TR Instruction Manual - Dover Flexo Electronics, Inc

DOVER FLEXO ELECTRONICS, INC.ISO 9001 CERTIFIEDINSTRUCTION MANUALTension Roll® Transducers 5 YEAR WARRANTY

217 Pickering RoadRochester, NH 03867-4630 U.S.A.For assistance, please call:TECHNICAL SERVICE - Installations, Start-Up, Troubleshooting, Repairs, FieldService, Returns. techsupport@dfe.comCUSTOMER SERVICE - Replacement Parts, Individual Products, Questions aboutOrders, Manuals. customerservice@dfe.comSALES - Product Information, Systems Application Questions, andplacing orders for standard products and special systems.sales@dfe.comTelephone: (603) 332-6150 Fax: (603) 332-3758E-mail: info@dfe.com Internet: www.dfe.com©2008 Dover Flexo Electronics, Inc. All rights reserved. Dover Flexo Electronics has made reasonable effort to ensure accuracy of thisdocument. However NO WARRANTY, whether expressed or implied, is given regarding the completeness or correctness of information inthis document. Dover Flexo Electronics shall not be liable for damages of any kind arising from the use or misuse of this document. DoverFlexo Electronics reserves the right to make changes, additions, and deletions to this document without notice and without obligation.

TABLE OF CONTENTSSECTION ONE DESCRIPTION PAGE1.1 General Description ................................... 11.2 Construction and Mechanical Operation .................... 11.3 Electrical Operation .................................... 21.4 Specifications ......................................... 31.5 Standard Features ..................................... 31.6 Configuration Choices .................................. 31.7 Options .............................................. 41.8 Accessories .......................................... 4SECTION TWO INSTALLATION2.1 Dimensions........................................... 52.2 Pre-Installation Requirements ............................ 62.3 Installation Instructions.................................. 82.4 How to Change Electrical Connector Position ................ 8SECTION THREE CALIBRATION AND SET-UP3.1 Introduction ........................................... 93.2 Zero the Tension Meter ................................. 93.3 Calibrate the Tension Meter.............................. 9SECTION FOUR CARE AND MAINTENANCE4.1 Bearing Life .......................................... 104.2 Lubrication ........................................... 124.3 Disassembly and Reassembly ............................ 13SECTION FIVE TROUBLESHOOTING .................................. 17SECTION SIX REPLACEMENT PARTS ................................ 19APPENDICES: A. Transducer Electrical Connections ...................... 20B. Selection of Load Rating .............................. 21C. Typical Tensions .................................... 23Terms and Conditions .................................. 24Declarations of Conformity............................... 25-26Index ................................................ 27LIST OF ILLUSTRATIONSFIGURE: 1. Cut-away View of Tension Roll ........................... 12. Strain Gage Connections ................................ 23. Dimensions........................................... 54. Tension Zones ........................................ 75. TR Mounting Styles .................................... 76. Tension Force Direction ................................. 87. Web Path ............................................ 98. Bearing Life Nomogram ................................. 119. Grease Fitting Location ................................. 1210. Decal End of Transducer ................................ 1311. The Beam Assembly ................................... 1412. Shaft and Beam Features ............................... 1513. TR Electrical Connections ............................... 2014. Load Rating Selection formulas ........................... 21i

SECTION 1PRODUCT DESCRIPTION1.1 GENERAL DESCRIPTIONThe Model "TR" Tension Roll® Transducer is an electro-mechanical device that converts web tensioninto a D.C. voltage which is proportional to tension. The voltage is amplified in external electroniccircuitry and displayed on an analog or digital meter which is calibrated to indicate actual web tension,expressed in pounds, ounces, grams, kilograms, newtons or any other desirable units. The output voltagemay also be supplied to a regulator circuit to control tension automatically.The TR transducer is unique because it combines a dead-shaft idler roll with tension sensors built intoeach end of the roll.The information in this Section will help give a clear understanding of the Model "TR" Transducer, how itworks and how it is used.1.2 CONSTRUCTION AND MECHANICAL OPERATION (see figure 1)In a typical installation, the transducer is mounted in the same way as any dead-shaft idler roll. No specialprovisions need be made. The transducer shaft is available with plain ends for mounting in shaft hangers,drilled and tapped ends for mounting by thru-frame bolts, or milled flats with a bolt hole thru formounting on the edge of machine frames. See Figure 5.The roll is manufactured to industry standards for Total Indicated Runout (TIR), surface finish and taper.Every roll is dynamically balanced to specifications more stringent than the typical idler roll.The stainless steel shaft inside the roll is much larger in diameter than the ends for increased stiffness.Figure 1 - CUT-AWAY VIEW OF MODEL TR TRANSDUCERThe bearings are self-aligning ball type with a seal on the side toward the center of the roll to preventgrease from entering the roll. An external flush-type grease fitting is provided for each bearing for relubrication.A shield on the other side of the bearing retains the grease without introducing any additionaldrag. A retaining ring at the bearing on the end of the transducer opposite the electrical connector keepsthe roll in place while a sliding sleeve on the other end allows the roll to expand in length with risingtemperature without causing any stress on the roll or bearings.Inside the transducer are two dual cantilever beams, one at each end of the roll, with strain gages mountedon the top and bottom surfaces of each. The bearings are attached to the free end of each beam. When webtension is applied the beam deflects a small amount, causing an electrical output from the strain gages.1

1.4 SPECIFICATIONSExcitation Voltage ............... 5 Vdc (10Vdc with XR option)Output ............... 500 mv, nominal, at 5V excitationStrain Gages Resistance ............... semiconductor, 100 ohms +/- 15 resistanceNon-Repeatability ............... ± 1/4 % full span (FS)Non-Linearity and Hysteresis Combined .... 1/2 %(FS)Temperature Range ............... -10° F to +200°F (-23° C to +93° C)Temperature Coefficient ............... 0.02% per degree F typical (0.036 % per ° C )Mating Electrical Connector: Size 1 ....... Amphenol KPT06F10-6S (PN:106-0050)Size 2 ....... Amphenol MS3106A-14S-6S (PN:106-0081)Electrical Connector Position ............. 6 o'clock (same as load direction)Connector Pin assignments ............. Pin A = (WHT- decal end) = output,............... Pin B = (BLK- decal end) = + 5V,............... Pin C = (RED- decal end) = - 5V,............... Pin D = (GRN- connector end) = output,............... Pin E = (BLU- connector end) = - 5V,............... Pin F = (BRN- connector end) + 5VRoll: Material ............... 6061 aluminum, 304 stainless steel (option), 1020 Steel(option)TIR ............... 0.002 inch (0.05 mm)Balance ............... Quality grade G2.5 per ISO 1940 and ANSI S2-19-75Finish ............... 32 microinchShaft ............... Stainless SteelMinimum Overload Capacity Size 1 ...... 660 lbs. (2,940 N)Size 2 ...... 3000 lbs (13,3300 N)Deflection of Sensor Beam............... 0.008 inch typical (0.2mm typical)Standard Shaft Diameter Size 1 .......... 0.750 inch (19.1 mm)Size 2 .......... 1.125 inch (28.6 mm)Shaft Size Tolerance ............... nominal -0.002 inch ( -0.05mm)Load Ratings: Size 1 .......... 12, 25, 50, 100, 150lbs. (55, 110, 225, 450, 670N)Size 2 .......... 12, 25, 50, 100, 200, 400 lbs. (55, 110, 225, 450, 900,1800 N)Basic Dynamic Load Rating of Bearings:Size 1: ......... 3510 lbs (15,600 N)Size 2: ......... 4480 lbs (19,913 N)1.5 STANDARD FEATURES• One Integral Package. Tension transducers and idler roll are combined into a single easy-to-installtransducer roll.• Grease Fitting. Allows quick lubrication without disassembly or removal from machine• Stainless Steel and Aluminum construction. Excellent corrosion resistance.• One Transducer Cable. No cable need cross the machine.1.6 CONFIGURATION CHOICESThese are explanations of standard choices of various configurations that were specified for yourapplication.• Size. Sizes offered are Size 1 and Size 2.• Roll Diameter. Choice of: 3 inch (Std. for Size 1 and Size 1 only), 4 inch (std. for Size 2), 5 inch, and6 inch. Other diameters available, consult factory.• Roll Length: Size 1: 6 inches to 60 inches. Size 2: 7 inches to 99 inches. Longer rolls available,consult factory. See tables in Section 2.2.1.1 for more information.3

1.6 CONFIGURATION CHOICES continued..• Shaft Length. Measured for application and length of roll required. See tables in Section 2.2.1.1 formore information.• Load Ratings. Size 1: 12, 25, 50, 100, 150 lbs. (55, 110, 225, 450, 670 N)Size 2: 12, 25, 50, 100, 200, 400 lbs. (55, 110, 225, 450, 900, 1800 N)• Connector Position. Choices are as follows: 12:00, 1:30, 3:00, 4:30, 6:00 (std.), 7:30, 9:00, 10:301.7 OPTIONS• 90 Degree Grease Fitting (90GF). Grease fitting located at end of roll rather than on OD. For 5" ODor larger rolls.• Counterbore, Drill and Tap (CDT). Shaft ends are counterbored and drilled and tapped.• Drill and Tap (D&T). Drill and tap ends of shaft. Size 1: 5/16-18 (8mm), Size 2: 1/2-13 (12mm)• Environmental Connector (EC). Seals with mating cable electrical connector to protect againstcontact oxidation; especially useful in corrosive environments.• Extended Range Output (XR). Extra sensitive at low tensions. Electronics must have extended rangealso.• Milled Flats (MF). Shaft with milled flats and a through hole at each end.• Non-standard Shaft Extensions (NSE). Shaft extends unequal lengths on ends. Specify lengths.• Oiled Bearings (OB). Oil instead of grease for lubrication. Not recommended by DFE and may voidwarranty.• Steel Roll (SR), or Stainless Steel (SSR) instead of standard aluminum roll.• Wet Environment Cable (WEC). Attached sealed cable for Tension Roll transducers.1.8 ACCESSORIES• Shaft Hangers. Size 1: #140-0005. Size 2: #601-1179 (small), #601-1181 (large)• Shaft Mounting Adapters. Size 1: #601-1201. Size 2: #601-1178• Flanged Shaft Mounting Adapters. Size 1: #601-1203. Size 2: 601-12024

SECTION 2INSTALLATION2.1 DIMENSIONSinches (mm)TENSION ROLL® TRANSDUCERA B C D E F GSIZE 1in. Ø 0.75 * * 0.31 1.12 Ø 3.0 3.0mm Ø 19.05 * * 7.87 28.45 Ø 76.20 76.20SIZE 2in. Ø 1.125 ** ** 0.31 1.50 Ø 4.0 4.0mm Ø 28.58 ** ** 7.87 38.10 Ø 101.60 101.60* Specified at time of order, B - C = 6.0 in. (152.4 mm) ** Specified at time of order, B - C = 8.0 in. (203.2 mm)SHAFT ADAPTER - Single Bolt MountSHAFT ADAPTER - Flange Mount(Size 1: #601-1201, Size 2: #203-0238) (Size 1: #601-1203, Size 2: #601-1202)SHAFT HANGERS FOR TR TRANSDUCERSMODEL A B C D E F G H J KSIZE 1(#140-0005)SIZE 2 - SM(#601-1179)SIZE 2- LG(#601-1181)in. 2.75 2.00 2.12 1.00 1.38 0.75 1.25 0.31 Ø 0.75 0 22mm 69.85 50.80 53.85 25.4 35.05 19.05 31.75 7.87 19.05 5.59in. 4.00 3.00 3.00 1.62 2.12 1.12 1.75 0.43 Ø 1.125 0.34mm 101.60 76.20 76.20 41.15 53.85 28.45 44.45 10.92 28.58 8.63in. 6.00 4.50 4.50 2.62 3.30 1.50 2.50 0.62 Ø 2.00 0.41mm 152.40 114.30 114.30 66.55 83.82 38.10 63.50 15.75 50.80 10.41Figure 3 - DIMENSIONS5

2.2 PRE-INSTALLATION REQUIREMENTS1. TRANSDUCER ROLL. Please Note! There can be no brakes, clutches, belts, chains or gears attachedto the TR transducer roll or shaft. It can not be a nip roll or be in contact with a nip roll. NOTHINGMUST CONTACT THE ROLL OR ITS SHAFT EXCEPT THE WEB!1. Roll Width The face width of the roll is normally the same as the other rolls in the machine.However in some cases, Dover Flexo Electronics may require a longer face width in order toreduce the length of the shaft extensions. Following are the maximum lengths of shaft extensionsper end for the various sizes: Size 1 a maximum of 3 inches per end and Size 2 a maximum of 4inches per end, These lengths were chosen to minimize shaft deflection.The maximum roll face width is usually limited by deflection of the roll caused by web tension.Too much deflection will cause problems with the web such as wrinkling. Refer to table below forthe maximum available roll face widths.SIZE 1 ALUMINUM STEEL STAINLESS STEELRoll Diameter, inch (mm) Roll Diameter, inch (mm) Roll Diameter, inch (mm)Load Rating lb.(N)3 (76) 3 (76) 3 (76)12 (55) 48 (1219) 48 (1219) 48 (1219)25 (110) 48 (1219) 48 (1219) 48 (1219)50 (225) 48 (1219) 48 (1219) 48 (1219)100 (450) 42 (1067) 48 (1219) 48 (1219)150 (670) 34 (864) 48 (1219) 48 (1219)Roll Weightlb./in. (kg/cm)0.30 (0.054) 0.88 (0.157) 0.88 (0.157)Weight of Bearing Assemblies is 1.4 lbs. (0.63 kg) total. Minimum Width of roll is 6 inches (152mm)SIZE 2 ALUMINUM STEEL or STAINLESS STEELLoad rating lb.(n)Roll Diameter, inch (mm)Roll Diameter, inch (mm)4 (102) 5 (127) 6 (152) 4 (102) 5 (127) 6 (152)12 (55) 112 (2845) 120 (3048) 120 (3048) 120 (3048) 120 (3048) 120 (3048)25 (110) 112 (2845) 120 (3048) 120 (3048) 120 (3048) 120 (3048) 120 (3048)50 (225) 100 (2450) 120 (3048) 120 (3048) 120 (3048) 120 (3048) 120 (3048)100 (450) 84 (2134) 120 (3048) 120 (3048) 120 (3048) 120 (3048) 120 (3408)200 (900) 69 (1753) 95 (2413) 120 (3048) 96 (2438) 120 (3048) 120 (3048)400 (1800) 51 (1295) 73 (1854) 95 (2413) 79 (2007) 100 (2540) 120 (3048)Roll Weight 0.54 (0.096) 0.69 (0.124) 0.85 (0.152) 1.56 (0.279) 2.00 (0.357) 2.44 (0.437)lb./in. (kg/cm)Weight of Bearing Assemblies is 4.3 lbs. (1.9 kg.) total. Minimum width of roll is 7 inches (178 mm).NOTES: 1. Roll may be too heavy for load rating. Be sure to check the sizing criteria and formulas. 2. Use the standardsizing formulas to determine the correct load rating. In the formulas, "W" is equal to the roll weight plus the weight of thebearing assemblies. 3. Normally, maximum roll width is limited to 120 inches by our machine shop capacity. Shorter widths areto limit roll deflection. Wider rolls are available on special order at additional cost. Consult factory.2. TENSION ZONE. The transducer must be located in the tension zone which is to be monitored orcontrolled. The beginning or end of any tension zone is always at a nip (driven or braked), unwindshaft, rewind shaft or drag bar. Any element in the web path that can change web tension is at one endof a tension zone.6

Figure 4 - TENSION ZONES3. WRAP ANGLE. The web must always contact the transducer roll in exactly the same way. The wrapangle must not change as the unwind or rewind roll diameter changes. Therefore there must be at leastone idler roll between the transducer and the unwind or rewind shaft. If the machine has more than onewebbing path, be sure to choose a location that is wrapped the same for each. Otherwise it will benecessary to install an additional transducer, or dual calibration circuitry, or both. If the wrap angle isallowed to change, the transducer output will change with angle as well as tension, and accuracy willbe reduced.4. MOUNTING SURFACE. The structure on which the transducer is mounted should be strong. Anymovement of the structure may cause the transducer to become mis-aligned. This probably will notaffect the transducer's performance but it could cause the web to shift toward one side when it goesover the roll.Figure 5 - MOUNTING STYLES7

2.3 INSTALLATION INSTRUCTIONSThe Model "TR" Transducer is very easy to install. Follow the same procedure as you would for anydead-shaft idler roll. The roll can rotate in either direction.1. VERIFY THE SHAFT LENGTH Measure the distance between the machine frames where thetransducer will be mounted to verify that the shaft length is correct.2. ORIENT THE TRANSDUCER (see figure 6) The transducer shaft must be turned so the Tension Forcearrow points in the same direction as the Tension Force. Tighten the shaft so it can not turn.Figure 6 - TENSION FORCE DIRECTIONNOTE: During installation and handling, be careful not to drop the transducer on its end. Damagecould result.3. ATTACH CABLE. Make sure cable does not get near the moving roll or web.2.4 HOW TO CHANGE THE ELECTRICAL CONNECTOR POSITIONIf needed, the electrical connector can be placed in any position relative to the tension force direction.Using clock face numbers as a reference, with the tension force direction at 6 o'clock (straight down), theconnector may be set in any position. The standard position is 6 o'clock. It may be changed easily byfollowing the procedures below.1. PROCEDURE1. Loosen but do not remove the clamp screw on the connector block.2. Hold the shaft with one hand and rotate the connector block with the other hand so the connector isin the desired position. DO NOT ROTATE THE HOUSING MORE THAN 1/2 TURN IN EITHERDIRECTION! The connector wires inside may be stretched or broken if the housing is turned toofar.3. Tighten the clamp screw.8

SECTION 3CALIBRATION3.1 INTRODUCTIONThere are no calibration adjustments on the Model "TR" Transducer itself. The instructions below are forthe electronic device which the transducer is connected to. All of the following terminology andprocedures assume that the transducer is connected to a Dover Flexo Electronics tension controller ortension indicator. If some other device is being used, you should follow the instructions furnished with it.These are general instructions which are correct for most DFE controllers and indicators, and are placedhere for your convenience. If you have any difficulty calibrating or if there is any discrepancy betweenthese instructions and those in the Instruction Manual for the indicator or controller, you should disregardthese instructions and follow the instructions in the Manual for the indicator or controller. The transducermust be properly installed and oriented as directed in Section 2.3.3.2 ZERO THE TENSION METER1. Turn the "POWER" switch OFF. If the meter does not read zero, turn the mechanical adjustment screwon the meter face so the needle indicates zero tension.2. Find an object of some kind that weighs at least 25% of the maximum value on the tension meter scale.(Be sure you know the exact weight).3. Find a rope, tape, or wire that will support the weight in 2. above.4. Verify that there is no web contacting the transducer roll. Turn the "POWER" switch on. Wait a fewseconds for the tension meter to settle. Turn the "CALIBRATE" pot. to approximately 75%. Then,turn the "ZERO" pot. so the tension meter reads zero tension.3.3 CALIBRATE THE TENSION METERSee Figure 7. Pass the rope over the Transducer Roll in exactly the same path as the web follows. Tie theend in the machine at least one idler roll beyond the Transducer Roll. Pass the other end by at least oneidler roll before the Transducer Roll. Be sure the rope does not pass over any driven rolls, braked rolls ordead bars. (This will cause inaccurate calibration). Attach the weight to the free end of the rope and let ithang without touching anything. Turn the "CALIBRATE" pot. so the tension meter reads the same as theweight. Remove the weight and rope. This concludes the calibration procedure.Figure 7 - WEB PATH9

SECTION 4CARE AND MAINTENANCE4.1 BEARING LIFEThe bearings in the Model "TR" transducer will turn continuously in normal operation. They have beenselected to give a long service life under typical operating conditions. Use the formulas below, or thenomogram on the next page, to find the L 10 life, in hours, for your application.To find the radial load (P) for your application, use the appropriate sizing formula in Figure 14 on page21, substituting 2 for the 4 in the numerator to eliminate the oversizing factor.RPM = 3.82 x web speed in feet per minute/diameter of transducer roll in inches.(RPM = 318.3 x web speed in meters per minute/diameter of transducer roll in millimeters).BEARING SPECIFICATIONSSIZE BEARING TYPE RATED LOAD (C) MAXIMUM SPEED (RPM)1 Self-aligning ball 3510 lbs. (15,600 N) 13,0002 Self-aligning ball 4480 lbs (19913 N) 10,000LIFE CALCULATION FORMULAS (where P is radial load as described above)L 10 = (16667 / RPM) x (C / P) 3 , for ball bearingsL 10 = (16667 / RPM) x (C / P) 3.33 , for roller bearings(roller bearings are not normally used in the TR transducer)An L 10 life of 20,000 to 30,000 hours is usually considered satisfactory for web process machinery such asprinting presses, coaters, etc.If preferred, the bearing life nomogram (Figure 8) on the next page can be used instead of the formulas.The result will be the same.TO USE THE NOMOGRAM:1. Use the left set of three scales for ball bearings, the right set for roller bearings.2. Compute the speed of the bearing, in RPM.3. Compute the ratio C/P.4. Find the speed on the left scale. Mark it.5. Find the value of C/P on the middle scale. Mark it.6. Connect the two marks with a straight line extending to the right scale. Read the L 10 life on the rightscale where the line intersects it.10

Figure 8 - BEARING LIFE NOMOGRAM11

4.2 LUBRICATIONThe bearings are lubricated at the factory with a high quality light grease. However, they should be regreasedperiodically because all greases lose their lubricating ability with use and time.1. PROCEDUREThe grease fittings are a flush-to-the surface type. (See Figure 9 for location and for housing capacity).Use a hand operated push-type grease gun and fill the housing only 1/3 to 1/2 full. Too much greasewill increase friction, causing the transducer roll to turn hard. It also causes churning, resulting inseparation of the grease components, breakdown in lubricating value and excessive temperature. It iscommonly known that grease life is halved with every 25°F (14° C) increase in temperature and isdoubled with every 25°F (14° C) reduction in temperature.SIZE 1SIZE 2GREASE CAPACITY0.5 oz (15 cc)1.5 oz. (45 cc)2. RECOMMENDED GREASEFigure 9 - GREASE FITTING LOCATIONThe grease should be a non-fibrous NLGI No.2 grade. The thickener should be a lithium or lithiumcomplex soap for resistance to water and high temperature. Greases with a polyurea or aluminumcomplex thickener may also be suitable. In any case, the maximum rated operating temperature of thegrease should be at least 250°F (121°C). The following are some that meet these requirements.MOBIL Mobilith AW2SHELL Darina 2KEYSTONE 81EP-2 and Zeniplex 2TEXACO Premium RBLUBRIPLATE 630-2 and 1200-2CHEVRON SRI-2(DOVER FLEXO ELECTRONICS uses MOBIL Mobilith AW2)3. LUBRICATION SCHEDULEThe bearings should be re-lubricated periodically. How often depends on the speed and operatingtemperature of the bearing. These are different for every application, so it is not possible to offer asingle recommendation for every case. Nor is it likely that the bearing temperature can be easily orwillingly obtained. So, since it is probably better to re-grease more often than necessary than to not doit often enough, we recommend re-greasing every six months of single-shift per day operation. Moreoften if speeds and temperatures are higher than normal. (Recall the effects of high temperaturementioned in Section 4.2.1 above.) If there is an established lubrication schedule for the other bearingson the machine it should be satisfactory for the transducer bearings as well.12

4.3 DISASSEMBLY AND REASSEMBLYNOTE: Following are some procedures for servicing your tension roll. It is highly recommended that thetension roll be returned to Dover for proper service and maintenance. Warranty will be void if unit isdisassembled before five year warranty expires unless specific permission is given by DFE’s TechnicalService Manager.1. TOOLS REQUIRED1. Socket head screw hex keysSCREW SIZE KEY SIZE (inch) TRANSDUCER SIZE & LOCATION OF USEM2 x 0.4 0.058 (1.5mm) Size 1: Bearing RetainerM3 x 0.5 Button 0.078 (2mm) Size 1: Electrical ConnectorM4 x 0.7 Set Screw 0.078 (2mm) Size 1: End Cover4-40 Button 0.0625 (1/16) Size 2: Electrical Connector4-40 0.0937 (3/32) Size 2: Bearing Retainer10-32 0.1562 (5/32) Size 2: Beam Retainer, Connector Blk10-32 Set Screw 0.0937 (3/32) Size 2: End Cover1/4-20 0.1875 (3/16) Size 2: Beam, Bearing Retainer2. Needle nose pliers.3. A small flat blade screwdriver.4. 20 watt soldering iron with small tip.5. Diagonal wire cutters.6. Wire stripper for 30 AWG wire.2. ELECTRICAL CONNECTOR REPLACEMENT1. Remove the four screws holding the connector in place.2. Unsolder the wires. (You need not remember where the wires came from because the correctconnections are listed in Section 1.4 Specifications on page 3 of this Manual.) Set the electricalconnector aside.3. Take a new electrical connector in hand. Look closely at the end where the wires will be soldered.Notice that each pin is identified by a letter.4. Turn to Section 1.4 Specifications, Page 3 of this Manual and solder the wires to the pins asdescribed under "Connector Pin Assignments".5. Carefully stuff the wires into the connector block and position the connector so the small key tab inthe threaded end of the connector faces the roll. Replace all four screws and tighten.3. SHAFT REMOVAL1. Place the transducer on a clean bench. Block it in place so it can not roll.2. Using an ink marker or piece of tape, identify the end of the roll near the electrical connector withthe letters "EC".3. Loosen the two set-screws and remove the end cover having the Tension Force direction decal. SeeFigure 10.Figure 10 - DECAL END OF TRANSDUCER13

4. Using a small screw driver, remove the bearing retaining ring from the roll bore. Remove theretaining ring from the shaft. Remove the four M3 x 6 BHCS with M2 allen wrench.5. Using a 20 watt soldering iron, unsolder the wires from the electrical connector (You need notremember where the wires came from because the correct connections are listed in Section 1.4Specifications on page 3 of this Manual.). Note position of connector position on mounting ringwith a marker.6. Rotate the mounting ring to locate the M4 x 16 cap screw. Loosen the screw with a M3 allenwrench and slide the mounting ring off the shaft.7. Have a helper hold the roll in place on the bench. Grip the shaft at the end having the electricalconnector. Gently pull the shaft. It will slide thru the bearing on the other end. The bearing on theend you are holding will slide out of the roll. If the shaft stops moving it may be caught on one ofthe balance weights inside the roll. DO NOT FORCE IT! Have your helper turn the roll 1/4revolution and/or lift his end of the shaft so it won't drag on the weights. Continue to withdraw theshaft carefully until it is free of the roll.STOPIf your intention is to repair or replace the roll, you can stop at this point. The roll is separated from theshaft. If you wish to service or replace the bearings or beams, please proceed to step 7.7. The electrical connector mounting block must be removed before the bearing can be removed. First,remove the four screws holding the connector in place. Un-solder the wires. Set the electricalconnector aside.8. Loosen the clamp screw on the connector block two turns. Slide the block off the shaft.9. Straighten the wires carefully and snip off any excess solder from the ends. Separate the two whitewires from each other. Also separate the two green wires.10. Remove the retaining ring from the shaft.11. Remove the four screws from the bearing retainer. Arrange the wires so they lay next to each otherin one layer extending from the end of the groove over the surface of the shaft.12. GENTLY slide the retainer away from the bearing and over the wires, being careful not to damagethe wires.13. Carefully pull the temperature compensation sleeve and bearing assembly off of the sensing beam.STOPIf your intention is to service or replace the bearings, you can continue to Step 14. If you wish toremove the sensing beams, please proceed to Step 15.14. To replace the bearing, remove inner retaining ring and draw out bearing with a bearing puller.Take note of the order of the aluminum lip spacer, rubber seal and stainless steel grease shield inthis end of the roll if these parts are to be replaced. Heat the end of the roll with a heat gun untilroll is too hot to handle and install the new bearing by gently tapping in an alternating fashion theouter ring with an aluminum or brass rod and hammer.Figure 11 - THE BEAM ASSEMBLY14

15. The disassembly procedure is slightly different for each beam so the following instructions areseparated into two parts.a. To remove the beam on the connector end of the shaft; remove the cord and tape holding thewires against the shaft nearest the beam. Do NOT remove the other cords. It is not necessary.Then, pull the blue, green and brown wires gently back thru the black plastic protective tubingtoward the beam. Next, loosen and remove the four screws holding the beam to the shaft clamp.Do NOT loosen or remove the shaft clamp or its screws. Finally, slide the beam toward the endof the shaft, pull back the remaining wires, leaving the protective tubing in place, so the beamcan be slid all the way off the shaft.b. To remove the beam from the decal end of the shaft; remove ALL of the cords and tape holdingthe wires against the shaft. Pull the red, white and black wires thru the protective tubing towardthe beam. Loosen and remove the four screws holding the beam to the shaft clamp. Do NOTloosen or remove the shaft clamp. Slide the beam off the shaft, being very careful to not pull thewires.STOPThis completes the disassembly of the transducer. See Step 4 below for reassembly instructions.4. REASSEMBLY PROCEDUREGenerally, you should follow the disassembly instructions in Step 15 above, but in reverse order. Thestarting point depends on the extent of the dis-assembly. If beams were removed, start at the end ofStep 15 and proceed backwards to Step 1. If only bearings were removed, start at Step 14. If only theroll was removed, start at Step 6.There are a few special instructions that pertain only to the reassembly procedure:1. Clean all parts before assembly. Pay particular attention to the bearings. If the old bearings arebeing reinstalled, remove all the old grease and pack with new grease. (See Section 4.2 forprocedure). Take special care to prevent any contamination.2. Place the shaft on the bench with the wire slot UP. The slot acts as a reference point and also needsto be accessed. The slot is on the connector end of the shaft. See Figure 18.Figure 12 - SHAFT AND BEAM FEATURES3. When installing the beams, be sure they are positioned as follows:a. Beam on the decal end ----- webs parallel to the bench, red wire on topb. Beam on the connector end - webs parallel to the bench, brown wire on top. Remember, theshaft is positioned with the slot on top.4. Also, when installing the beams, be sure there is at least a 0.007 inch (0.17mm) gap between theshaft and the bore of the beam under the bearing. Check the gap after the four beam retainer screwshave been tightened. If the gap is not the same all around the shaft, loosen the retainer screws andreposition the beam as needed. The gap is very important. It allows the beam to deflect as load isapplied to it.15

5. All eight wires must go thru the black plastic protective tube. The technique that works the best isto first twist all of the bare conductors together at the ends, only, and run the wires thru the slot.Then put the plastic tube over the wires and push it into the slot, under the beam and out past theshaft clamp. The wires act as a guide for the tube.6. The roll must only be installed with the identified end (refer to Section 4.3.3, Step 2) at theelectrical connector block which is at the slot end of the shaft.7. When installing the end cover (where the decal is located) observe the two small holes in the shaft.These are for the set screws in the end cover which must be positioned so the screws go into theholes. Otherwise, the Tension Force direction will be wrong.8. Use the procedure in Section 4.3.2, Steps 3, 4, and 5 above when installing the electrical connector.If you encounter any difficulties or have any questions regarding disassembly or reassembly of the TRtransducer, please call DOVER FLEXO ELECTRONICS and ask for the Technical ServiceDepartment.16

SECTION 5TROUBLESHOOTING GUIDEThis is a list of problems which could occur during initial start-up or afterwards. The probable causes arelisted with the most likely one first and the least likely one last.1. TRANSDUCER ROLL SHAKES, VIBRATES or BOUNCESa. Roll is not balanced.b. Transducer mounting bolts are not tight.c. Roll is turning at its natural frequency. Call DOVER for analysis of operatingconditions and solution to problem.2. CAN NOT ADJUST TENSION METER TO READ ZERO WHEN WEB IS SLACKa. Transducer roll is too heavy. See Appendix B, Step 4, page 21.b. Failure in the tension indicator circuit.3. TENSION METER READS BACKWARDSa. Transducer is installed backwards with force arrow pointing in opposite direction. See Section 2.3page 8.b. Transducer cable is connected wrong at controller/indicator terminal strip. Signal wires arereversed.4. TENSION METER NEEDLE PEGS HIGH OR LOWa. Meter is not electrically adjusted to zero. See Section 3.2 page 9.b. Transducer cable has broken wire, poor connection or short circuit.c. A strain gage has failed. To verify: Unplug the transducer cable and use an ohm-meter to measurethe resistance of the gages at the connector on the transducer. Measure between pins A,B, and A,C.Also measure between pins D,E and D,F. In each case the resistance should be about 100 ohms.Measure the resistance between any pin and the shaft of the transducer. The meter should readinfinite resistance. Apply a force to the roll by hand or by using a rope and a weight, in thedirection of the tension force and maintain it while again measuring between pins A,B and A,C.Repeat while measuring between pins D,E and D,F. The resistance should be only a few ohmsdifferent from before.d. Failure in the tension amplifier circuit of the controller/indicator.5. TENSION METER DOES NOT READ ZERO WHEN WEB IS SLACK AND READING DRIFTS WITHTIME.a. Meter is not calibrated. See Section 3.3 page 9.b. Transducer cable has a broken wire, poor connection, ground or short circuit.c. A strain gage is cracked. Perform the test in 4.c. above.6. TENSION METER DOES NOT READ THE SAME EACH TIME THE SAME FORCE IS APPLIED(Poor repeatability)a. Extreme build-up of dirt, ink, adhesive, grease or other foreign material inside end of roll causinginterference with beam movement.b. Transducer cable has a broken wire, poor connection, ground or short circuit.c. Strain gage failure. See 4.c. above for test.17

7. TENSION METER READING DOES NOT CHANGE WHEN FORCE IS APPLIED TO ROLL. METERREADS ZERO.a. Meter is not calibrated. See Section 3.3 page 9.b. Transducer roll is too heavy. See Appendix B, Step 4, page 21.c. Extreme build-up of dirt, ink, adhesive, grease or other foreign material inside end of roll causinginterference with beam movement.d. Transducer cable has broken wire, poor connection, ground or short circuit.e. Transducer cables connected incorrectly, or to wrong transducers.f. Failure of tension amplifier circuit in controller/indicator. Unit not turned on.8. TENSION METER NEEDLE BOUNCESa. Web tension is fluctuating because of machine speed fluctuations, bent roll shafts, worn idler rollbearings, chattering unwind brake, flat spot in unwind or rewind roll, etc.b. Transducer mounting bolts are loose.c. Tension controller is not adjusted properly. See controller Instruction Manual forprocedure.18

SECTION 6REPLACEMENT PARTS(Model TR Transducer)PART SIZE 1 SIZE 2ELECTRICAL CONNECTORCONNECTOR SCREWSPT02A-10-6P(DFE # 106-0049)SOCKET BUTTON HEADM3 x 0.5 x 6mm LONG(DFE # 123-0032)MS3102A-14S-6P(DFE # 106-0074)SOCKET BUTTON HEAD#4-40 x 1/4 LONG(DFE # 123-0272)BEARING 1206 (DFE # 133-0032) 1208 (DFE # 133-0006)BEARING RETAINERSCREWSM4 x 0.7 x 25mm LONG(DFE # 123-0219)#4-40x 3/4 LONG(DFE # 123-0205)RETAINING RING FOR ENDCOVERS (External)RETAINER RING FORBEARINGS (Internal)DFE # 135-0014 DFE # 135-0042DFE # 135-0076 DFE # 135-0063END COVER SCREWCONE POINT SOCKET SETM4 x 0.7 x 8mm LONG(DFE # 123-0220)CONE POINT SOCKET SET#10-32 x 1/4 LONG(DFE # 123-0202)WAVE SPRING DFE #128-0018 DFE #128-0021GREASE SHIELD DFE #501-0401 and 201-1906 DFE #201-1905NOTE: All screws are steel socket head, coarse thread unless otherwise noted.Call Customer Service for prices and for part numbers of items not listed. For help with service orrepairs, call Technical Service.DOVER FLEXO ELECTRONICSTelephone: 603-332-6150 Fax: 603-332-3758E-mail: customerservice@dfe.com. techsupport@dfe.comInternet: www.dfe.com19

Appendix A:Transducer Electrical ConnectionsFigure 13 - TR TRANSDUCER ELECTRICAL CONNECTIONS20

Appendix B:Selection of Load RatingSELECTION OF LOAD RATING1. LOAD RATINGS. The Model "TR"Transducer is available in several standard load ratings, rangingfrom 12 lbs. to 400 lbs. The correct rating for any particular application depends on web tension,transducer roll weight, wrap angle and the direction of the tension force on the transducer roll. Figure 5contains mathematical formulas which use these factors to determine the correct load rating.2. SELECTION PROCEDURE The correct load rating is found in four simple steps:Step 1.OBTAIN DATA TO PLUG INTO THE SELECTION FORMULAa. Compute the weight of the transducer roll and bearing assemblies. Refer to Section 2.2.1.1 for rolland bearing weights.b. Estimate the maximum web tension. Use Appendix C, Typical Tensions, as a guide if necessary.c. Determine the wrap angle.d. Determine the angle of the tension force, F T , relative to the vertical. (NOTE: F T bisects the wrapangle)Step 2. COMPUTE NET FORCE USING THE SELECTION FORMULARefer to Figure 14. Select the appropriate wrap configuration as determined by the direction of thetension force (above, below or on horizontal). Compute the Net Force, using the formula below thewrap diagram.Figure 14 - LOAD RATING SELECTION FORMULASStep 3. SELECT THE LOAD RATINGUse the Load Rating Chart below to select the correct load rating. In some cases, the load rating maybe LESS than the computed Net Force. This is acceptable because the Net Force formula contains anoversizing factor of 2. Therefore the actual force exerted on the transducer will not exceed its rating, ifthe transducer is chosen according to the chart.21

LOAD RATING CHARTNET FORCE -lbs. (N)LOAD RATING - lbs. (N)up to 15 (66) 12 (55)16 - 32 (71 - 142) 25 (110)33 - 63 (146 - 280) 50 (225)64 - 125 (284 - 556) 100 (450)94 - 188 (426 - 834) 150 (670)126 - 250 (560 - 1112) 200 (900)251 - 500 (1116 - 2224) 400 (1800)Step 4.COMPARE LOAD RATING WITH EFFECTIVE TRANSDUCER ROLL WEIGHTSometimes, a Tension Roll shell is so heavy that its weight uses up most of the operating range of thetransducer. When this happens, it may not be possible to adjust the tension indicating meter to readzero when tension is zero because the adjustment range of the electronic circuit has been exceeded. Tofind out if the roll is too heavy, compare the load rating with the effective weight of the roll as follows:Refer back to the Net Force formula used in Step 2 . The effective roll weight is the "W Cos(A)" termin the formula. If W Cos(A) is more than 95% of the load rating chosen, the tension meter willprobably not be adjustable to zero. If this is the case, one or more of the following changes must bemade to reduce W Cos(A) to less than 95% of the load rating:A. Reduce the roll weight by using a smaller diameter roll. This may not be possible due to strengthconsiderations.B. Increase angle A. (see Figure 14)C. Use the next higher load rating.22

Appendix C:Typical Tensions for Various MaterialsTYPICAL TENSIONS FOR WEB MATERIALSACETATE0.5 lb. per mil per inch of widthFOIL Aluminum 0.5 lb. per mil per inch of widthCopper 0.5 lb. "CELLOPHANE0.75 lb. per mil per inch of widthNYLON0.25 lb. per mil per inch of widthPAPER 15 lb * 0.4 lb. per inch of width20 lb 0.5 lb. "30 lb 0.75 lb. "40 lb 1.25 lb. "60 lb 2.0 lb. "80 lb 3.0 lb. "100 lb 4.0 lb. "* based on 3000 sq. ft. reamPAPERBOARD 8pt 3.0 lb. per inch of width12pt 4.0 lb. "15pt 4.5 lb. "20pt 5.5 lb. "25pt 6.5 lb. "30pt 8.0 lb. "POLYETHYLENE0.12 lb. per mil per inch of widthPOLYESTER (Mylar)0.75 lb. per mil per inch of widthPOLYPROPYLENE0.25 lb. per mil per inch of widthPOLYSTYRENE1.0 lb. per mil per inch of widthRUBBER GAUGE AT 25% STRETCH AT 50% STRETCH10 mil 1.75 3.6812 mil 1.10 2.0316.5 mil 4.09 8.1726 mil 2.47 4.97SARAN0.15 lb per mil per inch of widthSTEEL GAUGE - INS UNWIND-PSI REWIND-PSI0.001 - 0.005 1000 40000.006 - 0.025 850 35000.026 - 0.040 750 30000.041 - 0.055 650 26000.058 - 0.070 550 22000.071 - 0.090 450 18000.091 - 0.120 450 14000.121 - 0.140 400 12000.141 - 0.165 400 10000.166 - 0.200 400 9000.201 - 0.275 400 8000.276 - 0.380 300 700VINYL0.05 lb. per mil per inch of width*** For laminated webs, sum the tension for the individual webs and add 0.1 lb per inch of width.23

TERMS AND CONDITIONS OF SALE AND SHIPMENT1. THE COMPANYDover Flexo Electronics, Inc. is hereinafter referred to as theCompany.2. CONFLICTING OR MODIFYING TERMSNo modification of, additions to or conflicting provisions to theseterms and conditions of sale and shipment, whether oral or written,incorporated into Buyer's order or other communications are bindingupon the Company unless specifically agreed to by the Company inwriting and signed by an officer of the Company. Failure of theCompany to object to such additions, conflicts or modifications shallnot be construed as a waiver of these terms and conditions nor anacceptance of any such provisions.3. GOVERNING LAWThis contract shall be governed by and construed according to thelaws of the state of New Hampshire, U.S.A. The parties agree thatany and all legal proceedings pursuant to this contract shall takeplace under the jurisdiction of the courts of the State of NewHampshire in the judicial district of Strafford County.4. PENALTY CLAUSESPenalty clauses of any kind contained in orders, agreements or anyother type of communication are not binding on the Company unlessagreed to by an officer of the Company in writing.5. WARRANTYDover Flexo Electronics,Inc. warrants, to the original Buyer, its'products to be free of defects in material and workmanship for fiveyears from date of original shipment. Repairs on products arewarranted for 90 days from date of shipment. During the warrantyperiod the Company will repair or replace defective products free ofcharge if such products are returned with all shipping chargesprepaid and if, upon examination, the product is shown to bedefective. This warranty shall not apply to products damaged byabuse, neglect, accident, modification, alteration or mis-use. Normalwear is not warranteed. All repairs and replacements under theprovisions of this warranty shall be made at Dover Flexo Electronicsor at an authorized repair facility. The Company shall not be liablefor expenses incurred to repair or replace defective products at anyother location or by unauthorized persons or agents. This warrantycontains all of the obligations and warranties of the Company. Thereare no other warranties, either expressed or implied. No warranty isgiven regarding merchantability or suitability for any particularpurpose. The Company shall not be liable in either equity or law forconsequential damages, losses or expenses incurred by use of orinability to use its' products or for claims arising from same. Nowarranty is given for products of other manufacturers even thoughthe Company may provide these products with its' own or bythemselves. The provisions of this warranty can not be changed inany way by any agent or employee of the Company. Notice ofdefects must be received within the warranty period or the warrantyis void. The warranty is void if the serial number tag is missing or notreadable.6. PAYMENTSStandard terms of credit are net 30 days from date of shipment,providing satisfactory credit is established with the Company.Amounts past due are subject to a service charge of 1.5% permonth or portion thereof or 18% per annum. The Company reservesthe right to submit any unpaid late invoices to a third party forcollection and Buyer shall pay all reasonable costs of such collectionin addition to the invoice amount. All quoted prices and paymentsshall be in U.S. Dollars.If the Company judges that the financial condition or paymentpractices of the Buyer does not justify shipment under the standardterms or the terms originally specified, the Company may require fullor partial payment in advance or upon delivery. The Company reservesthe right to make collection on any terms approved in writingby the Company's Finance Department. Each shipment shall beconsidered a separate and independent transaction and paymenttherefore shall be made accordingly. If the work covered by thepurchase order is delayed by the Buyer, upon demand by Companypayments shall be made on the purchase price based uponpercentage of completion.7. TAXESAny tax, duty, custom, fee or any other charge of any naturewhatsoever imposed by any governmental authority on or measuredby any transaction between the Company and the Buyer shall bepaid by the Buyer in addition to the prices quoted or invoiced.8. RETURNSWritten authorization must be obtained from the Company's factorybefore returning any material for which the original Buyer expectscredit, exchange, or repairs under the Warranty. Returned material(except exchanges or repairs under the Warranty) shall be subjectto a minimum re-stocking charge of 15%. Non-standard material orother material provided specially to the Buyer's specification shallnot be returnable for any reason. All material returned, for whateverreason, shall be sent with all freight charges prepaid by the Buyer.9. SHIPPING METHOD AND CHARGESAll prices quoted are EXW the Company's factory. The Companyshall select the freight carrier, method and routing. Shipping chargesare prepaid and added to the invoice of Buyers with approved credit,however the Company reserves the right to ship freight-collect if itprefers. Shipping charges will include a charge for packaging.Company will pay standard ground freight charges for items beingreturned to Buyer which are repaired or replaced under the Warranty.10. CANCELLATION, CHANGES, RESCHEDULINGBuyer shall reimburse Company for costs incurred for any item onorder with the Company which is cancelled by the Buyer. Costs shallbe determined by common and accepted accounting practices.A one-time hold on any item ordered from the Company shall beallowed for a maximum of 30 days. After 30 days, or upon notice ofa second hold, Company shall have the right to cancel the order andissue the appropriate cancellation charges which shall be paid byBuyer. Items held for the Buyer shall be at the risk and expense ofthe Buyer unless otherwise agreed upon in writing. Companyreserves the right to dispose of cancelled material as it sees fitwithout any obligation to Buyer.If Buyer makes, or causes to make, any change to an order theCompany reserves the right to change the price accordingly.11. PRICESPrices published in price lists, catalogs or elsewhere are subject tochange without notice and without obligation. Written quoted pricesare valid for thirty days only.12. EXPORT SHIPMENTSPayment for shipments to countries other than the U.S.A. andCanada or to authorized distributors shall be secured by cash inadvance or an irrevocable credit instrument approved by an officerof the Company. An additional charge will apply to any letter ofcredit. There will also be an extra charge for packaging anddocumentation.13. CONDITION OF EQUIPMENTBuyer shall keep products in good repair and shall be responsiblefor same until the full purchase price has been paid.14. OWNERSHIPProducts sold are to remain the property of the Company until fullpayment of the purchase price is made.rev.8 8/9 /1024

DECLARATION OF CONFORMITYWe,Dover Flexo Electronics217 Pickering RoadRochester, NH 03867 USATel: (603) 332-6150Fax: (603) 332-3758declare under our sole responsibility that the product:Model TR1 Web Tension Transducer,manufactured after the date 1 May 1997, and to which this declaration relates, is in conformity with the followingstandards or other normative documents:EN 55011: Radiated and Conducted EmissionsEN 50082-2: Electromagnetic compatibility - Generic immunity standard,Part 2. Industrial Environment, to include:ENV 50140: Radio Frequency Immunity - AMENV 50141: Conducted Radio Frequency InterferenceENV 50204: Radio Frequency Immunity - Pulse ModulatedENV 61000-4-2: Electrostatic DischargeEN 61000-4-4: Electrical Fast Transient Burstsfollowing the provisions of Council Directive 89/336/EEC of 3 May 1989 on the approximation of the laws of themember states relating to electromagnetic compatibility (the "EMC Directive").The Technical Construction File is maintained at:Dover Flexo Electronics217 Pickering RoadRochester, NH 03867 USAPer Annex II R of the Machinery Directive (89/392/EEC):The machinery, product, assembly, or sub-assembly covered by this Declaration of Conformity must notbe put into service until the machinery into which it is to be incorporated has been declared in conformity with theprovisions of the applicable Directive(s).Date of issue: 5 May, 1997Place of issue: Rochester, NH USASigned:_____________________________________________Alan H. Wysocki, Engineering Manager8010719a.doc25

DECLARATION OF CONFORMITYWe,Dover Flexo Electronics217 Pickering RoadRochester, NH 03867 USATel: (603) 332-6150Fax: (603) 332-3758declare under our sole responsibility that the product:Model TR2 Web Tension Transducer,manufactured after the date 1 May 1997, and to which this declaration relates, is in conformity with the followingstandards or other normative documents:EN 55011: Radiated and Conducted EmissionsEN 50082-2: Electromagnetic compatibility - Generic immunity standard,Part 2. Industrial Environment, to include:ENV 50140: Radio Frequency Immunity - AMENV 50141: Conducted Radio Frequency InterferenceENV 50204: Radio Frequency Immunity - Pulse ModulatedENV 61000-4-2: Electrostatic DischargeEN 61000-4-4: Electrical Fast Transient Burstsfollowing the provisions of Council Directive 89/336/EEC of 3 May 1989 on the approximation of the laws of themember states relating to electromagnetic compatibility (the "EMC Directive").The Technical Construction File is maintained at:Dover Flexo Electronics217 Pickering RoadRochester, NH 03867 USAPer Annex II R of the Machinery Directive (89/392/EEC):The machinery, product, assembly, or sub-assembly covered by this Declaration of Conformity must notbe put into service until the machinery into which it is to be incorporated has been declared in conformity with theprovisions of the applicable Directive(s).Date of issue: 5 May, 1997Place of issue: Rochester, NH USASigned:_____________________________________________Alan H. Wysocki, Engineering Manager8010720a.doc26

INDEXAccessories .................................................... 4Balance, dynamic .......................................... 1, 3Beam ............................................ 1, 3, 9, 15, 16, 21Bearinglife calculation ........................................... 10lubrication ................................................. 12part number. .............................................. 19specifications ............................................. 3Calibration ..................................................... 9Dead shaft ..................................................... 1Declaration of Conformity ............................ 25 - 26Deflection ...................................................... 3Description .................................................... 1Dimensions .................................................... 5Direction of rotation ...................................... 8Disassemblyprocedure ................................................... 13tools needed ............................................... 13Effective roll weight ...................................... 22Electrical connections ............................... 2, 3, 4, 20Electrical connector ....................................... 1changing position of .................................. 8operation .................................................... 2part number .............................................. 3part number of mating part ........................ 3positions available ..................................... 3Excitation voltage ......................................... 3F T (see Tension force)Gage (see Strain gage)Gap, overload stop ........................................ 3Greasecapacity ..................................................... 12fitting ......................................................... 12gun ............................................................. 12type of ....................................................... 12Hysteresis ...................................................... 3Installation ..................................................... 5 - 8Load ratingselection of ................................................ 21sizes ........................................................... 3, 21Lubrication (also see Grease)procedure ................................................... 12schedule ..................................................... 12Mechanical Operation ................................... 1Mis-alignment ............................................... 6Mounting adapter .......................................... 3, 7Mounting styles ............................................. 3, 7Net force ........................................................ 21Non-Linearity ................................................ 3Nomogram of bearing life ............................. 11Options .......................................................... 4Output ........................................................... 3Overload ........................................................ 3capacity ..................................................... 3stop ............................................................ 3Parts, replacement ......................................... 19Reassembly ................................................... 15Repeatability ................................................. 3Rollmaterial ...................................................... 3, 6precautions ................................................ 6weight ........................................................ 6, 21width .......................................................... 5, 6Seals .............................................................. 1, 19Shaftdiameter ..................................................... 5ends ........................................................... 3, 7extension ................................................... 6length ......................................................... 4, 5, 21material ...................................................... 1, 3Shaft hanger ............................................... 2, 4, 5, 7Specifications ................................................ 3Strain gage .................................................... 2, 3Temperaturecoefficient .................................................. 3range .......................................................... 3effect on grease ......................................... 12Tension force ................................................ 2, 8, 21Tensions, typical ........................................... 23Tension zones ................................................ 7Terms and conditions of sale ........................ 24Transducer location ....................................... 6Troubleshooting ............................................ 17Warranty ....................................................... 24Web path ....................................................... 9Wheatstone bridge ......................................... 2Wrap angle .................................................... 21Zone (see Tension zone) ............................... 727

217 PICKERING ROADROCHESTER, NEW HAMPSHIRE 03867-4630 U.S.ATEL: 603-332-6150FAX: 603-332-3758E-mail: info@dfe.com Internet: www.dfe.comCANADAMEXICOUNITED KINGDOMEUROPETAIWANKOREAAUSTRALIACOLOMBIAINDIASOUTH AFRICACHINA©2008 DOVER FLEXO ELECTRONICS, INC. DOC 801-0648 R8ALL RIGHTS RESERVED F & C 0509 PRINTED IN USA