TC818 fully automatic and roll diameter tension controller
TC818 tension controller adopts graphic LCD display, can choose Chinese and English display, the interface is friendly and easy to use, it can output 0 ~ 24V / 4A or 0 ~ 36V / 3A to directly drive magnetic powder clutch, magnetic powder brake, or 0 ~ 5V ~ 20mA, -5V ~ + 5V signal, control the inverter, servo motor or other actuators, and perform tension control on the coil system. Can be widely used in papermaking, printing, packaging, textile dyeing and other industries.
TC818 can be set as a fully automatic tension controller or a roll diameter tension controller. When function selection   is set to automatic tension control, TC818 is a fully automatic tension controller, which requires a tension sensor to form a closed-loop control system. . When the function selection  is set to the roll diameter tension control, TC818 is the roll diameter tension controller. It only needs to install a proximity switch / encoder to measure the roll radius, and the controller controls the roll diameter tension.
The fourth chapter mainly introduces the debugging and operation of the automatic tension controller, and the fifth chapter mainly introduces the debugging and operation of the coil diameter tension controller.
128x96 graphic liquid display is used, Chinese or English display is not selected, and the operation interface is friendly.
Can choose full automatic tension control or roll diameter tension control function.
Full digital design, no adjustable potentiometer, simple tension calibration process, accurate, stable and reliable tension measurement.
Can receive single / double sensor input signals, adapt to various tension sensors as input signals:
①. Special micro-displacement tension sensor can be selected (input signal range is 200mV, power supply 5V)
②. Strain gauge type tension sensor can be selected (input signal range is 20mV, power supply is 10V)
③. It can be connected with 0 ~ 2KΩ resistance signal to measure the angular displacement. It is used for the floating roller tension control system.
The use of a proximity switch to measure the roll diameter can achieve the taper tension control function.
Optional serial communication function, optional RS485 or RS232 communication interface and PLC, PC form a distributed system.
The PID algorithm without overshoot is used to ensure that there is no overshoot during the start / stop of the system.
With dual-axis switching function and acceleration / deceleration control function.
The automatic / manual control mode is particularly disturbing to switch.
Password protection to prevent accidental modification.
The adaptable switch source (92 ~ 264V) is used to ensure long-term reliable operation.
 Controller parameters. The numbers in  indicate the parameter numbers. All parameters are expressed in this form.
TC818 tension controller hardware uses a modular structure, and the model definition is as follows:
(1) TC818-36V / 0/0 / 0-V3.00 means the tension controller whose main output is 36V / 3A and the software version number is V3.00.
(2) TC818-24V / V05V05V0-V4.00 means the tension controller whose main output is 24V / 4A, auxiliary output 1 and auxiliary output 2 are 0 ~ 5V, and software version number is V4.00.
4. Operation interface and operation introduction
1. Set / Esc key: Use these two keys to confirm the selection or setting of various menus.
Set key: Enter the lower menu or confirm execution.
Esc key: return to the previous menu or confirm the return.
2.Auto/manual switch key and indicator
Press this key to realize two-way non-disturbance switching between automatic control mode and manual control mode.
When the controller works in the automatic control mode, the automatic control indicator light (AUTO) lights up. You can rotate the value setting knob or press the increment / decrement key to modify the tension setting value. Press the AUTO / MAN key to switch to the manual control mode .
When the controller is stopped, the AUTO indicator flashes.
When the controller works in the manual control mode, the manual control indicator (MAN) is on. You can rotate the value setting knob or press the increment / decrement key to directly modify the output value. Press the AUTO / MAN key to switch to the automatic control mode.
When the controller switches from the manual control mode to the automatic control mode, the controller sets the measured value at this time to a set value to achieve a trouble-free switching.
When the tension measurement is wrong and the fault code is displayed, the controller will automatically switch to the manual control mode, and you cannot switch to the automatic control mode by pressing the AUTO / MAN key.
3.Output switch key and indicator
This key controls the output switch. Press this key repeatedly to switch the output between ON / OFF.
When output is enabled, the OUTPUT ON / OFF indicator is on;
When the output is disabled, the OUTPUT ON / OFF indicator is on, the LED indicator shows OFF, and the output value is 0.0%.
4.LED display switch key and indicator
Press this key to make the LED display window display the tension measurement value (kg / N indicator is lit), output value (% indicator is lit), and the diameter of the coil (mm indicator is lit).
5.Key lock key
When the controller is in the "automatic control" or "manual control" display interface, this key is used to lock (prevent misoperation) or unlock. After the key is locked, the increment key, decrement key, Set / Esc key, automatic / manual switch The key, output key and value setting knob are disabled.
The LOCK indicator is on to indicate lock, and the LOCK indicator is off to indicate that it is not locked.
If the function selection  is set to the roll diameter tension control, when it is in the "password input" display interface, press this key to restore the roll radius to the initial roll diameter R1. If the control mode  is set to curve program control at this time , Press this key to enter the “roll diameter-output” parameter setting menu to view or modify the curve program.
6. OUT: output indicator
This indicator is green. The brightness of the indicator is related to the output value. The larger the output value, the brighter the indicator.
When the output value is zero, the OUT indicator goes out.
7. OUTA: A-axis output indicator
This indicator is red. When the A axis is output, the indicator is on.
8. OUTB: B-axis output indicator
This indicator is red. When the B axis is output, the indicator is on.
9. ALM: tension alarm indicator
This indicator is red. During the operation of the tension system, according to the settings of the alarm output  and the tension alarm value , when the alarm conditions are met, the ZT relay will act and generate an alarm signal. No alarm during system start / stop and axis cutting. See alarm function for details.
10. COM: Communication indicator
This indicator is red. The TC818 receives a valid command from the host computer, and the COM indicator lights when the data is returned.
Installation and electrical connection
TC818 tension controller can adopt horizontal installation, vertical installation or screen opening installation method:
3.1 Wiring precautions
 The input and output signals should be kept away from strong wires such as the power cord and power cord of the instrument to avoid signal interference.
 Make sure that the weak current terminals such as input and output cannot be connected to strong current, otherwise the entire meter will be burned.
3.2 Wiring diagram
3.3 Terminal description
Terminal block 1:
Connected to 220V AC power
Tension alarm output
Output 24V / 4A or 36V / 3A
Connected to A-axis magnetic powder clutch or magnetic powder brake
Output 24V / 4A or 36V / 3A
Connected to B-axis magnetic powder clutch or magnetic powder brake
External input switch signal common terminal
External start / stop control signal input terminal
External biaxial switch control signal bow input terminal
External acceleration control signal input terminal
Pre-output selection switch input terminal
External deceleration control signal input terminal
Output ON / OFF control signal bow input terminal
+ 24V, GND
Power supply for external proximity switch (or rotary encoder)
Spindle proximity switch input terminal
Terminal block 2:
A-axis proximity switch input terminal
B-axis proximity switch input terminal
〜200mV 或0 〜20mV 或0 〜2K电阻信号 Input signal range 0 ~ 200mV or 0 ~ 20mV or 0 ~ 2K resistance signal
Left tension sensor input signal +
Left tension sensor input signal-
Output supply voltage 5V or 10V
Left tension sensor power supply +
Left tension sensor power-
〜200mV 或0 〜20mV Input letter bow range 0 ~ 200mV or 0 ~ 20mV
Right tension sensor input signal +
Right tension sensor input signal-
Output supply voltage 5V or 10V
Right tension sensor power supply +
Right tension sensor power-
0 ~ 20mA or 0-5V
〜5V，接A轴执行机构) Auxiliary output 1 (0 to 5V, connected to A-axis actuator)
0 ~ 20mA or 0-5V
〜5V,接B轴执行机构) Auxiliary output 2 (0 to 5V, connected to B-axis actuator)
TR + .TR-.TRG
Connect RS232 to RS485
RS232 / RS485 communication interface
Third, the menu operation
1. Picture and menu structure
2.Main screen introduction
(1) Automatic control-constant tension mode operation screen
(2) Automatic control—taper tension mode operation screen
(3) Manual control mode
(4) Tension measurement value monitoring
(5) Password interface
(6) Parameter menu
The following table sorts the parameters by function
Fourth, automatic tension control
Follow these steps to debug:
 Make sure that the tension controller is installed and connected correctly and then connected to the power supply.
 Make sure that the tension sensor is installed and connected correctly. Check and determine if the tension sensor signal is normal.
 Program related parameters for tension measurement.
 Calibrate the zero point and full scale of the tension signal, and confirm that the tension display is normal. If the tension display is abnormal, return to step .
 Check the system through manual adjustment and operation to confirm that the tension display is normal and the actuator is running normally.
 If the above steps are normal, switch to automatic control mode and adjust the PI parameters according to the operating conditions to ensure the smooth operation of the tension system.
1.1 tension sensor installation and wiring
TC818 can accept a variety of tension sensor input signals, and different jumpers should be set for different sensors:
 Special displacement sensor for micro displacement, input signal range is 200mV, 5V power supply (such as LX series, compatible with Mitsubishi tension sensor);
When using this type of sensor, please short the jumpers JP7 and JP8 on the control board, J8 to + 5V, and output 5V power.
 Strain gauge tension sensor, input signal range is 20mV, 10V power supply (such as SUP series, CTS / HTS series);
When using this type of sensor, please disconnect the jumpers JP7 and JP8 on the control board, J8 jump to the + 10V position, and output 10V power.
 In the floating roller tension system, when the selected angle sensor is a 0 ~ 2KΩ point device, please short the jumper L1 on the control board (provide a constant current source for the point device), JP7, JP8 Short.
1.2 Tension measurement related parameter settings
In order for the controller to measure the coil tension correctly, the parameters related to the tension measurement must be set correctly:
1. Sensor selection 
This controller can select single or two tension sensors to work, please set according to the installation of the sensor.
In the floating roller tension system, only one angle sensor (terminals GRL, WHL) needs to be connected, and the sensor selects  to set the force left tension sensor.
2, display single stand _12.5 丄
The TC818 can select two units to display the tension measurement value: "kg (Kg)" and "N (Newton)".
3. Signal range 
This controller can select two signal ranges of ± 30mV and ± 300mV, and select the corresponding signal range according to the installed sensor.
If you choose LX series tension sensor, set the signal range  to ± 300mV.
If you choose a SUP / CTS / HTS series tension sensor, set the signal range  to ± 30mV.
In the floating roller tension system, when the selected angle sensor is a 0-2KΩ potentiometer, set the signal range  to ± 300mV.
4. Left error correction  / Right error trimming 
When the measured value has a zero offset, if the offset error is small, the sensor error can be corrected, and the zero point can be corrected through the correction. The set correction value will be added to the tension display value. The controller performs a recalibration.
When the tension calibration is performed, the correction value is reset to 0.
5, explicit filtering 
The controller has a digital filtering algorithm, which can remove the measurement signal interference and transitions and make the measurement display stable.
The larger the filter coefficient, the more stable the measurement display, but the response becomes slower, generally set to 2.00.
1, 3 tension calibration
In order to perform correct closed-loop tension control, the tension display must be accurate, and the tension controller must be calibrated. The calibrated tension controller indicates the tension value to achieve the desired accuracy. The TC818 tension controller uses a two-point linear calibration method, and the calibration process is very simple.
(1) Matters needing attention
 Before marking, make sure that the tension sensor wiring is correct, and confirm that the positions of jumpers JP7, JP8, J8, L1, and L2 correspond to the selected sensor. Confirm that the tension sensor is working properly and that the tension signal is within the selected oxygen range.
 If you choose LX series tension sensor, please short the jumpers JP7 and JP8 on the control board, jump J8 to + 5V, and set signal range  to ± 300mV.
 If you choose SUP / CTS / HTS series tension sensor, please disconnect the jumpers JP7 and JP8 on the control board, J8 jump to + 10V, and the signal range  is set to ± 30 mV.
 In the floating roller tension system, when the selected state sensor is 0 ~ 2KL> potentiometer, please short the jumper L1 on the control board (provide a constant current source for the potentiometer), JP7, JP8 Short circuit and set the signal range "261 to ± 300mV.
 Use the multimeter 200mV to measure the sensor output signal. When the sensor is not stressed, it is about 0mV. When the sensor is stressed, the output signal will change: the greater the force, the greater the signal, but it cannot exceed the maximum output Signal, the LX series tension sensor will not exceed 200mV, and the SUP / CTS / HTS series tension sensor will not exceed 20mV, otherwise the sensor is faulty and needs to be replaced, calibrated after installation.
(2) Zero tension calibration
Purpose: To correct the gross load of bearings and detection rollers.
Note: Zero tension calibration should be performed with the detection roller installed, but without the roll material loaded.
In the floating roller tension system, the floating roller is adjusted to the lowest position for zero tension calibration.
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