Manual Erhardt Leimer DC 6100

Operating e
Instructiones
Web tension controller DC 600.
Assembly and commissioning
Controller type 2, electrically controlled
variable gearing
1. Safety 2
2. Input/output function 3
2.1 Analog inputs 3
2.2 Digital inputs 4
2.3 Analog outputs 4
2.4 Digital outputs 5
2.5 Controller status table 6
3. Operator panel RT 4101 6
4. Assembly 8
5. Installation 9
6. Commissioning 11
6.2 Setup mode 11
6.1 Setup editor 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 18
6.8 Calibrating the measuring amplifier 26
6.9 Adjusting the actuator 27
6.10 Optimising controller 28
7. Special functions 31
8. Operation 32
9. Error code 33
10. Control diagram 35
BEA--221852-E-02
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 Intendedusage The web tension 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 observance of the operating instructions.
Work relating to the operation, production gearing, conversion or ad-
justment of the controller as well as its inspection, maintenance and
repair may be performed by qualified personnel only.
1.2 Operating manual Keep this operating manual in a safe place, accessible to personnel
at all times.
1.3 Safety instructions Never reach into the rotating rollers with your hand or tools.
Never touch the edges of moving webs.
Never touch live parts.
1.4 Assembly and installation When mounting and installing controller DC 600. you must observe
the locally applicable and professional safety and accident prevention
requirement (e.g. VDE 0100, EN 294, EN 349, IEC).
Please ensure that:
- electrical components without enclosures are protected according
to the locally applicable safety regulations, e.g. VDE 0100,
- when running electrical lines that the insulation is not damaged
and the leads properly secured and protected,
- the controller power is switched on and off with your main machi-
ne switch,
- signal lines are run separately from heavy current-carrying leads.
2
See the attached connection diagram for the exact terminal assign-
2. Input/output ments for installation.
function 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 (voltage - current
conversion 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
2 22a 24a 3 4 not assigned
3 26a 28a 5 6 not assigned
F-target external
Use this analog input to set and store an analog voltage of 0 to 10 V
DC (or 0 to 20 mA). 10 Volt is the equivalent of the maximum web
tension (Parameter .24.).
The external set point is enabled by the controller when the appro-
priate 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
Use this analog input to set the actual tension value in the form of an
analog voltage of 0 to 10 V DC (or 0 to 20 mA) - e.g. of a previously
established web tension. 10 Volt is the equivalent of the maximum
web tension (Parameter .24.).
The external actual value is only effective as long as the "F-target
accepted" digital input is high.
3
2.2 Digital inputs Digital inputs should be used as required in the individual applicati-
ons. See the attached connection diagram for the installation ter-
+ 24 V DC external minal assignments.
(logic "0" -5 V to +3 V DC)
You have the option of inverting individual or all digital inputs, see
the special functions section.
Input
Digital inputs
Input Terminal Terminal X 1 Function
DC 6000 DC 6001
DE 0 6c 3 Not assigned
DE 1 8a 4 Automatic
Reference potential
(DC 6000 terminal 6a, DE 3 10a 6 F-target accepted
DC 6001 terminal 2) DE 4 10c 7 Not assigned
DE 5 12a 8 F-actual accepted
Digital input
- 6a 2 digital reference potential
Automatic Automatic
(green) Use this digital input to switch on the automatic tension control, the
display lights up green. The web tension is now controlled in accor-
dance with preset values.
F-target accepted
When the digital input is high the preset analog tension set point is
enabled.
F-actual accepted
When the digital input is high the preset analog actual tension value is
enabled.
2.3 Analog outputs See the attached connection diagram for the exact installation termi-
nal assignments.
The "Actuating signal (V)" analog output is works set as a voltage
output. On request, E+L can also supply it as a current output
(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) Uoutput 0 to ±10 V DC / 5mA
Ioutput 0 (4) to 20 mA (optional)
2 32a 32c 5 4 Monitor output (F actual) Uoutput 0 bis 10 V DC / 5 mA
4
Actuating signal (V)

The actuating signal on the controller output corresponds to the
"speed V". It is output as voltage or current.
Monitor output
The actual web tension ("Actual F") signal is available at the monitor
output in 8 bit resolution for measuring purposes or graphic represen-
tation. Due to circuit-related reasons, the zero point may waver by
5 % to 6 %.
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
Output DA 0 14a 3 Right run
(Imax = 500 mA)
DA 1 14c 4 Left run
DA 2 16a 5 Not assigned
DA 3 16c 6 F-actual limit value
DA 4 18a 7 Not assigned
DA 5 18c 8 Not assigned
Digital output
DA 6 20a 9 System operational
- 4c 2 +24 V DC external
Right run
If the output is logic 1, the electrical actuator control transmits the
actuating signal for running to the right. This output is only necessary
with a contactor control.
Left run
If the output is logic 1, the electrical actuator control transmits the
actuating signal for running to the left. This output is only necessary
with a contactor control.
F-actual limit value

If the actual web tension is less than the lower limit, output 3 beco-
mes logic 1.
System operational
Output 6 indicates the operational state of the web tension controller.
Output: logic 1 = system operational
logic 0 = error; controller malfunction
Access parameter . .5. to identify the error code (see error code sec-
tion).
Output 6 may also be used as an error indicator for the following con-
trols.
5
2.5 Controller status table 0 = off

1 = on
X = don't care
= switches with leading edge
Controller state Digital inputs Keys on the operator

panel in service mode
Automatic
Automatic
Manaul
Controller off 0 0 0
Controller off 0 0
Controller on 1 X X
Controller on 0 0
Use operator panel RT 4101 to enter all control parameters and

3. Operator panel select operating modes.
RT 4101
Operating voltage display

The display goes on when the operating voltage is supplied.
Automatic Automatic
(green) If automatic is enabled by the digital input of the same name, the dis-
play lights up. The web tension is controlled according to the preset
tension set point.
Automatic mode may only be selected directly with this key in service
mode (expanded setup, parameter .4.1.).
6
Manual mode Manual mode

(green) In service mode use the "manual" key to switch off the controller. The
actuating signal "0 V" is available at the controller output.
No function
Line 1: F-target, parameter number Digital display

If you press the "tension set point" key the tension set point will be
-8.8.8.8.8. indicated in the first line of the digital display and the actual tension
value in the second line.
-8 8 8 8 8 If you press the "material-specific parameter record" key, the number
of the "old" parameter record is indicated.
Line 2: F-actual, parameter value
In setup mode, the parameter number is indicated in the first line and
the parameter value in the second line.
The digital display indicates the set values with decimal point and
sign.
T-target F-target
(green) Press this key and the "Increase value, decrease value" keys to set
the desired web tension set point. The display lights up if the function
is selected.
Press the "F-target" key ...
- once, LED lights up, display selected.
- twice, LED flashes, change tension set point F.
- three times, LED lights up, tension set point F is stored.
No function
Material-specific Material-specific parameter record

parameter record (green) Press this key and the "Increase value, decrease value" keys to sel-
ect one of eight material-specific parameter records.
Press the material-specific parameter record" key ...
- once, LED lights up, display selected.
- twice, LED flashes. Set parameter record number (0-7).
- three times, LED lights up, parameter record is enabled. If you try
to set an invalid parameter record the LED will flash.
7
Select setup mode Setup

Press this key and additionally the "Increase value" key to access
+
setup mode, the green LED on the setup key flashes (always press
the setup key first).
Setup
(green) You have the following options in setup mode:
- change various parameters
- reset all works settings automatically (see commissioning section)
Down key
Use this key to reduce the value indicated (set value, parameter num-
ber etc.) in the digital display.
Up key
Use this key to increase the value indicated (set value, parameter
number etc.) in the digital display.
4. Assembly Please observe the relevant safety regulations!
The length of the connection cable between the load cells and the
controller DC 600. should not exceed 50 m and must be conti-
nuous.
➜ Mount the DC 6000 19" sub-assembly (28 TE, 3 HE, 160 mm
deep) in a rack or control console.
➜ Mount DC 6001 as near as possible to the load cells for field use.
4.1 Load cells ➜ See load cell description PD 21, 22, 23, 25.
4.2 Variable gearing If no limit switches have yet been built into your variable gearing (e.g.
a P.I.V. gearing) we recommend you install an E+L screw limit switch.
Control roller electrical

Feed roller actuator Chain
Cams
Variable
gearing
Chain wheel E+L screw limit switch

Line shaft
Limit switches
E+L screw limit switch assembly
8
➜ Mount chain wheels on the electrical actuator of the variable gea-

ring and the E+L screw limit switch (see fig. on page 8). Connect
the two chain wheels by a suitable chain. Screw limit switch setting
is described in the "Commissioning, variable gearing adjustment"
section.
4.3 Frequency converter If you are controlling the electrical actuator with a frequency conver-
ter, please observe the frequency converter operating manual.
5. Installation Please observe the locally applicabe and professional safety

and accident prevention regulations.
The DC 600. modules are already interconnected. Only the supply
voltage, the inputs and outputs and where necessary, the CAN bus
need to be connected.
➜ Wire the leads according to the attached wiring diagram.
Due to 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 the machine ground by a 4 mm2 lead.
5.1 Supply voltage The controller power supply is 24 V DC.
5.2 Analog current outputs The controller output and analog inputs are works set as voltage in-
and inputs puts/outputs. On request, E+L can also supply current inputs/outputs
(voltage - current conversion is only possible ex works).
5.3 Controlling the electrical An analog "actuating signal V" and two binary signals for right and left
actuator with a frequency running are available for controlling the electrical actuator on the va-
converter riable gearing with a frequency converter.
If you have a frequency converter on your system, you must ob-
V
serve the frequency converter operating instructions during instal-
lation.
∆F
Right run
Left run
Actuating signal N set and binary

outputs for right and left running
9
5.4 Controlling the electrical Two binary signals for right and left running are available for con-
actuator with a contactor trolling the electrical actuator on the variable gearing with a contactor
control control.
5.5 Analog current output and The controller output is works set as a voltage output, the analog in-
inputs puts as voltage inputs. On request E+L can also supply current out-
puts (conversion voltage - current may only be performed ex works).
5.6 CAN bus networking See "CAN bus, serial bus and setup editor" description.
for tension controller ➜ Lay CAN bus lines away from noisy or heavy current-carrying ca-
bles (e.g. motor cables).
The CAN bus must not exceed a maximum total length of 200 m.
5.7 Address setting when net- On digital controller designed by E+L the hardware address
working tension controllers (group and device number) of the web controller(s) is preset (see
block diagram for addresses), further address settings are not ne-
Device number DIP switches 1 - 4 cessary. The device number must always be set to 5 !
Group number DIP switches 5 - 7
The address is set via an 8-pole DIP switch on control board
5 dez. 0 dez.
RK 4101.
1 2 3 4 5 6 7 8
The address consists of two parts:
ON - the group number from 0 to 7
OFF
(is set on DIP switches 5 to 7)
- the device number from 1 to F (hex)
Binary value:
1 2 4 8 1 2 4 The device number must always be set to 5 = web controller!
(is set via DIP switches 1 to 4)
DIP switches Example: Address 2.5 2 = group number
5 = device number
Control card RK 4101 works setting: address 0.5
5.8 Address setting on web ➜ Open housing.

controller DC 6001 ➜ Set address on control card RK 4101.
10
5.9 Address setting on web The 19" rack housing must be opened in order to set the address
controller DC 6000 (see fig. below).
➜ Loosen the four securing screws "A" on the operator panel.
Operator panel RT 4101
Analog card AK 4101
➜ Loosen the two securing screws "B" on the pcb.
➜ 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 6100 19" web controller rack
PCB securing screws "B"

X1 X2 X3
Operator panel securing Socket connector 8-pole DIP switch

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 putting the operator panel 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 of
the values changed.
Expanded setup mode
In expanded setup mode all parameter values may be displayed and
changed (for commissionng and service personnel).
11
The parameter values may only be changed by qualified per-

sonnel. Parameter value changes are executed immediately
and are automatically stored after approx. 1 minute!
Setup mode Select setup mode

+
(flashes green) Press the "setup" and additionally the "Increase value" keys to ac-
cess setup mode, the green LED on the "setup" key flashes (always
press the setup key first).
Select parameter number

+
When you hold down the setup key in setup or expanded setup
mode, you may select another parameter number using the "Increase
+ value" or "Decrease value" keys. The parameter number is displayed
Line 1: tension set point, parameter in the first line of the digital display, the parameter value in the se-
number cond line. When the parameter number is displayed, all the decimal
points go on.
. . . .0.
When calling up setup mode, parameter number ..0. is always dis-
800 played first.
Line 2: actual tension value,

parameter value Increase or decrease parameter value
Use the "Increase value" and "Decrease value" keys to change (set)
a parameter value.
If a parameter value cannot be changed it may be for the following
reasons:
- the parameter value is fixed (works set)
- the parameter value may only be changed in expanded setup
mode.
Exit setup mode

If no key is pressed on the operator panel for longer than 1 minute or
a reset initiated in the "Start Service" parameter, setup mode is exi-
ted automatically, the changes are stored!
expanded setup mode Select expanded setup mode

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

You may exit expanded setup mode in two different ways. Either in-
itiate a reset in parameter ..3. "Start Service" by setting a "1" or en-
tering 6 in parameter ..3. "Start Service", change parameter and
press any function key (e.g. tension set point). The changes are
stored when setup mode is exited!
12
6.3 Commissioning sequence

Set controller type
Set parameter
Calibrate measuring amplifier
Adjust actuator
- variable gearing
- frequency converter,
if featured
Insert web
Optimise controller
6.4 Setting controller type ➜ Select expanded setup mode (set 42 in parameter ..3.).
➜ Set 2 in parameter .3.3. for controller type "2".
➜ Initiate a reset in parameter ..3. (enter "1" and change parameter).
➜ Select expanded setup mode (set 42 in parameter ..3. ).
➜ Enter 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.
13
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

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

0 = No function
1 = custom-optimized values
2 = Internal preset values (default)
..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
44 = Save modified actual parameter values as customer
optimized values.
..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.
14
4 = Value of last analog input calibrated bigger than ±10 V,

check and recude input voltage.
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.
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.
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. no function 0 0 0 - no function
..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. no function 0 0 0 - no function
.10. no function 0 0 0 - no function
.15. P-part 10 0 100 % P-Part

Amplification of web tension controller
100% = 1
.16. window 10 0 50 % 3-position controller window width
.17. hysterese 10 0 50 % 3-position controller hysteresis
.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.
15
.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.
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.
.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 = no function
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%
16
.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 % Actuating signal amplitude

100 % is the equivalent of the maximum output signal
(+10 V oder +20 mA)
If the actuator next in line has a lower voltage range,
you must reduce the actuating signal amplitude.
.39. no function - - - - no function
.40. no function - - - - no function
.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 - no display
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.

See block diagram.

See block diagram.

Input required only if web tension controllers are networked,
see block diagram.
17

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

see block diagram.

see block diagram.
.49 subsystem 7 00 00 7F hex Address serial bus board 7

see block diagram.
6.7 Parameter description Select address

Entries in the two parametern ..0. and ..1. is only necessary when
. . . .0. controllers are networked or when inverting digital inputs or out-
puts. See the "CAN bus, serial bus and setup editor" description or
the special functions section.
. . . .1.
Set the device number in parameter number ..0. and the group
number in parameter number ..1. of the CAN device, the parame-
ters of which you wish to change. There is a maximum of 8 groups
and 15 devices per group. The group and device numbers are listed
in the connection diagram.
The digitale inputs and outptus have the device number 6.
The digital display indicates whether the device selected is featu-
red in the control loop. A minus sign ("-") in front of the device
number means that the relevant device is not featured. If you
persist in selecting a parameter for the non-existent device, all the
decimal points will flash, no further entries are possible.
Default setting: Device number 5 (controller)
Group number 0
18
Works settings
. . . .2.
0 = no change
1 = customer-optimised values
2 = internal value specification (default)
If you set a 1 in this parameter, the values you have stored after opti-
misation are used, if you set a 2, the internal (default) values are
used. "0" means no change.
Entries in parameter ..2. are only effective if you subsequently sel-
ect a new parameter number (e.g. parameter number ..3.). A
wrong or invalid entry may lead to a system malfunction!
Start Service
. . . .3.
Various calibration and service routines may be called up in this pa-
rameter.
- "1" reset controller
- "6" exit expanded setup mode
- "10" perform tare setting
- "11" calibrate measuring amplifier
- "12 to 19" calibrate analog inputs (see section 7, special
functions)
- "42" select expanded setup mode
- "44" store changed (current) parameter values as customer-
optimised values
The Calibration or Service Routines 6, 10, 11 and 12 to 19 can be re-
called only in the Extended Setup Mode.
Entries in parameter ..3. are only effective if a new parameter
number is selected subsequently (e.g. parameter number ..4.). A
wrong or invalid entry may lead to a system malfunction!
Software version display

. . . .4.
The software version number is indicated in the digital display.
Error code display

. . . .5.
In the event of a malfunction this parameter displays an error code
(see error code section).
Material-specifc parameter record

. . . .6.
A material-specific parameter record consists of the control parame-
ters ..8. , .1.5., 1.6. and .1.7.: tension set point, P component, window
width and hysteresis.
You may enter eight different material-specific parameter records.
Parameter ..6. is used only to display the active parameter record.
If you wish to enter or change a material-specific parameter re-
cord proceed as follows:
19
. . . .6.
Press material-specific
parameter record key
Set parameter record number

e.g. 0 (0-7)
Acknowledge entry
Return to setup menu
. . . .8. Set parameters ..8. to .1.7.
yes
enter new parameter
record yes/no
no
proceed with
commissioning
Parameter ..7. no function

. . . .7.
F-target
. . . .8. Enter the tension set point by which the tension controller is to opera-
te.
F-target
(green) Entry range: 0 to F maximum (F maximum is set in parameter .2.4.)
The tension set point may also be entered directly using the key of
the same name on operator panel RT 4101. In this case the value in
parameter ..8. will be overwritten.
Parameter ..9. to .1.4. have no function

. . . .9. . . .1.4.
20
P-term
. . .1.5.
The P-term defines the amplitude of your tension contoller, 100 % is
the equivalent of an amplification of 1. We recommend that you set
an amplification of 10% for commissioning and optimise it later.
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".
3-position controller window width

. . .1.6.
Use the "3-position controller window width" and following "3-position
controller hysteresis" parameters to set the point from which deviati-
ons are corrected by the controller. This "switch on" point is calcula-
ted by taking half the window width and adding on the hysteresis.
If the window width entered is e.g. 2 % and the set hysteresis 10%,
the controller will only respond to deviations from the tension set
point of 11% upwards (see fig. below). The controller will only switch
off again when the deviation is less than half the window width (in
this example less than 1%).
Window width and hysteresis
Control signal right running
Hysteresis
Switch-off point Switch-on point
Control deviation -100 % +100 % Control deviation

1% 11 %
-11 %
Window width
Window width = 1 %
2
Control signal left running
21
You may set a value between 0 and 50 %. The smaller the window
width set, the smaller the permanent deviation will be. We recom-
mend that you set a value of 1 % for commissioning.
You may set a value between 0 and 50 %. The smaller the window
width set, the smaller the permanent deviation will be. We recom-
mend that you set a value of 1 % for commissioning.
If you are controlling the electrical actuator of your variable gea-
ring with a frequency converter, you must set a window width of
0 %.
Recommended value: 1 %
3-position controller hysteresis

. . .1.7.
The hysteresis is a value added to half the window width to determi-
ne the controller switch on/off point (see fig. above).
Without hysteresis the controller would switch on as soon as half the
window width was reached and switch off again as soon as it went
below half the window width, thus starting to oscillate.
You may set a value between 0 and 50 %. The lower the hysteresis
value, the greater the precision and also sensitivity of the controller's
response to deviations will be. We recommend that you set a value
of 10% for commissioning.
If you are controlling the electrical actuator of your variable gea-
ring with a frequency converter, you must set a hysteresis of 0 % .
Parameter .1.8. to .2.0. have no function.

. . .1.8. . . .2.0.
Tension set point ramp
. . .2.1.
Use this parameter to enter the time in which the tension set point
should change from "zero" to " maximum".
Entry range: 0 - 30 secs
Recommended value: 3 secs
Example for parameter .2.1
Tension set point ramp
Tension set point F
F maximum
Set point ramp

100
Time t/s
1 30
22
Calibration weight
. . .2.2.
Enter the weight being used to load your measuring roller for calibra-
ting the measuring amplifier (section 6.8 Calibrating the measuring
amplifier) - unit form freely selectable, e.g. N, kp, lbf).
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 how many measurements are to form the web actual tension
mean value calculation for web tension controlling. The mean value
calculation has the effect of a filter, the higher the set value, the stron-
ger the filter effect will be. This may be necessary for "noisy" or heavi-
ly oscillating actual tension signals (e.g. unbalanced roller).
0 = 1 measurement fg = 100 Hz
1 = 2 Measurements fg = 50 Hz
Recommended value: 0 = 1 measurement
F maximum (Measuring and control range)

. . .2.4.
Entries should only be made in this parameter after the measuring
amplifier has been calibrated (section 6.8 Calibrating the measu-
ring amplifier). The measuring and control range is limited during
measuring amplifier calibration and depends on the load cells.
Enter the highest (maximum) tension set point by 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 form freely selectable, e.g. N, kp, lbf)
F-actual value lower limit

. . .2.5.
If the limit value entered in this parameter is not attained, the digital
output of the same name is set to logic 1. Enter the lower limit for the
web actual tension value.
Entry range: 0 - 9999 (unit form freely selectable, e.g. N, kp, lbf)
Parameter .2.6. to .3.2. have no function.

. . .2.6. . . .3.2.
23
Controller type selection

. . .3.3.
Select controller type "2":
0 = controller type 0; electrical or pneumatic brake
1 = controller type 1; electrical reel drive, electrical transport drive,
electrically controlled superimposed drive (e.g.
harmonic drive, differential gearing)
2 = controller type 2; electrically controlled positioning drive
with variable translation ratio
3 = controller type 3; electrical or pneumatic brake on transport
units for corrugated cardboard systems
Entry range: 0, 1, 2, 3
Shut-off delay
. . .3.4.
Overrun may occur when you switch off the web tension control along
with your main system drive. Use the shut-off parameter to enter how
many seconds after "Automatic off" the web tension control should
remain active to ensure that the web tension control remains functio-
nal until the machine stops.
Entry range: 0 - 10 secs
Parameter .35. has no function.

. . .3.5.
Actuating signal output
. . .3.6.
Select the output range in this parameter.
Entry range: 0, 1, 2
0 = 0 - ±10 V
1 = 0 - 20 mA
2 = 4 - 20 mA
The actuating signal is works set as a voltage output. On re-
quest, E+L can also supply it as a current output (voltage -
current conversion may only be performed ex works).
Offset actuating signal

. . .3.7.
The offset entered is added to the actuating signal. The entry is in per
cent, in relation to 10 V. The offset is used to compensate for cable
voltage drops.
Entry range: ±10.0 %
24
Actuating signal amplitude

. . .3.8.
This parameter determines the actuating signal amplitude. 100 % is
the equivalent of the maximum output signal (+10 V or +20 mA). If
the actuator next in line has a lower voltage range, you must reduce
the actuating signal amplitude.
Parameter .3.9. and .4.0. have no function.

. . .3.9. . . .4.0.
Service mode
. . .4.1. Controller DC 600. must be set to service mode for commissioning. In
this mode, automatic or manual may be selected on the operator pa-
nel via the keys of the same name (see section "Operator panel
RT 4101"). In addition, various values are indicated on the display.
0 = Service mode off
Automatic 1 = Service mode on
(green) 2 = Service mode on
Press the "material-specific parameter record" key,
Manual
1. first line of the display - set line speed
(green)
2. second line of the display - no display
Material-specific (if the inputs are connected).
parameter record 3 = Service mode on
Press the "material-specific parameter record" key
1. first line of the display - actuating signal in volts
2. second line of the display - no display
External function selections via digital inputs are always gi-
ven priority in service mode!
You must switch off service mode once you have finished
commissioning (set 0) !
When in service mode, measured values will be shown unfil-
tered in the display.
Address serial bus card 0

. . .4.2. Use this parameter to assign the first of the following serial bus cards
a new free address.
The serial bus card addresses are automatically assigned by the
CAN bus card. If, for instance, a CAN bus card has the address 05, it
assigns the following serial bus card address 06, the one after that 07
etc.. Under certain circumstances it may however occur that an
address has already been assigned by CAN bus hardware. In this
case, the serial bus card 0 must be assigned a free address.
The serial bus card addresses are shown in the block diagram.
The address is entered as a two-digit hexadecimal number. The
first figure stands for the assigned group, the second for the device
number.
25
Entries are only necessary when 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 second following serial bus card a
• new (free) address.
•
•
Address for serial bus cards 2 to 7
. . .4.9. See parameter .4.2.
All further parameters (.5.0. to 1.9.9.) are internally set for the
controller and may not be changed!
6.8 Calibrating the measuring The measuring amplifier may only be used in expanded setup
amplifier mode. At first, the measuring roller must not be loaded.
Zero point adjustment

➜ Enter 10 in parameter ..3. "Start Service" in expanded setup mode
to initiate tare compensation (zero point adjustment) and then
select parameter ..4. an.
Calibrating using a calibration weight

The test calibration must be at least 60 % of the maximum web
tension or the load cell output signal must be greater than 2 mV
sein. If this is not the case, the calibrating process must be at
Mounting the test weight fault.
➜ Apply a belt to your measuring roller to simulate the way the web
will run later on (see fig. on left). Attach a calibration weight as
specified in parameter .2.2. to this belt. The calibration weight
Belt
should correspond as far as possible to the maximum web tension
Measuring
roller
(at least 60%).
➜ Enter 11 in parameter ..3. "Start Service" in expanded setup mode
to initiate the calibrating routine and then select parameter ..4..
➜ Remove the calibration weight and belt, measuring amplifier cali-
bration is now completed.
calibration ➜ Enter the highest (maximum) F-target by which you wish to control
weight your system in parameter .2.4. "F maximum (measuring and con-
trol range).
26
6.9 Adjusting the actuator Adjusting the variable gearing entails: synchronising the traction unit
6.9.1 Variable gearing peripheral speed (e.g. printing cylinder on the first press, see fig. on
left) with the control roller peripheral speed and setting the variable
Traction unit gearing limit switches.
Control roller (printing cylinder on
(Feed roller) first press) ➜ Set controller DC 600. to manual on the operator panel to adjust
the variable gearing.
➜ Now run your machine at an average speed, without a web.
➜ Measure the speed of the traction unit and control roller (feed rol-
Line shaft
ler) with a handheld tachometer.
➜ Synchronise the peripheral speed of the control roller and traction
unit.
variable gearing
You may increase the peripheral speed of the control roller e.g. by
Electrical actuator setting via a push button a control voltage parallel to the relevant
Example: web tension controlling
DC 600. controller digital output that triggers the electrical actuator
between feed roller and the first press of the variable gearing (see connection diagram and figure below).
You may thus adjust the variable gearing until the peripheral speed
on the control roller (feed roller) is the same as the peripheral
speed on the following traction unit.
24 V DC
Manual
Manual right
left
Output DC 600.
Right running
Right limit switch

Left running
Left limit
switch
The limit switches are provided to protect the variable gearing

and limit the control range.
➜ The maximum speed difference, dependent on the material
being processed, is set via the limit switches. The limit switches
should be set so that the control roller (feed roller) runs faster or
slower, e.g. by a maximum of 5 % depending on the material
type.
➜ Insert the web and optimise the controller.
6.9.2 Frequency converter See frequency converter description.

➜ Insert web and optimise the controller.
27
6.10 Optimising controller Controller optimisation should be performed by qualified per-

sonnel only (service technician, engineer).
We recommend optimising at the application critical low speed,
using a special oscilloscope or recorder.
The controller is optimally set when, after enabling DC 600., actual
and preset tensions coincide (have the same value) without oscillati-
on in the shortest possible time.
Basic premise
F
F-target F-actual
slow
t
F
F-target F-actual
optimized
t
F
F-target F-actual
oszilliert
t
When optimising control parameters you must harmonise the P com-

ponent, window width and hysteresis. As each system has different
control path requirements and the demands on the controller vary
accordingly, the values must be determined individually for each
application.
The aim of optimising the control parameters is to keep the control
difference (the difference between the set point and actual values) as
low as possible (see fig. above). During optimisation, the quality of
control may be assessed based on the response time to a set point
step change, i.e. the response of the actual value to a sudden chan-
ge in the set value.
➜ Connect an oscilloscope at the actual value input (see connection
diagram) to optimise the controller with greater accuracy.
For safety's sake, begin with a small P component.
28
Controller output block diagram

P controller Absolute value generattor
Analog
actuating signal
∆X
Set F
3-position controller
Actual Right run
Left run
Use the window width to change the permanent control deviation

(siehe figure below). The smaller the window width, the smaller the
permanent control deviation will be and the more frequent switching
(left and right edge).
Use the hysteresis to change the switching frequency on an edge
3-position controller output with (siehe figure below).
contactor control
Contactor control Motor rotational direction
Hysteresis
Switch-off point Switch-on point

-11 % -1 %
Control deviation ∆X Control deviation ∆X
1% 11 %
-100 % +100 %
Window width Window width = 1 %

2
Binary switch outputs:

Right run
Left run Right run
Left run
➜ We suggest you modify the P-term and window width alternately

in steps of 5 %.
➜ Increase the P component gradually until you can observe the
actuating signal oscillate on the oscilloscope. If the oscillation
remains strong and does not abate, you must again reduce the
P component a little.
➜ Reduce the window width gradually until you can see the actual
web tension value oscillate on the oscilloscope or the contactors
switch continuously. If the oscillation remains strong and does not
abate, you must again increase the window width a little.
➜ Increase the hysteresis graudually until the contactors no longer
switch continuously.
29
➜ Note down the optimised values in the parameter list.
Now that the control parameters are optimised, controller com-

3-position controller output with
frequency converter missioning is complete.
Analog actuating signal

Large P-term Large P-term
100 %
Small P-term Small P-term
Right run
Motor speed
Control deviation ∆X Control deviation ∆X
Left run 100 %
30
The digital inputs and outputs may be inverted in the software. To in-
7. Special vert proceed as follows:
functions ➜ Select setup mode.
➜ Enter 6 in parameter ..0. "Device number" to select the parame-
. . . .0. 0.6 ters for the digital inputs and outputs (see table below).
➜ Select expanded setup mode, i.e. enter 42 in parameter ..3. "Start
Service" and change parameter.
. . . .3. 42
➜ Select parameter ..6. to invert the inputs or parameter ..7. to invert
the outputs.
Setup mode Device number 6 digital inputs/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 paramter values
Expanded setup mode Device number 6 digital inputs/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 - ..9. Free

-
➜ Function of digital inputs/outputs

. . . .5. This parameter must always be set to "2" (web tension con-
trolling).
➜ Inverting digital inputs
. . . .6. Inputs 0 to 3 and 4 to 7 are inverted via a 4-digit binary code.
Logic "0" means not inverted, logic "1" inverted.
The binary code must be entered as a hexadecimal number (see
examples).
Entry range: 0.0 to F.F hex.
➜ Inverting digital outputs
. . . .7. The digital outputs are also inverted via a two-digit hexadecimal
number (see explanation - inverting digital inputs).
Entry range: 0.0 to F.F hex.
31
➜ After inverting the inputs/outputs, enter 5 in parameter ..0. "Device

. . . .0. 0.5 number and exit setup mode.
Examples: Inverting 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.
Address 0.0 hex 0 0 hex.

All inputs inverted I I I I I I I I bin.
Address F.F hex F F hex.

Input 7, 3, 2 I 0 0 0 I I 0 I bin.
and 0 inverted
Adresse 8.D hex 8 D hex.
➜ Insert web.
8. Operation
➜ Set web tension set point, press tension set point key
- once, LED lights up, the web tension set point is indicated in the
first line, the actual web tension value in the second line of the dis-
play.
- agein, LED flashes. Use the "Increase value, decrease value"
keys to set the desired tension set point.
- a third time, LED lights up, the tension set point is stored.
or specify the tension set point via the analog input of the same
name.
or set a material-specific parameter record, press the material-speci-
fic parameter record key
- once, LED lights up. The current parameter record is indicated in
both display lines.
- again, LED flashes. Use the "Increase value, decrease value"
keys to set the new parameter record number (0-7). The number
is indicated in the first line.
- a third time, 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.
➜ Select automatic (controller enable via machine control), display

lights up.
32
A system error is displayed at the "System operational" output by lo-

9. Error code gic 0 and in parameter number ..5. by an error code.
If "HELP" appears in the display, not all calibration / adjustment pro-
cedures have yet been performed.
Once an error has been detected and cleared, a "0" must be entred
in parameter ..5. or a reset initiated in parameter ..3. . Error codes 3
and 4 refer to the input that was calibrated last.
9.1 Error code table Error code Meaning
0 No error,
Output "System operational" logic "1"
1 Error not recognized,

contact E+L service center
2 Internally establisehd measuring range is smaller than set

measuring range: set parameter .2.4. F max. 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 compensation 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 Tension set point 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.
10 Web tension higher than permissible (load cell overload):

change max. permissible web tension and recalibrate
measuring amplifier
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
33
9.2 Calibrating analog inputs All 3 analog inputs must be calibrated if error codes 20 and 21 oc-
on error codes 20 and 21 cur.
The calibration procedure is the same for all three inputs. The values
in lines A, B and C of the following table should 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 not assigned not assigned
or F-actual external
A 18 15 12
B 19 16 13
C - 17 14
➜ Apply a 0 V signal (or 0 mA respectively 4 mA, see parameter 36)

to the analog input you are going to calibrate.
analog
Input A B C
➜ Enter the appropriate value from line "A" in parameter ..3. "Start
+ -
Service" and change parameter to adopt the entry.
➜ Apply +10 V (or 20 mA) to the analog input.
0V 10 V 10 V
➜ Enter 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.
➜ Enter the value from line "C" in parameter ..3. "Start Service" and
change parameter. (This entry is not required for input1)
➜ When all three inputs are calibrated, rewire them according to the
connection diagram.
34
0.21. 0.15. 0.38. 0.37.
diagram
10. Control
F-target ABS V signal-output
F-actual monitor-output
0.16.
0.17.
move right
move left
0.25.
F-actual-limit
Technical data subject to modification without notice.

35
Erhardt + Leimer GmbH
Postfach 10 15 40
D-86136 Augsburg
Phone (0821) 24 35-0
Web tension controller DC 600. Telefax (0821) 24 35-666
36

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Operating e

Explanation of symbols ➜ = jobs to be performed

= important information and instructions

= text sections due particular attention to assure the safe

Never touch the edges of moving webs.

Never touch live parts.

Output Terminal Terminal X 11 Signal connected Voltage / current

Actuating signal (V)

F-actual limit value

2.5 Controller status table 0 = off

Controller state Digital inputs Keys on the operator

Use operator panel RT 4101 to enter all control parameters and

Operating voltage display

Manual mode Manual mode

Line 1: F-target, parameter number Digital display

Material-specific Material-specific parameter record

Select setup mode Setup

4. Assembly Please observe the relevant safety regulations!

Control roller electrical

Chain wheel E+L screw limit switch

E+L screw limit switch assembly

➜ Mount chain wheels on the electrical actuator of the variable gea-

5. Installation Please observe the locally applicabe and professional safety

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

Actuating signal N set and binary

5.8 Address setting on web ➜ Open housing.

DC 6100 19" web controller rack

PCB securing screws "B"

Operator panel securing Socket connector 8-pole DIP switch

Commissioning should be performed by qualified personnel

6.2 Setup mode There are two setup modes:

The parameter values may only be changed by qualified per-

Setup mode Select setup mode

Select parameter number

Line 2: actual tension value,

Exit setup mode

expanded setup mode Select expanded setup mode

Exit expanded setup mode

6.3 Commissioning sequence

Calibrate measuring amplifier

6.6.1 Setup Mode

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

6.6.2 Extended Setup Mode

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

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

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

No. Name Default Min Max Unit Explanation

4 = Value of last analog input calibrated bigger than ±10 V,

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

..7. no function 0 0 0 - no function

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

..9. no function 0 0 0 - no function

.10. no function 0 0 0 - no function

.11. no function 0 0 0 - no function

.12. no function 0 0 0 - no function

.13. no function 0 0 0 - no function

.14. no function 0 0 0 - no function

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