DFC-90 Follower Arm User Manual: MAGPOWR
Contents
1. 222 W Memorial Road Oklahoma City OK 73126 0508 MAGPOWR EE itterational Phone 1 800 624 7697 Fax 405 755 8425 Compan pey www magpowr com E mail magpowr magpowr com INSTRUCTION MANUAL MODEL DFC 90 DANCER FOLLOWER ARM CONTROL 90 VDC All of the information herein is the exclusive proprietary property of Maxcess International and is disclosed with the understanding that it will be retained in confidence and will neither be duplicated nor copied in whole or in part nor be used for any purpose other than for which disclosed Copyright 2004 all rights reserved Periodically there will be updates to this manual The latest version is available at www magpowr com or by calling 1 800 MAGPOWR 624 7697 1 0 Introduction The MAGPOWR Model DFC 90 is a complete solution for follower arm or dancer control applications The DFC 90 provides a 90 vdc current regulated output to control electromagnetic clutches and brakes The DFC 90 also provides a small reverse current to minimize the drag torque of the clutch brake The Model DFC 90 has four jumper selectable current ranges Maximum outputs for the individual ranges are 0 125 0 25 0 5 and 1 0 adc The appropriate range is determined by the current rating of the clutch or brake to be controlled For best torque control resolution the lowest current range providing sufficient current for maximum operating torque should be selected Connections are provided for an external 1 madc cu2. Clockwise 2 Set the external TENSION pot full Clockwise 3 Position the follower arm on an empty core 4 Adjust the CORE pot to obtain zero on the remote meter 5 Adjust the ZERO pot until the meter just starts to increase and then reverse adjustment direction to just return the meter to zero 6 From published torque versus current curves adjust the CORE pot for the desired output current at core Example y madc to provide xx ft Ib at core 7 Place the follower arm at the full roll position and adjust the FULL pot to the desired output current at full roll Setup is complete and the DFC 90 is ready for operation Optional adjustments Stop Multiplier and Stop Time The STOP MULT pot can be used to increase the torque while the machine is stopping The increased torque is applied when the RUN STOP input is closed terminals 17 and 18 The length of time the increased torque is applied is adjusted by the STOP TIME pot The STOPPED indicator illuminates when the Stop Time expires 5 4 Operation Tension is adjusted using the external 10 kohm tension pot Rewind taper can be adjusted using the FULL pot The tension will decrease as the roll diameter increases without changing the remote TENSION pot setting Counter Clockwise rotation of the FULL pot will decrease the tension at full roll thereby increasing the amount of taper If the stop multiplier function is used Clockwise rotation of the STOP MULT pot will increase the s
3. by the STOP TIME pot Using the stop multiplier feature in dancer mode could cause the dancer to oscillate while the machine is stopping 7 0 Optional Dancer Optimization After tuning of the dancer the following method will usually optimize the stability and responsiveness of the dancer The method begins by placing the dancer in PD mode with a roll diameter near core and reducing the gain to a level which the user may consider unacceptable Gain will subsequently be increased to a more desirable level If using PID mode the dancer is placed in PID mode with a roll diameter near full roll and the integrator is reduced to a level which the user may consider unacceptable Then the integrator will be increased to a more desirable level Sometimes it may be necessary to first make the PD mode adjustment at a larger roll diameter and then refine the adjustment near core Do not switch between PD PID while the machine is running since this may result in a large transient jump in the output 1 With a roll diameter near core and the machine stopped set the switch to PD mode 2 Run the machine and adjust the POS1 pot to center the dancer arm 3 Decrease the P pot by rotating Counter Clockwise until the dancer stabilizes The POS1 pot may require readjustment several times in order to keep the dancer roll centered DEFINITION In the following steps the user will have to determine if the dancer is overshooting To do this move the stable dan
4. white wire wiper to the red or black wire Turn the potentiometer shaft until the meter reads 500 ohm Install the DFP 2 sensor so that at the 500 ohm meter reading the follower arm is halfway through its travel Soy Imi TENSION POSITION m OPENFORRUN RUN STOP I SHIELD SHIELD 17 18 19 20 21 22 23 24 25 26 115 vac 50 60 Hz SWITCH NOT ALLOWED IN D C OUTPUT L __ _ _J4 Re ei ee a CLUTCH BRAKE cw e 10K DFP OR DFP2 METER RUN STOP TENSION INCREASING 1 made OPEN FOR RUN INCREASING DIAMETER OPTIONAL REQUIRED FOR TENSION STOP MULTIPLIER OPTIONAL OTHERWISE Figure 5 Follower Arm Electrical Connections 5 3 Follower Arm Control Setup The control adjustments marked with an underline on the label are the only ones needed for follower arm adjustment see Figure 6 Stop time and Stop multiplier apply to all operating modes and are not distinctively marked STOPPED O O MAGPOWR O POSs1 ZERO _ move DFC S0 O O DANCER FOLLOWER CONTROL F PD P FULL STOP TIME baci alts aS a re el us EQ K ON T N MAX AMB 50 C C INPUT 115 VAC 1 1 AMP D STOP MULT OUTPUT 80 VDC MAX 1 0 AMP Figure 6 1 Set the following switch and 22 turn potentiometers to the settings given below switch F ZERO full Counter Clockwise FULL full Clockwise D full Counter Clockwise CORE full Counter Clockwise STOP TIME full Counter Clockwise STOP MULT full Counter
5. cer away from its set position by pushing on the dancer by bumping the unwind rewind roll or by some similar means If the dancer goes past the set position before settling to the set position it is overshooting If the dancer goes straight to the stable position without going past it the dancer is not overshooting 4 Increase the P pot by rotating Clockwise in small steps checking for dancer overshoot at each step Do this until overshoot is obtained 5 Adjust the D pot in small steps checking for dancer overshoot at each step Do this until the overshoot is eliminated The direction to adjust D for no overshoot is system dependent 6 Repeat steps 4 and 5 until the overshoot cannot be eliminated using the D pot or until the P pot is full Clockwise 7 Decrease the P pot by the amount necessary to eliminate the overshoot Adjustment is now complete for the dancer operating in PD mode The next steps complete the tuning of the dancer operating in PID mode 8 With a roll diameter near full roll and the machine stopped set the mode switch to PID 9 Run the machine and adjust the pot to center the dancer roll 10 Decrease the i pot by rotating Counter Clockwise in small steps checking for dancer overshoot at each step Do this until overshoot is obtained 11 Increase the i pot by the amount necessary to eliminate the overshoot Adjustment is now complete for the dancer operating in PID mode 8 0 Follower Arm Dancer Opti
6. cer is half way through its travel This is an approximate adjustment and is intended to center the sensor position to allow maximum rotation in both directions during operation DFP 2 To find the electrical center point of pot rotation use a digital multimeter type ohm meter to measure from the white wire wiper to the red or black wire Turn the potentiometer shaft until the meter reads 500 ohm Install the DFP 2 sensor so that at the 500 ohm meter reading the dancer is halfway through its travel 6 3 Dancer Control Setup and Tuning The controls marked on the label without an underline or box are the only ones needed for dancer adjustment see Figure 6 Stop time and Stop multiplier apply to all operation modes and are not distinctively marked 1 Set the following switch and 22 turn potentiometers to the settings given below switch PD P full Clockwise D mid rotation approximately 11 turns CORE full Counter Clockwise STOP TIME full Counter Clockwise STOP MULT full Counter Clockwise 2 With the machine running with web adjust the POS1 pot to center the dancer roll 3 Adjust the D pot to minimize dancer arm oscillations 4 If dancer arm oscillations cannot be eliminated turn the P pot Counter Clockwise and repeat step 3 Calibration is complete and the DFC 90 is ready for operation Optional Adjustments Integrator Many machines run quite successfully after the above adjustments have been made If the dancer arm mo
7. ed Verify DFP or DFP 2 sensor is wired properly and follow the calibration procedure in section 6 3 Voltage between terminals 24 and 26 should be 10 vdc Voltage between terminals 25 and 26 should change as the DFP or DFP 2 is moved through its travel Dancer not calibrated Follow the calibration procedure in section 6 3 DFC 90 in PID mode and RUN STOP switch is not wired properly Verify RUN STOP switch wiring PID mode needs a RUN STOP switch for proper operation Clutch Brake output does not increase during stop time RUN STOP switch not connected or not wired properly Verify RUN STOP switch wiring STOP MULTiplier potentiometer not set properly Turn STOP MULT potentiometer clockwise to increase the stopping torque Dancer arm hunting during stopping STOP MULTiplier is being used Turn STOP MULT potentiometer counter clockwise to decrease the hunting during stopping See Stop Multiplier note at end of section 6 3 Remote meter not working Incorrect type of meter Meter should be a current meter with 1 ma full scale and no more than 3 kohm resistance Meter wires shorted or open Disconnect meter wiring at the DFC 90 and check for proper meter resistance between the wires 10 0 Specifications Supply Voltage Fuses F1 F2 Enclosure Climatic Class Temperature Range Operating Storage Relative Humidity Pollution Degr
8. ee Altitude Compatible Residual Current Device Types Worst Case Fault Current Inputs Signal RUN STOP Outputs Clutch Brake Voltage Current Regulation Meter Signal DFP or DFP 2 Reference Voltage MAXCESS INTERNATIONAL COMPANIES 115vac 10 50 60 Hz 1 1 amp maximum sinusoidal 1 6 amp Littelfuse Part No 21601 6 or Wickmann Part No 19194 053 FS IP20 3K3 EN60721 0 C to 50 C 30 C to 80 C 5 to 85 2 IEC664 1 0 to 2000 m A or B IEC755 1 6 amp ac DFP or DFP 2 Potentiometer 1 to 10 kohm watt minimum Tension Potentiometer 10 kohm minimum watt minimum Contact closure 30 ohm maximum 0 2 vdc maximum 3 to 90 vdc full wave phase controlled Adjustable in four ranges 0 004 to 0 125 adc 0 008 to 0 25 adc 0 016 to 0 5 adc 0 032 to 1 0 adc lt 1 of range 0 to 1 madc 2 into 3 kohm maximum 10v 2 10 madc maximum E GUIDING INSPECTION Filled TENSION CONTROL SLITTING WINDING
9. n section 5 3 Voltage between terminals 24 and 26 should be 10 vdc Voltage between terminals 25 and 26 should change as the DFP or DFP 2 is moved through its travel Follower Arm not calibrated Follow the calibration procedure in section 5 3 Clutch Brake output does not increase during stop time RUN STOP switch not connected or not wired properly Verify RUN STOP switch wiring STOP MULTiplier potentiometer not set properly Turn STOP MULT potentiometer clockwise to increase the stopping torque Remote meter not working Incorrect type of meter Meter should be a current meter with 1 ma full scale and no more than 3 Kohm resistance Meter wires shorted or open Disconnect meter wiring at the DFC 90 and check for proper meter resistance between the wires 9 2 Dancer Applications Symptom Possible Cause Solution or Diagnostic No clutch brake output No AC power Verify incoming power is correct voltage and frequency Fuses blown Clutch Brake wires shorted together or shorted to ground Clutch Brake wires open circuit Disconnect clutch brake wires at the DFC 90 and check for proper clutch brake resistance between the wires Jumper not installed between 20 and 21 Install jumper between terminals 20 and 21 Clutch Brake output full on or full off DFP or DFP 2 sensor not wired properly or wires short
10. ons The DFC 90 is factory adjusted to provide full reverse current with O vdc input If some other current is desired with 0 vdc input the minimum current potentiometer may be adjusted by cutting out the hole shown on the label and then using a trimpot adjustment tool Modifying this setting will cause the clutch brake drag torque to be higher than expected and is not recommended 9 0 Troubleshooting 9 1 Follower Arm Applications Symptom Possible Cause Solution or Diagnostic No clutch brake output No AC power Verify incoming power is correct voltage and frequency Fuses blown Clutch Brake wires shorted together or shorted to ground Clutch Brake wires open circuit Disconnect clutch brake wires at the DFC 90 and check for proper clutch brake resistance between the wires Remote tension adjust potentiometer turned full counter clockwise or not wired properly Verify tension pot wiring turn tension adjust pot full clockwise and follow me calibration procedure in section Voltage between terminals 20 and 22 should be greater than zero and should change as the DFP or DFP 2 is moved through its travel Remote tension otentiometer resistance is ess than 10 kohms Use a 10 kohm potentiometer for the Remote tension control DFP DFP 2 position sensor not wired properly or wires shorted Verify position sensor is wired properly and follow the calibration procedure i
11. rent Range Settings 4 0 Maintenance The only maintenance that may be required on the DFC 90 is fuse replacement Replacement of the fuse 2 requires first removing ac power then opening the enclosure The enclosure must be re installed to maintain the IP rating The enclosure may be opened by inserting a flat blade screwdriver under the retaining tabs in the base See figure 2 5 0 Follower Arm Applications 5 1 Electrical Connections Figure 5 shows the connections that are required for the basic follower arm system They are 115 vac power input 90 vdc output for clutch brake DFP or DFP 2 roll diameter sensor 10 kohm tension potentiometer The clutch brake output and the remote meter output are not isolated from the AC line and must not be ground referenced The control inputs are isolated and may be ground referenced 5 2 Sensor Setup See Figure 4 The DFP or DFP 2 position sensor should be at the center of rotation when the follower arm is halfway through its travel This is an approximate adjustment and is intended to center the sensor position to allow maximum rotation in both directions during operation f FULL ROLL DIAMETER 7 CORE DIAMETER Figure 4 2 DFP Install the DFP sensor so that its keyway is pointing towards the top cover when the follower arm is half way through its travel DFP 2 To find the electrical center point of pot rotation use a digital multimeter type ohm meter to measure from the
12. rrent meter The meter display will indicate clutch brake output current as a percentage of the output range selected The control circuits are electrically isolated from the power circuits 2 0 Installation The DFC 90 is intended for installation on a vertical panel using a DIN 35 rail with the wiring terminals facing down Figure 1 shows the enclosure dimensions Wiring to and from the DFC 90 must be done with double or reinforced insulation or protective screening which provides protective separation All wiring should comply with the essential requirements of the appropriate standard s and is the responsibility of the installer Route control signal wiring away from AC wiring Connect shields of shielded cable to the terminals indicated as SHIELD Maximum shield length and maximum length of wires outside of the shield is 3 in 75 mm M 2 30 58 4mm ooo 6 18 157 0mm 1 39 35 2mm L Figure 1 Enclosure Dimensions 850A265 1 10 04 Rev D 3 0 Setup Remove the enclosure top by inserting a flat blade screwdriver under the retaining tabs in the base See figure 2 Set the JP1 current range selection jumpers to the range appropriate for the clutch brake connected to the DFC 90 See figure 3 for current range settings The factory setting is 1 8 amp range Replace the enclosure top JP1 CURENT RANGE Figure 2 Figure 3 Enclosure Top Removal JP1 Cur
13. topping torque Clockwise rotation of the STOP TIME pot will increase the time that the stopping torque is applied The STOP TIME may be adjusted from 0 2 to 60 seconds 6 0 Dancer Applications 6 1 Electrical Connections Figure 7 shows the connections that are required for the basic dancer system They are 115vac power input 90 vdc output for clutch brake DFP or DFP 2 dancer position sensor Install jumper between terminals 20 and 21 The clutch brake output and the remote meter output are not isolated from the AC line and must not be referenced to ground The control inputs are isolated and may be ground referenced TENSION POSITION 90V 1imA RUN va OUTPUT METER COPEN FORRUN STOP I SHIELD SHIELD 17 18 19 20 21 22 23 24 25 26 AMA AMAMA AMAMA 50 60 Hz a l l SWITCH NOT l ALLOWED IN i D C OUTPUT J CLUTCH BRAKE DFP REMOTE ee METER RUN STOP INCREASING 0 1 madc OPEN FOR RUN LOAD CURRENT OPTIONAL OPTIONAL FOR PD REQUIRED FOR PID REQUIRED FOR STOP MULTIPLIER Figure 7 Dancer Electrical Connections 6 2 Sensor Setup The DFP or DFP 2 position sensor should be at the center of rotation when the dancer is halfway through its travel This is an approximate adjustment and is intended to center the sensor position to allow maximum rotation in both directions during operation DFP Install the DFP sensor so that its keyway is pointing towards the top cover when the dan
14. ves too much while the roll changes size the integrator can be turned on to keep the dancer centered The control adjustments marked with a box apply to a dancer with integrator 5 Set the I pot full Clockwise 6 With the machine stopped set the switch to PID This turns the integrator on 7 Run the machine near full roll and at a slow speed and use the POS2 pot to center the dancer Clockwise rotation of POS2 moves the dancer up towards an empty dancer condition 8 Turn the Ll pot Counter Clockwise until the dancer begins to oscillate around the setpoint position Then turn the I pot Clockwise until the oscillation stops The RUN STOP input must be used if the integrator is on switch in position The RUN STOP input should be closed terminals 17 and 18 when the machine starts its deceleration The DFC 90 keeps the integrator on until Stop Time expires Stop Time may be increased by Clockwise rotation of the STOP TIME pot The STOPPED indicator lights when the Stop Time expires While the STOPPED indicator is lit the DFC 90 provides a hold level current to the clutch brake This hold level may be adjusted by turning the HOLD pot Stop Multiplier and Stop Time Even if integrator mode is not used the STOP MULT pot can be used to increase the torque while the machine is stopping The increased torque is applied when the RUN STOP input is closed terminals 17 and 18 The length of time the increased torque is applied is adjusted
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