➜ Run the leads according to the attached wiring diagram.
For reasons of EMC compatibility it is absolutely essential
that the PE conductor be connected to all control compon-
ents.
Free, analog inputs must be grounded. The controller must be con-
nected to machine ground by a 4 mm2 lead.

5.1 Supply voltage The controller power supply is 24 V DC.

5.2 Analog current output and The controller output is works set as a voltage output, the analog in-
analog current inputs puts as voltage inputs. On request E+L can also supply current out-
puts (conversion voltage to current only possible ex works).

5.3 CAN bus networking for See "CAN bus, serial bus and setup editor" description.
tension controller ➜ Run the CAN bus lines away from noisy or heavy current-carrying
cables (e.g. motor cables).
The CAN-Bus may not exceed a maximum total length of 200 m.

5.4 Address setting when On digital controllers designed by E+L the hardware address
networking tension con- (group and device number) of the web controller(s) is preset
trollers (see block diagram for addresses), further address settings
are not necessary. The device number must always be set
Device number DIP switches 1 - 4 to 5!
Group number DIP switches 5 - 7 The address is set via an 8-pole DIP switch on control card RK 4101.
5 dec. 0 dec.
The address consists of two parts:
1 2 3 4 5 6 7 8
- the group number from 0 to 7
ON (is set on DIP switches 5 to 7)
OFF
- the device number from 1 to F (hex)
The device number must always be set to 5 = web controller!
Binary value: (is set via DIP switches 1 to 4)
1 2 4 8 1 2 4
Example: address 2.5 2 = group number
DIP switches
5 = device number
Control card RK 4101 works setting: address 0.5

5.5 Address setting on web ➜ Open housing

controller DC 6001 ➜ Set address on control card RK 4101.

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 Web tension controller DC 600.

5.6 Address setting on web The 19" rack housing must be opened in order to set the address
controller DC 6000 (see fig. on left).
Operator panel RT 4101 ➜ Loosen the four securing screws "A" on the operator panel
➜ Loosen the two securing screws "B" on the pcb.
Analog card AK 4101
➜ Pull out the pcb by a half and unplug connectors X 1, X 2 and X 3.
➜ Loosen the securing screws on analog card AK 4101 and remove
the analog card.
➜ Set the address on the RK 4101 control card 8-pole DIP switch.
➜ Reassemble the device in reverse order.

Control card RK 4101

8-pole DIP switch
DC 6000 19" controller rack

PCB securing screws "B"

X1 X2 X3

Command device Socket connector 8-pole DIP switch

securing screws "A"

Commissioning should be performed by qualified personnel

6. Commissioning only.

6.1 Setup editor The setup editor is a software tool for setting and initialising E+L con-
trollers and CAN bus cards (e.g. control card RK 4101). The setup
editor may be started from operator panel RT 4101 or remote control
DO 6000 by setting the command device in setup or expanded setup
mode.

6.2 Setup mode There are two setup modes:

Setup mode
In setup mode all parameter values may be displayed and some
changed.
Expanded setup mode
In expanded setup mode all parameter values may be displayed and
changed (for commissioning and service personnel).

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Web tension controller DC 600.

Parameter values may only be changed by qualified person-

nel. Parameter value changes are executed immediately and
stored automatically after approx. 1 minute!

Setup mode Select setup mode

(flashes green) + Press the setup and additionally the "Up" key to enter setup mode,
the green LED on the setup key flashes (press the setup key first).

Select parameter number

+ If you hold down the setup key in setup or expanded setup mode,
you can use the "Up" or "Down" keys to select another parameter
+ number. The parameter number is indicated in the first line of the di-
gital display, the parameter value in the second line. All decimal
Parameter number
points light up when the parameter number is displayed.
. . . . 0. When setup mode is activated, the parameter number ..0. is al-
ways displayed first.

800
Parameter value

Increase or decrease parameter value

Use the "Up" and "Down" keys to change a parameter value.
If a parameter value cannot be changed it may be for the following
reason:
- parameter value cannot be changed (ex works protected)
- parameter value can only be changed in expanded setup mode.

Exit setup mode

If no key on the control panel is pressed for longer than 1 minute or a
reset initiated in the "start service" parameter, setup mode is quit au-
tomatically, the changes stored!

Select expanded setup mode

expanded setup mode
(lights up green) First select setup mode and enter 42 in parameter ..3. "Start Ser-
vice". Then change parameter. In expanded setup mode the green
LED on the setup key lights up.

Exit expanded setup mode

You can exit expanded setup mode in two different ways. Either initia-
te a reset in parameter ..3. "Start Service" by setting a "1" or enter 6
in parameter ..3. "Start Service", change parameter and press any
function key (e.g. F-Target). The changes are stored when setup
mode is exited!

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 Web tension controller DC 600.

6.3 Commissioning sequence

Set controller type

Set parameters

Calibrate measuring amplifier and

set parameter .2.4.

Synchronise drives

Wind or No
unwind

Yes
Adjust diameter capture

Insert web

Optimise controller

6.4 Setting controller type ➜ Select expanded setup mode (set "42" in parameter ..3. ).
➜ Set "1" in parameter .3.3. for controller type "1".
➜ Initiate a reset in parameter ..3. (set a "1" and change parameter).
➜ Select expanded setup mode (set "42" in parameter ..3.).
➜ Set "2" in parameter ..2. and change parameter.

6.5 Setting parameters ➜ Set parameters. See chapter "Parameter listing" and "Parameter
description".
The values listed in the Default column are internal values which
must be optimized during the initial test runs (see chapter "Optimi-
zing").
➜ Make a note of the changed parameter values.

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Web tension controller DC 600.

6.6 Parameter listing The field Name shows the abbreviated parameter name. The field
Default shows the standard settings, Min and Max are the respecti-
ve limit values. The unit is shown in the Unit field. The field Explana-
tion describes the parameter functions.

6.6.1 Setup Mode

No. Name Default Min Max Unit Explanation

..0. edit device X.5 X.1 X.F hex Selection of equipment number
Device number see block diagram.

..1. edit group 0.X 0.X 7.X hex Selection of group number
Group number see block diagram.

..3. start service 0 0 199 - Starting a function

0 = No function
1 = Reset controller
42 = Select extended Setup Mode
44 = Save modified actual parameter values as customer
optimized values.
An input becomes valid only if another parameter number is
selected afterwards, for example parameter ..4. .
A wrong or incorrect input may cause system malfunction.

6.6.2 Extended Setup Mode

No. Name Default Min Max Unit Explanation

..2. reset settings 0 0 2 - Works settings

0 = No function
1 = custom-optimized values
2 = Internal preset values (default)
An input becomes valid only if another parameter number is
selected afterwards, for example parameter ..4. .
A wrong or incorrect input may cause system malfunction.

..3. start service 0 0 199 - Starting a function

0 = No function
1 = Reset controller
6 = Exit extended Setup Mode
10 = Tara compensation
11 = Calibrate measuring amplifier
12-19 = Calibrate analog inputs
20 = Compensate diameter calculation
44 = Save modified actual parameter values as customer
optimized values.
An input becomes valid only if another parameter number is
selected afterwards, for example parameter ..4. .
A wrong or incorrect input may cause system malfunction.

..4. controller type 1 1.x 1.x 1.x E+L Software version

Display of software version number.

..5. error code 0 0 21 Error code (also refer to chapter Error Codes)
0 = No error, output „System operational“ logic 1
1 = Unidentified error, contact E+L Service
2 = Internally computed measuring range smaller than set
measuring range. Reduce parameter .24. F max
3 = Input offset of last analog input calibrated bigger than ±1 V,
reduce line offset.
4 = Value of last analog input calibrated bigger than ±10 V,
check and recude input voltage.

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 Web tension controller DC 600.

No. Name Default Min Max Unit Explanation

5= Zero compensation imossible as own weight of measuring

axle bigger 100% of measuring range, contact E+L Service.
6= Calibrating weight too small for preset measuring range,
use bigger calibrating weight.
7= F-target value bigger than acceptable,
change parameter .24. F max.
8= V-web bigger than acceptable,
change parameter .26. V-web max.
9= batch r.p.m. higher than acceptable,
modify parameter .28. N-winder range
10 = Web tension bigger than permitted (load cell overloaded),
change max. permissible tension and recalibrate
measuring amplifier.
12 = Web tension amplifier overflow,
check signal voltage of web tension.
18 = Diameter constant incorrect:
Readjust diameter capture (chapter 6.9)
19 = Calibration of web tension of measuring amplifier incorrect,
repeat calibration.
20 = Zero point compensation of analog inputs incorrect,
recalibrate analog inputs.
21 = Calibration of analog inputs incorrect,
recalibrate analog inputs.

..6. recipe number 0 0 7 - Material-specific parameter record

Displays the actual parameter record

..7. start diameter .... D min. D max. - Start diameter

is set in is set in Actual batch diameter when control begins
parameter parameter Usually, the start diameter is entered directly using the
.30. 31 appropriate key (same name) on the control panel. In this case the
value in parameter ..7. will be overwritten.
(No input if diameter sensor is used.)

..8. F-target .... 0 F max. F-target value

is set in Web tension target value by which the web tension controller has
parameter to control the actual web. Usually the web tension target value is
.24. entered directly via the key of same name on the operator panel.
In this case the value in parameter ..8. will be overwritten.

..9. F-target at D0% 100 0 100 % F-target factor for a batch diameter D = 0 %
Web tension target value in relation to batch diameter D
Example:
F-target = 300 N (..8.)
F-target factor for D 0% = 50 % (..9.)
If batch diameter D is 0% web tension target is 150 N.

.10. F-target at D20% 100 0 100 % F-target factor for a batch diameter D = 20%

.11. F-target at D40% 100 0 100 % F-target factor for a batch diameter D = 40%

.12. F-target at D60% 100 0 100 % F-target factor for a batch diameter D = 60%

.13. F-target at D80% 100 0 100 % F-target factor for a batch diameter D = 80%

.14. F-target at D100% 100 0 100 % F-target factor for a batch diameter D = 100%

.15. P-part 10 0 100 % P-Part

Amplification of web tension controller
100% = 1

.16. I-part 0,200 0,001 2,000 s I-Part

Integral action time Tn of web tension controller

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Web tension controller DC 600.

No. Name Default Min Max Unit Explanation

.17. D-part 0,0 0 0,100 s D-Part

Set-up time Tv of web tension controller

.18. delta diameter .0 0 5 mm Material thickness

Input required only for winding/unwinding without diameter sensor.

.19. no function 0 0 0 no function

.20. output norm/inv .0 0 9999 % Correctino signal controller dV

0 = normal (positive)
1 = inverted (negative)

.21. F-target slope 3 0 30 s F-target ramp

Period it takes for the web tension target value to change from 0 to
F max.

.22. F-calibration 100 1 9999 Calibrating weight

Weight used to burden the measuring roller during the calibration
process of the measuring amplilfier.
The unit is freely selectable, e.g. N, kp, lbf

.23. F-actual sample 0 0 4 F-actual mean value calculation

0 = 1 measurement
1 = 2 measurements
2 = 4 measurements
3 = 8 measurements
4 = 16 measurements
The mean value calculation has a filtering effect on the
web tension measured.
A reset must be made after each modification (see parameter 3)

.24. F-actual range .... 0 9999 F max (measuring and control range)
Highest F-target value of the system which must be controlled.
The unit is freely selectable, e.g. N, kp, lbf
This parameter must be entered only after the calibration of the
measuring amplifier.

.25. F-actual limit 0 0 9999 F-actual limit value

If the limit value entered here for the web tension actual value
is not attained, then the digital output of same name will be set
to logic 1.
The unit is freely selectable, e.g. N, kp, lbf

.26. V-web range 100 0 9999 m/min V-web target

Web speed at +10 V at analog input V-web target.
The unit is freely selectable, e.g. m/min, ft/min.
This parameter may also be entered during commissioning.

.27. V-web limit 10,0 1,0 100,0 % V-web target limit value
If the limit value entered here is not reached,
the digital output of same name will be set to logic 1.

.28. N-winder range 636 0 9999 1/min N-batch-actual

Batch r.p.m. at +10 V actuating signal at the speed controller
of the drive to be controlled.
This parameter may also be entered during start-up.

.29. N-winder limit 1,0 1,0 100,0 % N-batch-actual limit value

If the limit value entered here is not reached, the digital output
same name) is set to logic 1. In addition, the diameter computation
is switched OFF when this value is not reached.

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 Web tension controller DC 600.

No. Name Default Min Max Unit Explanation

.30. diameter 50 50 300 mm D min

Outer diameter of sleeve.
Unit form freely selectable, e.g. mm, inch.

.31. diameter 2000 300 3000 mm D max

Max. outer diameter of batch
Unit form freely selectable, e.g. mm, inch.

.32. diameter calc 0 0 3 Selection of diameter value

0 = Diameter sensor analog (0 ... +10 V = 0 ... Dmax)
or no diameter sensor connected
1 = calculation of diameter V, N analog
2 = calculation of diameter V, N impuls, 0 ... 10 kHz
3 = Diameter sensor analog inverted (0 ... +10 V = Dmax .... 0)
This parameter may be entered only after the measuring
amplifier has been calibrated.

.33. controller type 0 0 3 Selection controller type

0 = actuator brake
1 = actuator electrical drive
2 = actuator positioning gear
3 = actuator brake at corrugators

.34. control off delay 0 0 10 s Cut off delay

Defines for how long the web tension controller should continue
to control the web tension after the digital input "automatic"
has been cut off.

.35. monitor output 0 0 1 Selection monitor output

0 = actual diameter D-batch-actual
0 ... +10 V = 0 ... D max
1 = actual web tension F-act
0 ... +10 V = 0 ... F max
For technical reasons it is quite possible that the zero point varies
by 5% to 6%

.36. controller output 0 0 2 Selection output actuating signal

0 = 0 - ±10 V DC
1 = 0 - 20 mA
2 = 4 - 20 mA
Ex works the analog output will be a voltage output unless
specified as current output in the order.
Any conversion can only be made by E+L.

.37. output offset 0,0 0 ±10,0 % Offset actuating signal

The offset is added to the positioning signal.
The input is in percent (%) based on 10 V.
The offset is used to compensate loss of line voltage.

.38. output positiv 20 0 100 % Positive controller correction signal

Level of positive controller correction signal as per cent figure.
The controller correction signal refers always to the speed signal
V-web target available "this moment".

.39. output negativ 20 0 100 % Negative controller correction signal

Level of negative controller correction signal as per cent figure.
The controller correction signal refers always to the speed signal
V-web target available "this moment".

.40. output V/N 0 0 1 Selection positioning signal

0 = V-web target (transport unit / surface-driven winder)
1 = N-batch target (center-driven winder)

17
Web tension controller DC 600.

No. Name Default Min Max Unit Explanation

.41. service field 0 0 3 Service Mode

0 = Service Mode OFF
1 = Service Mode ON
2 = Service Mode ON
When pressing the material-specific parameter key:
1st line display - V-web target
2nd line display - N-batch-actual
3 = Service Mode ON
When pressing the material-specific parameter key:
1st line display - actuating signal
2nd line display - no display
The Service Mode is used to commission the web tension
controller. The 3 keys Manual, Automatic and Synchronous run
on the operator panel are enabled in the Service Mode. However,
the signals with the same name on the digital inputs always
come first.
When commissioning is terminated the Service Mode must be
cut off.

.42. subsystem 0 00 00 7F hex Address serial bus board 0

Input required only if web tension controllers are networked.
See block diagram.
The addresses of the serial bus boards are attributed automatically
by the CAN bus board. If, for example, the CAN bus board has
address 05, it will attribute address 06 to the first serial bus board 0
which follows, address 07 to the second one etc. .
However, if address 06 has already been allocated to a CAN bus
board which is addressed by hardware, then a new (free) address
must be allocated to the serial bus board 0. The first digit indicates
the allocated group, the second digit the equipment number.

.43. subsystem 1 00 00 7F hex Address serial bus board 1

Input required only if web tension controllers are networked.
See block diagram.

.44. subsystem 2 00 00 7F hex Address serial bus board 2

Input required only if web tension controllers are networked.
See block diagram.

.45. subsystem 3 00 00 7F hex Address serial bus board 3

Input required only if web tension controllers are networked,
see block diagram.

.46. subsystem 4 00 00 7F hex Address serial bus board 4

Input required only if web tension controllers are networked,
see block diagram.

.47 subsystem 5 00 00 7F hex Address serial bus board 5

Input required only if web tension controllers are networked,
see block diagram.

.48. subsystem 6 00 00 7F hex Address serial bus board 6

Input required only if web tension controllers are networked,
see block diagram.

.49 subsystem 7 00 00 7F hex Address serial bus board 7

Input required only if web tension controllers are networked,
see block diagram.

18
 Web tension controller DC 600.

6.7 Parameter description Address selection

An entry in the two parameters ..0. and ..1. is only required where
. . . .0. controllers are networked or on inverting digital inputs or outputs.
See the "CAN-Bus, serial bus and setup editor" description or spe-
cial functions section on the subject.
. . . .1. In parameter number ..0. set the device number and in parameter
number ..1. the group number of the CAN device the parameters of
which you wish to change. A maximum of 8 groups and per group 15
devices is possible. The group and device numbers are specified in
the connection diagram .
The digital inputs and outputs carry device number 6.
The digital display indicates whether the selected device is present
in the control loop. A minus sign ("-") in front of the device number
means that the relevant device is not present. If you still select a
parameter for the non-existent device, all decimal points will flash,
further entries will not be possible.
Default setting: device number 5 (web tension controller)
group number 0

Works settings
. . . .2. 0 = no change
1 = customer-optimised values
2 = internal set value (default)
If you enter "1" in this parameter, the values stored by you after opti-
misation will be implemented, if you enter "2", the internal (default)
values are implemented. "0" means no change.
Entries in parameter ..2. are only effective if you then select a new
parameter number (e.g. parameter number ..3.). A wrong or invalid
entry may cause a system malfunction!

Start Service
. . . .3.
In this parameter various calibrating and service routines may be cal-
led up.
- "1" Reset controller
- "6" Exit expanded setup mode
- "10" Perform tare compensation
- "11" Calibrate measuring amplifier
- "12 to 19" Calibrate analog inputs (see chapter 7 "special
functions")
- "20" Compensate diameter calculation (see chapter 6.9)
- "42" Select extended Setup Mode
- "44" store changed (current) parameter values as customer-
optimised values
The Calibration or Service Routines 6, 10, 11 and 12 to 20 can be re-
called only in the Extended Setup Mode.
Entries in parameter ..3. are only effective if you then select a new
parameter number (e.g. parameter number ..4.). A wrong or invalid
entry may cause a system malfunction!

19
Web tension controller DC 600.

Software version display

. . . .4. The software version number is indicated on the digital display.

Error code display

. . . .5. This parameter outputs an error code in the event of a malfunction
(see error code section).

Material-specific parameter record

. . . .6. A material-specific parameter record consist of control parameters ..7.
to .1.7.. You may store parameter records for eight different materials.
For winders the parameter sets consist of: F-target, start diameter,
reel characteristic, P-, I- and D-term.
For transport units the parameter sets consist of: F-target, P-, I- and
D-term.
Parameter ..6.. is used only to display the current parameter re-
cord. If you wish to enter or change a material-specific parameter,
you must proceed as follows:

20
 Web tension controller DC 600.

. . . .6.
Press material-specific
parameter record

Set parameter record number,

e.g. 0 (0-7)

Acknowledge entry

Return to setup menu

. . . .7. Set parameters ..7.to .1.7.

yes
enter new parameter
record yes/no

no

proceed with
commissioning

Start diameter
....7. Actual batch diameter when control is initiated.
Diameter This parameter must be set for winding/ unwinding only.
(green) No input of start diameter required if diameter sensor is used.
Entry range: D min to D max (D min is set in parameter .30., D max
in parameter .3.1.)
The start diameter may also be entered directly with the key of same
name on operator panel RT 4101. In this case the value in parameter
..7. will be overwritten.

F-target
. . . .8. Enter the F-target value according to which the web tension controller
should operate.
F-target
(green) Entry range: 0 to F maximum (F maximum is set in parameter .2.4.)
The F-target value may also be entered directly using the key of the
same name on operator panel RT 4101. In this case the value in pa-
rameter ..8. will be overwritten.

21
Web tension controller DC 600.

F-target factor for a batch diameter of D = 0 %

. . . .9.
This parameter must be set for winding/unwinding only.
In a winding situation, the web tension may be controlled in relation
to the batch diameter (F set f[D]) - winder characteristic.
In parameters ..9. to .1.4. you may specify by which F-target value
your fabric is to be wound or unwound given a specific batch diame-
ter.
Enter the F-target factor in per cent for a batch diameter of D = 0 % .
The factor entered in % is always in relation to the F-target value en-
tered in parameter ..8. .
Entry range: 0 to100 %

F-target value F
E.g. 100 % = 300 N
100 %

50 %

0 20 40 60 80 100
min. max.
Batch diameter in %
Example of a set winder characteristic

Example:
F-target value = 300 N
F-target factor when D 0 % = 50 %
Given a batch diameter of 0 %, F-target value of 300 N is effective.

F-target factor for a batch diameter D = 20 %

. . .1.0.
This parameter must be set for winding/unwinding only.
Enter the F-target factor in per cent for a batch diameter D = 20 %.
Entry range: 0 to 100 %

F-target factor for a batch diameter D = 40 %

. . .1.1.
This parameter must be set for winding/unwinding only.
Enter the F-target factor in per cent for a batch diameter D = 40 %.
Entry range: 0 to 100 %

22
 Web tension controller DC 600.

F-target factor for a batch diameter D = 60 %

. . .1.2.
This parameter must be set for winding/unwinding only.
Enter the F-target factor in per cent for a batch diameter D = 60 %.
Entry range: 0 to 100 %

F-target factor for a batch diameter D = 80 %

. . .1.3.
This parameter must be set for winding/unwinding only.
Enter the F-target factor in per cent for a batch diameter D = 80 %.
Entry range: 0 to 100 %

F-target factor for a batch diameter D = 100 %

. . .1.4.
This parameter must be set for winding/unwinding only.
Enter the F-target factor in per cent for a batch diameter D = 100 %.
Entry range: 0 - 100 %

P-term
. . .1.5. The P-term specifies the amplification for your controller, 100 % cor-
responds to an amplification of 1. We recommend you set an amplifi-
cation of 10 % during commissioning which may be optmised later
on.
Entry range: 0 - 100 %
If 0 is entered into parameter ..15. this specific parameter series
will be suppressed; in other words it can no longer be selected via
key "material-specific parameter record".

I-term
. . .1.6. The I-term specifies the reset time Tn in secs and prevents a perma-
nent control deviation. We recommend you set an I-term of 0.2 secs
during commissioning which may be optimised later on.
Entry range: 0.001 - 2.000 secs

D-term
. . .1.7. The D-term specifies the rate time Tv in secs. The D component is
used for mass inertia compensation. We recommend you set a
D-term of 0 secs during commissioning which may be optimised later
on.
Entry range: 0 - 0.100 secs

The values entered in parameter ..7. to .17. are in relation to

the material-specific parameter record selected in parameter
..6. .

23
Web tension controller DC 600.

Fabric thickness
. . .1.8.
This parameter must be set only for winding/ unwinding without
diameter sensor. Enter the fabric thickness in mms.
Entry range: 0, 1, 2, 3, 4, 5 mm

. . .1.9. Parameter number non-functional

Controller correction signal ∆V

. . .2.0. In this parameter the controller correction signal ∆V may be inverted.
0 = normal
1 = inverted

Controller correction signal ∆V normal (0) Controller correction signal ∆V inverted (1)
F set > F actual = ∆V positive F set > F actual = ∆V negative

Main drive Follow-up drive Follow-up drive Main drive

. . .2.1. F-target ramp

Use this parameter to set the time period in which the F-target should
rise from "zero" to "maximum".
Entry range: 0 - 30 s
Recommend setting: 3 s

F-target F

F maximum

Set point ramp

100
Time t/s
Example for parameter .2.1.
1 30
F-target ramp

Calibration weight
. . .2.2. Enter the weight being applied to the measuring roller to calibrate the
measuring amplifier (step 6.8 of commissioning) - unit form freely
selectable, e.g. N, kp, lbf.

24
 Web tension controller DC 600.

F-actual mean value calculation

. . .2.3.
This parameter may only be changed when the machine is at
a standstill. A reset should be initiated afterwards (enter 1 in
parameter ..3. ).
Enter the number of measurements to be taken to establish the
mean value which has the effect of a filter: the higher the figure set,
the stronger the filter effect. This is required whenever there is a noi-
sy or heavily oscillating actual tension signal (e.g. unbalanced roller.
0 = 1 measurement fg = 100 Hz
1 = 2 measurements fg = 50 Hz
2 = 4 measurements fg = 25 Hz
3 = 8 measurements fg = 12 Hz
4 = 16 measurements fg = 6 Hz
Recommended value: 0 = 1 measurement

F maximum (measuring and control range)

. . .2.4.
Entries should only be made in this parameter after the measu-
ring amplifier has been calibrated (see section 6.8 Calibrating
measuring amplifier. The measuring and control range is limited
during measuring amplifier calibration and depends on the load
cells.
Enter the highest (maximum) F-target value with which you wish to
control your system. This entry determines the operating range of
your web tension controller and display range.
Entry range: 1 - 9999 (unit freely selectable, e.g. N, kp, lbf)

F-actual lower limit

. . .2.5. If the limit value set in this parameter is not attained the digital output
of the same name will be set to logic 1. Enter the actual tension lower
limit.
Entry range: 0 - 9999 (unit freely selectable, e.g. N, kp, lbf)

Line speed range V-web target

. . .2.6.
This parameter must be set only for winding/ unwinding without
diameter sensor or for web speed control (parameter .2.7.).
Enter the maximum line speed for your system, in relation to 10 V si-
gnal voltage at the line speed analog input V-web target.
Eingabebereich: 0 - 9999 (Einheit frei wählbar, z.B. m/min, ft/min)

25
Web tension controller DC 600.

Line speed V-web target lower limit

. . .2.7. This parameter has various functions:
- the lower limit is used to control the web tension even when at
standstill or at low speed (see fig. below).
- In case of winding / unwinding the calculation of the diameter will
be activated if the limit value has been exceeded.
- alarm output
If the limit value entered in this parameter is not attained, the out-
put of the same name will be set to logic "1".

Follow-up drive Main drive

Actuating signal
+10

+ Controller correction signal

- Line speed -
min
-10 +10
Line speed V-web target
min

F actual > F set

F actual < F set

-10
Example: Line speed lower limit

If the speed signal is not available as a voltage but is determined

by the main drive via a mechanical shaft, you must set the line
speed to 100 % (e.g. superimposed gearing, harmonic drive). A
speed-dependent signal is no longer available.
Enter the lower limit value in per cent related to the speed range pa-
rameter .2.6..
Entry range: 1.0 - 100.0 %

26
 Web tension controller DC 600.

Batch speed range N-batch actual

. . .2.8.
This parameter must be set only for winding/ unwinding without
diameter sensor or for control of the batch speed (parameter
.2.9.).
Enter the maximum batch speed, in relation to 10 V, at maximum
web speed and minimum core diameter. If you don't know the batch
speed, you may calculate it according to this equation:

max. N-batch actual = V-web target max.

π x D min. (core diameter)

Entry range: 0 - 9999 (unit freely selectable, e.g. min-1, rpm)

Batch speed N-batch actual lower limit

. . .2.9.
This parameter must be set only for winding/ unwinding without
diameter sensor or for control of the batch speed (parameter
.2.8.).
Alarm output: if the lower value set in this parameter is not attained,
the digital input of the same name is set to logic 1 and the diameter
calculation is interrupted for the time the lower limit is not attained.
Enter the lower limit value in per cent, in relation to the maximum
batch rotational speed.
Entry range: 1 - 100 %

Batch diameter D min.

. . .3.0.
This parameter must be set for winding/ unwinding only.
Enter the minimum batch diameter (core outer diameter).
Entry range: 50 - 300 (unit freely selectable, e.g. mm, inch)

Batch diameter D max.

. . .3.1.
This parameter must be set for winding/ unwinding only.
Enter the maximum batch diameter (see also parameter ..7.).
Entry range: 300 - 3000 (unit freely selectable, e.g. mm, inch)

Diameter form
. . .3.2.
This parameter must be set for winding/ unwinding only.
Enter a value only after having calibrated the measuring amplifier
(chapter 6.8 Calibrating the measuring amplifier).
This parameter is used to indicate in which form the batch diameter
is being acquired.

27
Web tension controller DC 600.

0 = Diameter sensor analog

Enter the batch diameter directly as an analog voltage from
0 to +10 V . 10 V corresponds to the batch diameter D max en-
tered in parameter .3.1. (0 V correspond to 0 mm diameter).
1 = Diameter calculation V/N
Enter the batch diameter indirectly by means of an analog line
speed and batch speed signal. The actual batch diameter is calcu-
lated as follows: D~ line speed V (V/Nmax = 10 V).
actual batch diameter N

2 = Diameter calculation impuls V/N

Enter the batch diameter indirectly by means of a line speed and
batch speed pulsed signal (e.g. incremental encoder). The actual
batch diameter is calculated as follows: D~ line speed V
actual batch diameter N

3 = Diameter sensor analog inverted

Enter the batch diameter as an analog voltage of 0 to +10 V. 0 V
corresponds to the batch diameter D max entered in parameter
.3.1. (10 V = 0 mm diameter).

Select controller type

. . .3.3.
Select controller type "1":
0 = controller type 0; electrical or pneumatic brake
1 = controller type 1; electrical batch drive, electrical transport
drive, electrically controlled superimposed
drives (e.g. harmonic drive, differential
drive)
2 = controller type 2; electrically controlled positioning drive with
variator
3 = controller type 3; elektrical or pneumatic brake on corrugated
cardboard system transport units
Entry range: 0, 1, 2, 3

Shut off delay

. . .3.4.
Overrun may occur if the web tension control is switched off together
with the main machine drive. In this parameter enter in seconds how
long the web tension control is to remain active after "Automatic off"
so that the web tension control remains functional until the machine
stops.
Entry range: 0 - 10 secs

Monitor output, signal options

. . .3.5.
Determine whether the monitor output should represent the actual
batch diameter D or the actual web tension F.

28
 Web tension controller DC 600.

Voltage from 0 to 10 V corresponds to 0 to D max. or 0 to F max. For

circuit-related reasons, the zero point may waver by 5 % to 6 %.
0 = actual batch diameter D
1 = actual web tension F
Entry range: 0, 1

Actuating signal output

. . .3.6.
Selec the output range in this parameter.
0 = 0 - ±10 V
1 = 0 - 20 mA
2 = 4 - 20 mA
Entry range: 0, 1, 2
The "actuating signal" analog output is works set as a voltage out-
put. On request, E+L can also supply it as a current output (volta-
ge to current conversion only possible ex works).

Offset actuating signal

. . .3.7.
The offset entered is added to the actuating signal. Entry is in per
cent (%) related to 10 V. The offset serves as compensation for cable
voltage drops.
Entry range: ±10,0 %

Amplitude of positive controller correction signal

. . .3.8.
Use this parameter to establish the amplitude of the positive control-
ler correction signal in per cent.
The controller correction signal always relates to the momentary line
speed signal V-web target.
Entry range: 0 - 100 %
The maximum possible actuating signal ist ±10 V or +20 mA for a
current output.
Example:
With VMachine 50 % = 5 V line speed signal and ±10 % = ±0.5 V con-
troller correction signal the actuating signal may lie between 5.5 V
and 4.5 V.

29
Web tension controller DC 600.

Example: positive actuating signal as a function of line speed V-web target

Actuating signal Controller correction signal +10 %

+10 V

Actuating
signal
5,5 V
5V
4,5 V

V-web target
5V +10 V

Amplitude of the negative controller correction signal

. . .3.9. In this parameter the amplidtude of the negative controller correction
signal is defined in per cent.
The controller correction signal always refers to the momentary line
speed signal. The maximum possible actuating signal is -10 V.
Entry range: 0 - 100 %
With a current output no negative actuating signal is possible.

Select actuating signal

. . .4.0. Select whether the actuating signal should be a line speed for a mul-
tidrive configuration or a batch speed for a center driven winder.
0 = set line speed
1 = set batch rotational speed

Service mode
. . .4.1. Controller DC 600. must be set to service mode for commissioning. In
this mode, automatic, manual or synchronous mode may be selected
by pressing the key of the same name on the operator panel. In addi-
tion, various values are indicated on the display.
0 = Service mode off
1 = Service mode on

30
 Web tension controller DC 600.

Automatic 2 = Service mode on

(green) press the "material-specific parameter record" key
1. first line of the display - set line speed
Synchronous mode 2. second line of the display - actual reel speed
(red)
(if the inputs are connected).
Manual mode 3 = Service mode on
(green) press the "material-specific parameter record" key
Material-specific 1. first line of the display - actuating signal in volts
parameter record 2. second line of the display - no display
External function selections via digital entries are always gi-
ven priority in service mode!
When in service mode, measured values will be shown unfil-
tered in the display.
You must switch off service mode once you have completed
commissioning (set 0)!

Address for serial bus card 0

. . .4.2. Use this parameter to assign the first following serial bus card a new
(free) address.
The CAN bus card automatically programs the serial bus card
addresses. If for example, a CAN bus card has address 05, it will pro-
gram address 06 for the first following serial bus card and 07 for the
second etc.. Under certain circumstances it may however occur that
this address has already been assigned to a hardware-addressed
CAN bus card. In this case, assign a free address to serial bus card
0.
The serial bus card addresses are shown in the block diagram.
The address is entered as a two-digit hexadecimal number. The
first figure indicates the assigned group, the second the device num-
ber.
Entries are only necessary where controllers are networked. See
"CAN-Bus, serial bus and setup editor" description and connection
diagram.

Address for serial bus card 1

. . .4.3. Use this parameter to assign the a new (free) address to the second
• following serial bus card.
•
•
Address for serial bus cards 2 to 7
. . .4.9. See parameter .4.2.

All further parameters (.5.0. to 1.9.9) are set controller inter-

nally and may not be changed!

31
Web tension controller DC 600.

6.8 Calibrating the measuring The measuring amplifier may only be calibrated in expanded setup
amplifier mode.
Initially, the measuring roller must be unloaded.

Zero point adjustment

➜ Enter 10 in parameter ..3. "Start Service" in expanded setup mode
to start tare compensation (zero point adjustment) and then select
parameter ..4..
belt
measuring Calibrating with a calibration weight
roller
The calibration weight must be the equivalent of at least 60 % of
the maximum web tension or the load cell output signal must be
greater than 2 mV. If this is not the case, the calibrating process
must be at fault.
➜ Lay the belt over your measuring belt to simulate the web path as
calibration weight it will run subsequently (see fig. on left). Attach a test weight as
specified in parameter .2.2. . This should correspond as far as
Mounting the test weight possible to the maximum web tension (at least 60%).
➜ Enter 11 in parameter ..3. "Start Service" in expanded setup mode
to start the calibrating routine and then select parameter ..4. .
➜ Remove the test weight and belt, the measuring amplifier calibrati-
on is now complete.
➜ Enter the highest (maximum) set web tension point by which you
wish to control your system in parameter .2.4. "F maximum
(measuring and control range).
➜ Enter the form in which you wish to record the diameter in para-
meter .3.2. "Set diameter".

6.9 Synchronising drives The drives must be synchronised differently depending on whether
you are using an electrical batch drive (winding/unwinding), an elec-
trical transport drive or a superimposed gearing with electrical
actuator.
Synchronisation is always performed before the web is inserted!
➜ Increase the machine to maximum line speed.
➜ Check the set line speed voltage on the analog input of the same
name: the voltage measured must not exceed 10 V (DC 6000 ter-
mina 26a and 28a; DC 6001 terminal X 10.5 and X 10.6).
➜ Measure the maximum line speed on the main drive with a hand-
held tachometer and enter in parameter .2.6..
➜ Stop the machine.

32
 Web tension controller DC 600.

6.9.1 Synchronising winds ➜ Check whether value 1 or 2 (V, N, analog; V, N, pulsed) is set in
and unwinds and setting parameter .3.2. "select diameter form".
batch calculator with set ➜ Check the error code. If 18 is set in parameter .5.. , the diameter
diameter V, N, analog and constant is incorrect. Select parameter ..3. "Start Service" in ex-
V, N, pulsed panded setup mode and enter 20 (diameter calibration), then
change parameter.
➜ Clamp the core to the batch axle.

a. Calculate and adjust batch speed

N max
1.1 = safety factor, D min = core diameter
V-web target max.
max. N-batch actual = x 1,1
π x D min.
+10 V

➜ Measure the speed on the batch shaft with a speed counter and
set the speed controller to max. actual batch speed at 10 V signal
voltage (see fig. on left).
Speed counter ➜ Set the measured speed value in parameter .2.8. "Batch speed
range N-batch actual".
Adjust batch speed

Diameter ➜ Set the current diameter (e.g. core diameter).

(green)

b. Check batch speed adjustment

➜ Select synchronous mode. Press the "synchronous run" key when
Synchronous service mode is switched on or apply 24 V DC to the digital input
mode
"synchronous run" (DC 6000 terminal 8c; DC 6001 terminal X1.5).
N max The display on the "Automatic" key flashes.
M ➜ Increase the machine speed to 50 % to 100 % .
Main drive
➜ Measure the machine speed and the peripheral speed on the core
using a handheld tachometer, both values should be the same.
Actual batch speed ≠ set line speed, check the start diameter
entered and parameter .2.8. "Batch speed range N-batch actual"
Batch core and change if necessary.
Handheld tachometer ➜ Switch from synchronous to automatic mode and increase the
machine speed to 50 % .
Automatic Winds: when the measuring roller (actual tension < set tensionl)
(green)
is not loaded the batch drive must accelerate (over-synchronous
speed). When the measuring roller is heavily loaded (actual ten-
sion > set tension) the batch drive must brake (sub-synchronous
speed). If necessary, the actuating signal in parameter .2.0. must
be inverted.
Unwinds: exactly the reverse to the winds.
➜ Stop the machine and insert the web.

33
Web tension controller DC 600.

c. Diameter adjustment
Diameter calibration may only be performed in expanded setup
mode.
Diameter ➜ Set the current diameter (e.g. core diameter) on the operator pa-
(green) nel when the machine is at a standstill.
➜ Enter 20 in parameter ..3. "Start Service" to adjust the batch cal-
culator and then select parameter ..4..
➜ Increase the machine speed to approx. 20 % . After approx. 10 se-
conds the atuomatic batch calculator adjustment is completed, the
machine may be stopped again.
➜ Adjustment is now completed. The web tension controller may
now be optimised (section 6.10)

6.9.2 Synchronising winds and a. Calculate and adjust batch speed

unwinds with an absolute
set diameter 1,1 = safety factor, D min = core diameter
V-web target max.
max. N-batch actual = x 1,1
π x D min.
N max
➜ Measure the speed on the batch axle with a speed counter and
adjust the speed setter at +10 V signal voltage to max. actual
batch speed (see fig. on left).
+10 V
➜ Set the speed measured in parameter .2.8. "Batch speed range
N-batch actual".

b. Sensor mounting and adjustment (absolute)

Speed counter
➜ Check whether 0 (absolute 0 to +10 V DC) is set in parameter
Adjust batch speed .3.2. "Diameter form".
➜ Mount the sensor so that is produces a voltage of + 10 V at D max
Batch diameter D and 0 V for a theoretical diameter of 0 mm (batch axle center (see
max fig. on left).
➜ Enter the core diameter in parameter .3.0. "Batch diameter D min"
for the minimum limit value (see fig. below).
➜ Enter the batch diameter in parameter .3.1. "Batch diameter
D max" at 10 V sensor voltage.

Batch diameter Display range DC 600.

Sensor voltage Sensor voltage

D max
10 V 0V

Set diameter via sensor

Core diameter
D min
0 Sensor voltage
0V 1,5 V 10 V
Example: Absolute set diameter

34
 Web tension controller DC 600.

c. Sensor mounting and adjustment (absolute inverted)

Batch diameter
D max ➜ Check whether 3 (absolute inverted 0 to +10 V DC) is set in para-
meter .3.2. "Diameter form".
➜ Mount the sensor so that it produces a voltage of + 0 V at D max.
and +10 V for a theoretical diameter of 0 mm (batch axle center) -
see fig. on left.
➜ Enter the core diameter in parameter .3.0. "Batch diameter D min"
for the lower limit value (see fig. at top of page 29).
➜ Enter the batch diameter at 0 V sensor voltage in parameter .3.1.
Sensor voltage Sensor voltage "Batch diameter D max".
0V 10 V

Set diameter via sensor

Batch diameter

D max
Display range DC 600.

Core diameter
D min
0 Sensor voltage
Example: 0V 1,5 V 10 V
Absolute inverted set diameter

d. Checking batch speed adjustment

➜ Select synchronous mode. Press the "sychronous run" key when
Synchronous run
service mode is switched on or apply 24 V DC to digital input
"Synchronous run" (DC 6000 terminal 8c; DC 6001 terminal X1.5).
N max The display on the "Automatic" key flashes.
M
Main drive ➜ Increase the machine speed to 50 % to 100 %.
➜ Use a handheld tachometer to measure the machine speed and
the core peripheral speed, both values must be the same.
Actual batch speed ≠ set line speed: check the displayed dia-
meter (press the "diameter" key) and parameter .2.8. "Batch
Batch core
speed range N-batch actual" and change if necessary.
Handheld tachometer ➜ Switch from synchronous to automatic mode and increase the
machine speed to 50 %.
Automatic
(green) Winds: increase the batch drive speed (over-synchronous speed)
when the measuring roller is not loaded (actual tension < set ten-
sion). If the measuring roller is heavily loaded (actual tension > set
tension) brake the batch drive (sub-synchronous speed). The ac-
tuating signal may have to be inverted in parameter .2.0. .
Unwinds: exactly the opposite procedure to the winds.
➜ Stop the machine and insert the web.
➜ The compensation procedure for the batch calculator is now com-
pleted. The web tension controller may now be optimized (section
6.10).

35
Web tension controller DC 600.

6.9.3 Synchronising transport a. Synchronising transport drives

drives ➜ Select synchronous mode. Press the "Synchronous mode" key in
Synchronous service mode or apply 24 V DC to the digital input "Synchronous
run mode (DC 6000 terminal 8c; DC 6001 terminal X1.5). The display
on the "Automatic" key flashes.

n max.
➜ Accelerate machine speed to 50 % to 100 % .
➜ Measure the line speed on the main drive with a handheld tacho-
meter and set the synchronous speed on the transport drive
speed setter (check with handheld tachometer, see fig. on left).

b. Check the effective direction of the actuating signal

➜ Switch from synchronous to automatic mode. Check the controller
Main drive effective direction at half line speed. Change the setting in para-
meter .2.0. "controller correction signal ∆V" in the event of positive
Actual line speed = Set line speed feedback.
➜ Insert the web and optimise the web tension controller (section
Setting synchronous speed 6.10).

6.9.4 Sychronising superimpo- ➜ Set the following parameters to 100 %:

sed gearing with electrical - Parameter .2.7. "Line speed V-web target lower limit"
actuator (differential gea-
- Parameter .3.8. "Positive controller correction signal amplitude"
ring, harmonic drive)
- Parameter .3.9. "Negative controller correction signal amplitude".

10 V a. Sychronising actuator
➜ Adjust actuator speed setter.
Example: given a 100 % controller actuating signal, set the maxi-
n max. mum speed n2 on the speed setter so that 5 % of the maximum
line speed may be measured on the web tension generating roller
(use a handheld tachometer for measuring, see fig. on left).
n2

n1 n1 n1
b. Check actuating signal effective direction
➜ Switch from synchronous to automatic mode. Check the controller
n3 n1 effective direction at half line speed. Change the setting in para-
meter .2.0. "controller correction signal ∆V" in the event of positive
feedback.
➜ Insert the web and optimise the web tension controller.
Main drive
n3 = n1 + n2

Synchronising actuator

36
 Web tension controller DC 600.

6.10 Optimising controller

Optimisation should be performed by qualified personnel only.
We recommend optimising at the application critical low speed sta-
ge using a storage oscilloscope or recorder.
The tension controller is optimally set when, after enabling the
DC 600., actual and preset tensions coincide (have the same value)
without oscillation in the shortest possible time.

Basic premise
PID control characteristic on a step
change Voltage V
D-term
I-term

Controller output
(V oder N) P-term

t
Tv Time

t
Time
Set value deviation negative
(Set - actual = error) set value deviation

Voltage V

With a PID controller the actuating signal changes initially proportio-

nally to the D-term change in speed. After expiry of the rate time Tv
the actuating signal returns to the P component level and then varies
P-term according to the I-term (see figure on page 30).
The P-term (see fig. on left) reacts immediately to a set point deviati-
on by a change in the actuating signal. With a pure P controller, there
I-term is always a control deviation.
The I-term (see fig. on left) prevents this permanent control deviation.
The D-term (see fig. on left) makes the controller very fast, but at the
same time also very sensitive. Too large a D-term leads to oscillati-
D-term
on. The D-term is used to compensate for rapidly recurring distur-
bance factors (e.g. lobbing reels).
P, I and D -terms of a PID controller
Optimising the P, I and D -terms
When optimising the control parameters, the P, I and D -terms must
be matched to one another. Criteria in the control zone differ from ap-
plication to application as do the demands made of the web tension
controller. The individual settings must therefore be determined from
case to case.

37
Web tension controller DC 600.

The purpose behind optimising control parameters is to reduce the

control difference (difference between set and actual points) in all
operational situations as much as possible (see fig. below). During
optimisation the qualityof control, based on response time, may be
assessed by introducing a step change to the command.

F
F-target F-actual

slow
t
F
F-target F-actual

optimized
t
F
F-target F-actual

oszillates
t

For safety reasons we recommend starting with a small P compo-

nent and a large I component. If the actual tension signal varies
greatly (e.g. unbalanced rollers, lobbing reels) use parameter .2.3.
"F-actual mean value calculation" to set another value to obtain
stronger filtering.
➜ Connect an oscilloscope to the monitor output and measure the ac-
tual tension signal (see connection diagram). This will help you to
optimise more accurately.
➜ First match the P and I -terms and then change the D-term.
We recommend you increase the P-term in 2 % increments and re-
duce the I-term in 5 ms steps alternately. To do so, access expan-
ded setup mode and select parameter numbers .1.5. und .1.6..
Both values, the P and I -terms, are adopted immediately by the
controller.
➜ Increase the P-term and reduce the I-term until you observe an
oscillation of the actuating signal on the oscilloscope (or web oscil-
lation). If oscillation remains strong and does not abate, reduce the
P-term a little again and/or increase the I-term.
➜ Once you have matched the P and I -terms, you may increase the
D-term. To do so, select parameter number .1.7..
➜ Increase the D-term in small increments until oscillation of the actu-
al web tension (or web oscillation) may be observed on the oscillos-
cope. In the event of strong, unabating oscillation you must once
more reduce the D-term a little.

38
 Web tension controller DC 600.

➜ Note down the optimised values in the parameter list.

Controller optimisation is now complete.

Now store the optimised values.

➜ Enter 44 in parameter ..3. "Start Service" and change parameter.
➜ Enter 1 in parameter ..3. "Start Service".

Your settings are now stored, controller commissioning is com-

pleted.

The digital inputs and outputs may be inverted by software. To invert

7. Special proceed as follows:
functions ➜ Select setup mode.
➜ Set 6 in parameter ..0. "Device number" to access parameters for
digital inputs and outputs (see table below) .
➜ Select expanded setup mode, i.e. enter 42 in parameter ..3. "Start
Service" and change parameter.
➜ Select parameter ..6. to invert the inputs or parameter ..7. to invert
the outputs.

Setup mode device number 6 digital inputs and outputs

Parameter number Parameter Entry range Customer setting

..0. Select device number (see connection diagram) 1-F

Set device numbers
Web tension controller = 5
Digital inputs and outputs = 6

..3. Start Service 0 - 44

1 = reset
6 = exit expanded setup mode
42 = select expanded setup mode
44 = store changed parameter values

Expanded setup mode device number 6 digital inputs and outputs

..5. Digital input/output function 1, 2 2

..6. Invert digital inputs 0.0 - F.F hex.

..7. Invert digital outputs 0.0 - F.F hex.

..8. Not assigned -

..9. Not assigned -

39
Web tension controller DC 600.

➜ Function of the digital inputs/outputs

. . . .5.
This parameter must always be set to "2" (web tension control)
➜ Inverting digital inputs
. . . .6.
Inputs 0 to 3 and 4 to 7 are each inverted by a 4-figure binary
code. Logic "0" means not inverted, logic "1" inverted. The binary
code must be entered as a hexadecimal number (see example on
page 34).
Entry range: 0.0 to F.F hex.
➜ Inverting digital outputs
. . . .7. The digital outputs are also inverted by a two-figure hex number
(see digital input inversion explanation)
Entry range: 0.0 to F.F hex.
➜ After input/output inversion, set 5 in parameter ..0. "Device num-
. . . .0. ber and exit setup mode.

0.5 Example: inverting of digital inputs

Inputs 7 6 5 4 3 2 1 0

Binary value 8 4 2 1 8 4 2 1

All inputs "normal" 0 0 0 0 0 0 0 0 bin.

Adress 0.0 hex 0 0 hex.

All inputs inverted I I I I I I I I bin.

Adress F.F hex F F hex.

Input 7, 3, 2 I 0 0 0 I I 0 I bin.
and 0 inverted

Adress 8.D hex 8 D hex.

40
 Web tension controller DC 600.

➜ Insert web.
8. Operation
➜ Enter tension set point, press the tension set point key
- once, LED lights up. In the first line of the display the web tension
set point is indicated, in the second line the web tension actual
value.
- twice, LED flashes. Use the "Increase value, decrease value"
keys to set the desired tension set point.
- three times, LED lights up, the tension set point is stored.
or specify web tension set point via the analog input of the same
name.
or control according to a material-specific parameter record, press
material-specific parameter record key
- once, LED lights up. The number of the current parameter record
is indicated in both lines of the display.
- twice, LED flashes. Use the "Increase value, decrease value"
keys to set the new parameter record (0-7). The number is indica-
ted in the first line.
- three times, LED lights up. The parameter record is adopted, the
number is indicated in both lines. If you try to set an invalid para-
meter record, the LED will flash.

➜ Correct the start diameter if necessary (for winds and unwinds

with diameter calculation only). If the start diameter has changed
due to a batch change, press the start diameter key
- once, LED lights up. In the first line, the most recently entered
start diameter is indicated, in the second line the most recently
established batch diameter.
- press again, LED flashes. Use the "Increase value, decrease
value" keys to set the new start diameter.
- press a third time, LED lights up, the start diameter is stored.

➜ Set automatic (controller enable via machine control), display

lights up.

41
Web tension controller DC 600.

A system error is indicated by logic 0 at the output "system operatio-

9. Error code nal" and in parameter number ..5. by an error code.
If "HELP" appears on the display, not all calibration / adjustment pro-
cedures have yet been performed.
Once an error has been identified and cleared, a "0" must be entered
in parameter ..5. or a reset performed in parameter ..3. Error codes
3 and 4 refer to the input that was calibrated last.

Error code table

Error code Operation

0 No error
Output "System operational" logic "1"

1 Not recognized:
Contact E+L service center

2 Intern. establ. measuring range smaller than set measuring range:

set parameter .2.4. max. tension to a lower value

3 Analog input offset is greater than ±1 V and not may therefore

be overriden (line offset is too high):
reduce line offset

4 Analog input is greater than ±10 V (maximum permissible value):

check and reduce input voltage

5 Zero point adjustment not possible as self weight of

measuring axle greater than 100 % measuring range:
contact E+L service center

6 Calibration weight for specified measuring range is too small:

increase calibration weight

7 F-target is higher than permissible:

change parameter .2.4. F max.

8 Line speed (V-web target) higher than permissible:

change parameter .2.6. V-web target max.

9 Batch rotational speed higher than permissible:

change parameter .2.8. max. batch rotational speed

10 Web tension greater than permissible (load cell overload):

change maximum permissible web tension and
recalibrate measuring amplifier

18 Diameter constant incorrect:

readjust diameter capture (chapter 6.9)

19 Measuring amplifier tension calibration incorrect:

repeat calibration

20 Analog inputs zero point adjustment incorrect:

Recalibrate analog inputs

21 Analog inputs calibration incorrect:

Recalibrate analog inputs

42
 Web tension controller DC 600.

Calibrating analog inputs on error codes 20 and 21

When error codes 20 and 21 occur all 3 analog inputs must be
calibrated.
The calibrating procedure is the same for the three inputs. The values
listed in lines A, B and C in the table below must be entered.

Input 1 Input 2 Input 3

Terminal DC 6000: + 24c / -26c Terminal DC 6000: + 22a / -24a Terminal DC 6000: + 26a / -28a
Terminal DC 6001: + X 10.7 / -X 10.8 Terminal DC 6001: + X 10.3 / -X 10.4 Terminal DC 6001: + X 10.5 / -X 10.6
Line F-target external N-batch actual V-web target
or F-actual external or D-batch actual
or start diameter
A 18 15 12
B 19 16 13
C - 17 14

➜ Apply a 0 V (or 0 mA respectively 4 mA, see parameter 36) to the

analog analog input to be calibrated.
input A B C
➜ Set the appropriate value from line "A" in parameter ..3. "Start Ser-
+ -
vice" and change parameter to adopt the entry.
0V 10 V 10 V
➜ Apply +10 V (or 20 mA) to the analog input.
- +
➜ Set the value from line "B" in parameter ..3. "Start Service" and
change parameter.
Calibrating analog inputs
➜ Change the polarity of the voltage supplied to the analog input.
➜ Set the value from line "C" in parameter ..3. "Start Service" and
change parameter. (This entry is not required for input 1)
➜ Once all three inputs are calibrated, reconnect them according to
the connection diagram.

43
44

10. Control diagram

Web tension controller DC 600.
0.15.
0.16. recipe 0.38.
0.21. 0.17. number 0.20. 0.39. 0.28. 0.40. 0.37.

0
F-target +/- dV scale
1
0
signal-output
1
scale
F-actual

0.26.

0.26.

web-target scale V-web-target

Technical data subject to modification without notice

0.28.

0.30.
D=V/N 0.32. 0.31. 0.35.
N-winder scale

Telefax (0821) 24 35-666

F-actual

Erhardt + Leimer GmbH

1

Phone (0821) 24 35-0

D-start monitor-output
1 0

D-86136 Augsburg
Postfach 10 15 40
D-actual 0 D-actual
3
0.27.

V-limit
0.29.

N-limit
0.25.

F-actual-limit

D-actual Actual batch diameter N-winder Actual batch speed

F-actual F-Actual tension value Recipe number Material-specific parameter record
F-actual limit F-actual tension limit value Scale Scaling
F-Target F-tension set point Signal-output Actuating signal
Monitor output Monitor output V-limit Set line speed limit value
N-limit Actual batch speed limit value V-Web-target Set line speed