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ALTEC

TENSION CONTROLLER
TC950

INSTRUCTION MANUAL
TENSION CONTROLLER TC950 ALTEC

Table of Contents

1 Introduction ............................................................................1
2 Features ..................................................................................1
3 Order Code .............................................................................2
4 Installation ..............................................................................2
5 Electrical Wiring.....................................................................3
6 Operator Interface..................................................................6
7 Operation ................................................................................7
8 Operation of Tension Control System .................................10
9 Tension Calibration................................................................13
The Mounting of SUP Series Tension Sensor..........................15
Typical Applications ...................................................................15
Technical Data ............................................................................18

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TENSION CONTROLLER TC950 ALTEC

1 Introduction

The TC950 Tension Controller is an application-specific controller designed to provide you with precise
control over winding and unwinding tension control applications for web and strand.

The tension controllers can be divided into manual, half-automatic and full automatic controller. According to
the different needs of customers, the TC950 tension controller can be configured as manual, half-automatic
or full-automatic tension controller.

For manual tension controller, the operator adjusts the actuation current of the powder clutch/brake manually
to get the desired tension control.

The half-automatic tension controller also known as diameter or opened-loop tension controller, the tension
controller calculates the reel radius automatically during winding or unwinding process, according to the
current reel radius and setting tension, the tension controller adjusts the output to get the constant tension
controls.

The full automatic tension controllers detect the web tension with tension sensor directly. According to the
difference between setting tension and measured tension and the build-in PID algorithm, the controller
adjusts the output automatically to get the precision constant tension control of the web.

2 Features

● Full digital circuits, easy tension calibration. ● Measured Tension transmission.

● Speed synchronous tracking function, speed ● Automatic/Manual tension control.


signal input range: 0~10V.
● Reel exchange function.
● Various optional outputs for different
applications. ● Wide range switching power supply (85~264V).

● Advanced PID control algorithm provides high ● Friendly user interface, easy to use.
control precision.
● More cost efficient.
● RS485/RS232 serial communications.

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TENSION CONTROLLER TC950 ALTEC

3 Order Code
Model Number - Output Comms Comments
TC950 - Automatic Tension Controller
A420 4~20 mA
V10 0~10 V
V05 0~5 V
PWM Pulse Width Modulation
Y1 Phase-shifting signal
0 None
RS232 RS232
RS485 RS485
BS Measured tension(PV) transmission

Model code examples:


TC950-A420-0:TC950 with 4~20mA outputs.
TC950-V10-0: TC950 with 0~10V outputs.

Note:
For phase-shifting output, please specify the frequency of the power supply if it is not 50 Hz.

4 Installation
1). Prepare a square cut-out on the mounting panel to the size shown below.
2). Insert the controller through the cut-out.
3). Catch the mounting bracket to the holes top and bottom of the case, and screw to fix.

+ 0 .5
Cut-out:□92 - 0 .0

AL

.
M
CO

8 .8 .8
N

PV
.
8 .8 .
%

.8 TO

8.8
AU
B
SV D
H AN
P
A D IS C T
N LE
RU SE
OG
ON PR T
T
T1
OU SE
OU UT C
TP TE
T2 OU /OFF AL
OU ON
L
CA TO
T AU D
SE N
HA
R
PA
T
SE

0
95
TC

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TENSION CONTROLLER TC950 ALTEC

Dimensions

8.8.8.8.
PV
AL

COM

8.8.8.8.
SV N

□91
R

OUT1 RUN HAND AUTO

OUT2 OUT ON A B

CAL OUTPUT PROG DISP


SET ON/OFF SET SELECT

PAR AUTO
SET HAND

TC950 ALTEC

100 10
□96

5 Electrical Wiring
Notice

● In order to avoid electrical noise to the input signal, the signal line should be seqarated from the power
line.

● If the AC power supply is connected to the I/O terminals or DC supply terminals, the tension controller will
be burn out.

5.1 Rear Terminals Layout

1 21 31 11

2 22 32 12

3 23 33 13

4 24 34 14

5 25 35 15

6 26 36 16

7 27 37 17

8 28 38 18

9 29 39 19

10 30 20

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TENSION CONTROLLER TC950 ALTEC
5.2 Wiring Diagram

1 31 11
Power Supply AL1
100~260VAC
2 32 12
MC2
3 33 13 Reel exchange
MC1
+ 4 34 14 Run/Stop
OUT1
MCC
- 5 35 15

6 36 16 +
Vin Synchronous Speed
Tracking Signal (0~10V)
+ 7 37 17 -
OUT2
- 8 38 18 +
T/R(+)
Input 1 Tension Signal Input
RS485/
9 39 19 -
PV Transmission
10 20
T/R(-)

1) OUT1 and OUT2 can be configured as 0~20mA or 4~20mA, max load capacity: 750Ω.
2) Alarm relay (AL1) contact rating: 3A/250VAC.
3) The wire connected to terminal 13, 14 and 15 must be shield cable and far away from the power/load line otherwise
the electrical noise may damage the controller.

5.3 TC950-Y1 Wiring (Drive SCR)

Power supply 1 31 11
100~260VAC AL1
2 32 12
MC2
3 33 13 Reel exchange
Sync. Voltage MC1
4 34 14 Run/Stop

G1 MCC
5 35 15
K1
6 36 16 +
Vin Speed Synchronous
To SCR
G2 Tracking Signal (0~10V)
7 37 17 -
K2
8 38 18 +
Input 1 Tension Signal Input
T/R(+)
RS485/ 9 39 19 -
PV Transmission
10 20
T/R(-)

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TENSION CONTROLLER TC950 ALTEC

5.3.1 Half-Bridge Rectifier Connection

6
K1 Protection Diodes for
5
G1 Inductive Loads
8
K2
7
G2
3
DC Motor or
TC950-Y1 4 Sync. Voltage M other Loads

220VAC

Half-Bridge Rectifier Module

5.4 Tri-Phase Torque Motor Driver Connection (TC950-V05)


The TC950 tension controller can output a signal of 0~5V. The signal can be applied to the tri-phase torque
motor driver (model: AL33) to drive the torque motor directly. This driving system is simple, reliable, etc...,
idea for various high precision tension control systems.

Several models are available for AL33 series torque motor driver, please specify the motor’s power or current
while ordering.

380VAC
C B A
~ ~ ~

TC950-V05

C1 B1 A1 12VDC
6
5 OUT1
4
Torque Motor Driver 4
3 5
2 0V
1

C2 B2 A2

M Torque Motor

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TENSION CONTROLLER TC950 ALTEC

6 Operator Interface

0. 2 . 4.9 .
PV
AL 5
1 COM

6
8. 2 . 5.0 .
SV N

%
2
R

3 OUT1 RUN HAND AUTO

4 OUT2 OUT ON A B

CAL OUTPUT PROG DISP


7 SET ON/OFF SET SELECT

PAR AUTO
8 SET HAND

TC900 ALTEC

SN Item Description SN Item Description

Indicates the Process Value, N Tension SV displaying LED


1 PV Display Parameter display
6 % Output power displaying LED

Indicates the Setting Value, R Sync. speed displaying LED


2 SV Display parameter value, output power
OUTPUT
ON/OFF
Output ON/OFF switch
OUT1 Output 1 indicator
PROG
Run indicator, lit when the 7 Programming key
RUN Run/Stop switch(MC1-MCC) is ‘ON’
SET
3
DISP
HAND Manual mode indicator SELECT
Lower display selector

AUTO Automatic mode indicator PAR


SET
Parameter scroll key
OUT2 Output 2 indicator
AUTO Automatic/Manual mode
Output ON/OFF LED switching key
OUT ON lit when output is ‘ON’
HAND
4 8
A Reel A running indicator Raise key, increase value

B Reel B running indicator


Lower key, decrease value
AL Alarm indicator
5
COM Communication indicator

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TENSION CONTROLLER TC950 ALTEC
7 Operation
7.1 Display & Basic Operation
There are two LED displays indicate the operating parameters.
The upper display(green) indicates the measured tension value(PV) when in base condition. On modifying a
parameter, the appropriate parameter appears.

The Lower display(red) indicates the setting tension value(SV) in the automatic mode. On modifying a
parameter, the appropriate parameter value appears here. This display also indicates the output power in
some case.

When the controller is powered on, the upper display indicates the model code of the controller, and the
lower display indicates the software version.

3 seconds later, the upper display will indicates the measured tension(PV) while the lower display will
indicates the setting tension(SV).

The type of contents displayed on the lower display is changed every time the ‘Lower display selector’ key is
pressed. The type of contents displayed is indicated by the LED provided on the right side of the lower
display.

Press the AUTO/HAND key, the automatic operation mode and manual operation mode can be changed
conveniently.

When TC950 performs automatic operation, indicator ‘AUTO’ will be lit, if the setting tension is displaying on
the lower display(at this time, LED ‘N’ is lit) press keys ▲ and ▼ to modify the setting tension. Adjustable
range: SP K~SP L.

When the controller performs manual operation, indicator ‘HAND’ will be lit, if output power is displaying on
the lower display(at this time, LED ‘%’ is lit) the control output power can be modified by pressing ▲ and ▼
key.

Control output can be turned ON or OFF by pressing ‘OUTPUT ON/OFF’ key. When indicator ‘OUT ON’ is lit,
output is ‘ON’ otherwise output is ‘OFF’, the output value becomes 0.

In automatic operation mode and when MC1 switch is turned on, indicator ‘RUN’ will be lit; when MC1 switch
is turned off, indicator ‘RUN’ will be off.

When ‘Synchronous Run/Stop’ function is available(SYNT = YES), and the Run/Stop switch is turned on.

When VIN > AL,N, system starts, indicator ’RUN’ will be lit.
When VIN < AL,N, system stops, indicator ’RUN’ will flash.

Run/Stop doesn’t act in reel exchange progress.

The green LEDs ‘OUT1’ and ‘OUT2’ indicate the current control output level, higher the output power level,
brighter the LED. The LED will be turned off when the output becomes 0.

LED indicator ‘A’ indicates the output status of Reel-A, it is lit when Reel-A output is ON.
LED indicator ‘B’ indicates the output status of Reel-B, it is lit when Reel-B output is ON.

When measured tension is lower than ‘zero tension alarm value’(Code AL0), zero tension alarm indicator ‘AL’
will be lit and at the same time the alarm relay will be ‘ON’, generate an alarm signal. Zero tension alarm
don’t act in Run/Stop and reel exchange progress.

The indicator 'COM' flashes when the controller is in active communication with a host computer.

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TENSION CONTROLLER TC950 ALTEC
7.2 Modifying the Operation Parameter

When the controller is in the PV/SV displaying status, press PAR/SET key and hold for 3 seconds reveals the
first parameter. The parameter value can either be modified with the ▲ or ▼ key, or left unmodified. Press
PAR/SET key again, the next parameter and its current value appears, the modified data has been saved.

If the last parameter is displayed or there’s no key operation within 16 seconds, the menu times out
automatically.

Operation Parameter List

SN Mnemonic Parameter Adjustable Range Comments


Appears if SYNT = ON
1 AL,N Start speed 0.1~30.0% If VIN > AL,N, system starts
If VIN < AL,N, system stops
2 AL0 Zero tension alarm value 0.0~999.9 Kg Only alarms while running
3 P.ON Start output value 0~100.0% Available when PL.ON = KAND
4 T.ON Start time 1~30.0 seconds
5 P.OFF Stop output value 0~100.0%
6 T.OFF Stop time 1~30.0 seconds

The smaller PROP value, the faster response


7 PROP Proportional band 0.1~999.9 Kg
The greater PROP value, the slower response

The smaller INT.T value, the faster response


8 INT.T Integral time 0.1~10.0 seconds
The greater INT.T value, the slower response

The greater DB value, the more stable but


9 DB Dead band 0.1~999.9Kg slower response.

10 P.CHA Reel exchange output 0~100%


11 T.CHA Reel exchange time 1~30.0 seconds
12 OVT2 Output 2 0.0~100.0%
Speed Synchronous Appears when the speed synchronous tracking
13 D1 -2.00~2.00
Coefficient function is enabled.( P.,N2 = ON)
14 LOC Configuration password 0~9999 Set to 808 to enter the configuration menu

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TENSION CONTROLLER TC950 ALTEC
7.3 Software Configuration

The TC950 tension controller must be configured properly in order to perform the correct control function.
How to enter software configuration menu:
1) Press PAR/SET key and hold for 3 seconds to enter the first level menu(i.e. operation parameter list);
2) Press PAR/SET key to scroll the parameter to LOC and set its value to 808(the initial password);
3) Press PAR/SET key, the first parameter appears on the upper display, at the same time the lower display
will display the value of this parameter. The values can be modified by pressing keys ▲ and ▼ . After
modification, press the PAR/SET key, the next parameter appears, at the same time, the modified data has
been saved in the memory.
If the last parameter is displayed or there is no key operation within 16 seconds, the controller will return
back to the PV/SV display status.
After configuration, set the configuration password(code LOC) to data other than 808 in order to protect the
parameter values from being inadvertent modification.

Software Configuration Paramter List


SN Mnemonic Parameter Adjustable Range Comments
1 SP K Tension setpoint high limit Measurement Range always > SP L
2 SP L Tension setpoint low limit Measurement Range always < SP K
3 K PL Max output power 0.0~100.0%
“Speed synchronous Appears if P.,N2 = ON
4 PL1 0.0~100.0%
tracking” Power Limitation
5 0FST Input/calibration offset -9.99~10.00
TC without tenths’ precision
6 SN Display units of input signal
.TC with tenths’ precision
7 ADDR Instrument address 00~99
8 BAVD Baud rate 2400, 4800, 9600, 19.2
P,D Constant tension control
9 (TRL Control algorithm
R SP Taper tension control
10 SPRR Taper ratio 0.01~10N/min. Appears if (TRL = R SP
0-20 0~20 mA
11 0P1 Output 1
4-20 4~20 mA
0-20 0~20 mA
12 0P2 Output 2
4-20 4~20 mA
0FF Alarms OFF
13 AL1 Alarms K,AL Full-scale high alarm
LOAL Full-scale low alarm
D,R direct control
14 ACT Control action
REV reverse control
NO Disable
15 SYNT Synchronous Run/Stop
YES Enable
Speed synchronous ON Enable
16 P.,N2 tracking function 0FF Disable
AVTO Automatic setting
17 PL.ON Start output selection
KAND Manual setting
18 F,L Input filter 0.01~99.99
P1 zero tension calibration
19 PROC Tension calibration
P2 full-scale tension calibration

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TENSION CONTROLLER TC950 ALTEC
8 Operation of Tension Control System
8.1 Speed Synchronous Tracking Function

When P.,N2 = ON, the ‘speed synchronous tracking function’ is enabled, Speed Synchronous
Tracking Signal*DI(Speed Synchronous Coefficient) will be added to the control output.
In winding systems, normally set DI as positive(DI > 0), when systems speed up, the control output increase with the
system speed at the same time, make the system speed synchronous.
In unwinding systems, normally set DI as negative(DI < 0), when systems speed up, the control output decrease with the
system speed at the same time, make the system speed synchronous.
When P.,N2 = 0FF, the ‘speed synchronous tracking function’ will be disabled, the parameter DI will be hidden.

8.2 Run/Stop
The run/stop operation of TC950 tension controller is controlled by terminal MC1 and MCC. Connect a switch
across the terminal MC1 and MCC, the switch is called Run/Stop switch of the tension system. See the
wiring diagram.

ON OFF

MC1 input

Speed Stop timer


T.ON Start timer T.OFF

0 t
Control output
Stop output(P.OFF)
Automatic control output

Start output(P.ON) Start output(P.ON)

0 t
Starting Procedure: Before starting, TC950 outputs P.ON to generate preparatory tension. When the
Run/Stop switch(MC1-MCC) is turned on and after an overflow of time set in start timer T.ON, the automatic
control will start. At this time, indicator ‘RUN’ will be lit. See the figure above.

Stopping Procedure: When the Run/Stop switch is turned off, the controller output stop power P.OFF instantly
until the stop timer T.OFF times up. After that, controller outputs P.ON to generate preparatory tension. At this time,
indicator ‘RUN’ will be turned off. See the figure above.

When ‘Synchronous Run/Stop’ function is enabled(SYNT = YES), the run/stop operation is not only controlled by the MC1
input but also the synchronous speed tracking signal(Vin).

When Run/Stop switch is turned on and VIN > AL,N, system starts, indicator ’RUN’ will be lit.
When Run/Stop switch is turned off and VIN < AL,N, system stops, indicator ’RUN’ will flash.

In full automatic tension control systems, generally short-circuit MC1 and MCC, the system will run/stop according to the
tracking speed automatically. TC950 don’t act run/stop operation during reel exchange process.

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TENSION CONTROLLER TC950 ALTEC

8.3 Start Output Selection


The system’s start output is controlled by the ‘start output selection’ parameter(code: PL.ON).
When PL.ON = KAND, the start output is P.ON saved in controller memory(can be modified manually).
When PL.ON = AVTO, the start output is the output when system stops.

8.4 Reel exchange


In the two-reel operation, the reel exchange is controlled by the ‘reel exchange’ switch(MC2-MCC). This
function is applicable when material on reel is over or full.
When the switch is turned off, reel A is active.
When the switch is turned on, reel B is active.

Reel A Reel A

Reel B Reel B

Control output
OVT2(Auxiliary output) OVT2(Auxiliary output)

Reel-A output OUT1

OVT2(Auxiliary output)
Control output OVT2(Auxiliary output)
Control output

Reel-B output OUT2

Reel Exchange Process


Assume that reel-A is controlled by OUT1 and reel-B is controlled by OUT2.
Suppose that the reel exchange switch is off, reel A is active. At this time, if change the switch from OFF to
ON, the control output exchanges to reel B. The control output is preset to P.CHA. When the reel exchange
timer T.CHA times up, the automatic control starts. At the same time, the auxiliary output OVT2 is applied to
reel A to brake reel A.
For exchanging from reel B to reel A, reverse above process. See the figure above.

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TENSION CONTROLLER TC950 ALTEC

8.5 Taper Tension Control

Set ‘Control algorithm’(Code [TRL) to RSP, TC950 is configured as Taper Tension Controller.

In winding tension control systems, to prevent the material from winding too tight or too loose on the reel,
TC950 may be setting as Taper Tension Controller. This control as to increase/decrease the working
tension depending on the change in winding diameter, in which the tension is controlled in accordance with
the preset pattern, to suit the change in winding diameter.

The TC950 decreases the target tension according the the presetting taper ratio SPRR, to get the purpose of
taper tension control.

While TC950 is working in taper tension control mode and the indicator ‘N’ is lit, the lower display will indicate
the setting tension, when the indicator ‘R’ is lit(Press DISP/SELECT key), current target tension F appears in
the lower display.

When [TRL = P,D, TC950 is configured as constant tension controller which is idea for unwinding tension
controls.

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TENSION CONTROLLER TC950 ALTEC

9 Tension Calibration

The tension controller must be calibrated after


Tension sensor
installation, and only the proper calibrated
controller can get the desirable measurement
precision. Suspend weight

The controller uses two-points linear calibration


method, the process is very easy.
Tension sensor
Stretch a string in the
center of the roller.

Input signal calibration

The input to the controller must be between -10~50mV, voltage signal which exceed this range must
be attenuated with an appropriately sized input adapter. Current signals are converted to the -10 to
50mV range with a shunt input adapter.

Sensor 1
+ red

+ green
Power Supply 1(10V) +
- black - white

+ red Tension Siganl outputs

Power Supply 2(10V) + green

- white
- black -
Sensor 2

Two tension sensor connection diagram

Note: Connect the tension sensor according to the wiring diagram before calibration.

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TENSION CONTROLLER TC950 ALTEC
9.1 Zero Tension Calibration(P1)

Step Button Operation Display

1
Turn on the power switch, add no weight on the tension sensor, PROC
press PAR/SET key until PROC appears in the upper display ----

2 Press ▲ key, P1 appears in the lower display PROC


P1

3
Press PAR/SET key, the number in the lower display will be the value P1
after adjustment assigned to the injected input signal 15 . 0
Press ▲ and ▼ key to adjust the number in the lower display until it P1
4
corresponds to the represented by the injected signal 0.0

5 Press PAR/SET key 0.0


NO

6 Press ▲ key to affirm 0.0


YES

7
Press PAR/SET key, P1 appears in the upper and lower display at the P1
same time P1

8 5 seconds later, the scaling of the 1st point is completed PROC


----
9.2 Full Scale Tension Calibration(P2)
(Suppose that the max load of the tension sensor is 50.0Kg in this example)

Step Button Operation Display

1
Load weight of 50Kg on the tension sensor, press PAR/SET key until PROC
PROC appears in the upper display ----

2 Press ▼ key, P2 appears in lower display PROC


P2

3
Press PAR/SET key, the number in the lower display will be the value P2
after adjustment assigned to injected input signal 45 . 0
Press ▲ and ▼ key to adjust the number in the lower display until P2
4
it corresponds to the value represented by the injected signal(here 50) 50.0

5 Press PAR/SET key 50.0


NO

6 Press ▲ key to affirm 50.0


YES
Press PAR/SET key, P2 appears in the upper and lower display at P2
7
the same time P2

8 5 seconds later, the scaling of the 2nd point is completed PROC


----

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TENSION CONTROLLER TC950 ALTEC
Appendix A: The Mounting of SUP Series Tension Sensor

Bearing

Spacer

SUP series tension sensor


>2mm
Spacer
Force
>2mm

Please note that the force direction of tension sensor.

Appendix B: TC950 Typical Application 1

Tension Sensor

Induction Motor

4~20mA
C
TE
AL

00
TC9

TC950-A420 Inverter

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TENSION CONTROLLER TC950 ALTEC

Appendix C: TC950 Typical Application 2

Tension Sensor

Torque Motor

Phase-shifting signal
C
TE
AL

0
90
TC

TC950-Y1 SCR Module

Appendix D: TC950 Typical Application 3

Tension Sensor

Magnetic
Powder Brake

0~5V

RSP Power Unit


TC950 Tension Controller (24V/4A)

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TENSION CONTROLLER TC950 ALTEC

Appendix E: TC950 Typical Application 4

Tension Sensor

Magnetic
Powder Clutch

Motor

0~5V

RSP Power Unit


TC950 Tension Controller (24V/4A)

Appendix F: TC950 Typical Application 5

Plating Roller

Tension
Sensor
Plating Solution

Reel-B Magnetic Reel-A Magnetic


Powder Brake Powder Brake

0~5V

0~5V
RSP Power Unit
(24V/4A)
TC950 Tension Controller
RSP Power Unit
(24V/4A)

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TENSION CONTROLLER TC950 ALTEC

Appendix G: TC950 Typical Application 6

Print Roller A Print Roller B Print Roller C

Unwinding Reel Winding Reel

Tension Sensor Tension Sensor Tension Sensor Tension Sensor

M1 M2 Torque
Motor
Motor M3 Torque
Motor
M4 Torque
M5 Motor

TC808
PV

8888
8.8.8.8. 8.8.8.8. 8.8.8.8.
TENSION CONTROLLER
SV

8888 8.8.8.8. Speed 8.8.8.8. 8.8.8.8.


Inverter Setting
ALTEC

TC90 0 ALTEC TC90 0 ALTEC TC90 0 ALTEC

Electromagnetic Inverter Speed sync signal Inverter Inverter


Powder Brake

Technical Data

Resolution ±0.2%FS ± 1 digit

Sampling rate 100 ms


Tension signal input 0~50 mV

Analog, 4~20mA, 0~20mA, 0~10V


Outputs PWM
Phase-shifting output

Relay, NO, Max.250VAC, 2A


Alarm
Zero tension alarm
Control algorithm PID
RS232
Communications
RS485
Power supply 100~260VAC, 50/60 Hz
Ambient temperature: 0~50 °C
Environmental
Relativity humidity: ≤85%
Dimensions 96mm(W)*96mm(H)*100mm(D)

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