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Spyder Plus User Manual

1. 12 0 COMMUNICATION OPTIONAL Starting Parameter Name Parameter Parameter Used with Read Range Modbus Format Type Control Write Register Types 0x99 Actual Output FLOAT None LC DT DS Read 0 0 100 0 OPT Only 0x9B Actual Diameter FLOAT None LC OPT Read 0 0 999 0 in Only 0x9D Position Setpoint FLOAT None DT DS Read 0 0 100 0 Only Ox9F Actual Position FLOAT None DT DS Read 0 0 100 0 Only OxA1 Device Name STRING Data LC DT DS Read 31 Characters Maximum OPT Write OxB1 Program Version UINT32 None LC DT DS Read 920Axxx yyy OPT Only xxx yyy 0 999 xxx High Word yyy Low Word 0xB3 Modbus Address UINT16 Data LC DT DS Read 0 255 OPT Write 0xB4 Modbus Byte Order BYTE Data LC DT DS Read 0 MSB First OPT Write 1 LSB First 0xB5 Modbus Word Order BYTE Data LC DT DS Read 0 MSB First OPT Write 1 LSB First OxB6 Actual Manual Level FLOAT None LC OPT Read 0 0 100 0 Only 0xB8 Enable Load Cell Reading Dancer BYTE Data DT DS Read 0 Load Cells Not Enabled Write 1 Load Cells Enabled 0xB9 Remote Dancer Setpoint FLOAT Data DT DS Read No Integrator mode P or Write PD range 0 0 5 0 With Integrator mode PI or PID range 0 0 1 0 Multiply this value by 100 to get percent 0xBB Setpoint Tension Percent FLOAT Data OPT Read 0 0 100 0 Write 0xBD System Type Open L
2. TaperPercent 100 NOTE The desired Taper is dependent on material and machine type and is totally subjective Determination of the correct amount of taper for your application is a trial and error process 8 2 1 5 MANUAL LEVEL This screen shows the manual level being input on Term 20 8 2 1 6 OUTPUT LEVEL This screen shows the actual output level of the Spyder in numeric form The bar graph also shows actual output level in analog form The lower left character displays the status of the Spyder See Section 8 2 1 1 for description of the status character ETHERNET Dcore CAT 5 Dactual SHIELDED O 1mA OR 0 10V TO REWIND MOTOR f Rh 7A CONTROLLER CO CH CO w N a a oo E MAIN OUT SHIELD METER METER MAIN OUT 5 D zu gt 3 g si 5 a i a z 9o t KE a r e bei x zZ Z2Zzz al ar al w H BS 289898 o 333 9 G5 5 ft o E D D nn o D gt 32 D E gt D Z D TF D DD TZ e et et FT ZZ cw o st mt tt D SS So CAO 9 10 11 12 13 14 16 16 17 18 19 20 21 22 38 39 DIAMETER SENSOR 24v f DEE GND Geer MANUAL SETPOINT 1K TO 10K OPTIONAL OPEN FOR RUN OPEN FOR E STOP TENSION SETPOINT CLOSE FOR MANUAL OPTIONAL 1K TO 10K CLOSE FOR TENSION OFF OPTIONAL v o Figure 16 Complete Open Loop Tension System Wiring www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 30 of 60 8 0 OPEN LOOP TENSION CONTROL BASED O
3. a o gt N N Ki N A TENSION SETPOINT 1K TO 10k OPEN FOR RUN OPEN FOR E STOP JUMPERED FROM FACTORY Figure 5 Basic Load Cell System Connections www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 13 of 60 6 0 TENSION CONTROL 6 2 2 CONFIGURE MENU Navigate to the Configure menu Press 4 This section describes all CONFIGURE t the screens in the Configure menu This menu contains screens which wi configure various options D 6 2 2 1 CONTROL TYPE Select the Load Cell control type Load cell systems must use a torque device which can be a motor in torque mode 6 2 2 2 SYSTEM TYPE Select the appropriate system type for the application rewind unwind or one of the point to point types See Figure 6 for information on the point to point types 6 2 2 3 OUTPUT RANGE Select the main output range For a main output range of either 0 10 VDC or 4 20 mADC select NORMAL For the 10 to 10 VDC range select 10V to 10V The software is factory calibrated for the 0 10 VDC and the 10 to 10 VDC output ranges See Section 9 4 for recalibrating the output when using the 4 20 mADC range See Figure 4 for jumper settings UNWIND REWIND T gt Ty TENSION INCREASES SPYDER TENSION DECREASES SPYDER Figure 6 Load Cell System Types www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 14 of 60 6 0 TENSION CONTROL 6 2
4. e RUN STOP using the Spyder internal logic supply between Term 9 and Term 11 this is typically accomplished by using a switch between these terminals e E Stop jumper in place between Term 10 and Term 11 This is supplied by default from the factory e Analog control output to clutch or brake amplifier current to pressure transducer motor controller etc Term 30 to Term 31 refer to Sections 5 1 and 5 3 for output configuration The Spyder inputs and outputs are referenced to Earth ground and the negative of the 24 VDC power 2 When using a power amplifier set the current range jumper to the proper setting for the clutch or brake being used refer to amplifier User s Manual and the clutch or brake User s Manual for proper settings The following is also required e Power amplifier input if used 115 VAC for PS 90 or 24 VAC or 24 VDC for PS 24 e Output from power amplifier to clutch or brake e The Spyder output is referenced to Earth ground and the negative of the 24 VDC power 3 Close the RUN STOP circuit Term 9 and Term 11 to put the Spyder into HOLD mode see Section 5 2 1 4 Using the Configure menu select Control Type Dancer Torque if a clutch or brake is being controlled or Control Type Dancer Speed if a motor is being controlled In the Configuration menu also select if integrator control will be used and select the appropriate system type See Section 7 2 2 for the Configure menu 5 Using the Con
5. Storage Relative Humidity Pollution Degree Altitude Compatible Residual Current Device Types Worst Case Fault Current Inputs Load cell Tension Setpoint Manual Setpoint Position Setpoint Dancer Input Diameter Input E Stop Run Stop Tension Off Auto Manual Outputs Torque Main Output Tension meter or Inverse Diameter output Communications Ethernet 14 0 SPECIFICATIONS 24 VDC 10 250 mADC 6 VA 2 5 amp Littlefuse Part No 21602 5 or Wickmann Part No 19194 058 FS IP20 IEC529 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 2 5 amp 2 1 millivolts volt using 5 and 5 VDC 10 VDC across one 350 ohm sensor or two 350 ohm sensors in parallel 65 mADC maximum excitation current 0 to 10 VDC 0 25 mADC maximum or 1K to 10K ohm potentiometer 0 to 10 VDC 0 25 mADC maximum or 1K to 10K ohm potentiometer 0 to 10 VDC 0 25 mADC maximum or 1K to 10K ohm potentiometer 0 to 10 VDC 0 25 mADC maximum or 1K to 10K ohm potentiometer 0 to 10 VDC 0 25 mADC maximum switch closure or 5 VDC or 24 VDC active High Low logic 8 mADC maximum switch closure or 5 VDC or 24 VDC active High Low logic 8 mADC maximum switch closure or 5 VDC or 24 VDC active High Low logic 8 mADC maximum switch closure or 5 VDC or 24 VDC active High Low logic 8 mADC maximum 0 to 10 VDC 1 mADC maximum 4 to 20 mADC 500 ohms maximum 10 to 10 VDC 1 mADC
6. Down arrow keys while turning on the power Hold the keys for at least 6 seconds after power is on The display will repeatedly sweep through the full contrast range until the Enter key is pressed When the display is readable press the Enter key to exit contrast adjustment 13 2 Reset All Parameters Except Calibrations to Defaults All parameters except calibrations will be reset to defaults by holding down the Left and Right arrow keys while turning on the power Hold the keys until the screen shows Resetting Parameters 13 3 Reset All Parameters to Defaults Including Calibrations All parameters will be reset to defaults by holding down the Right and Up arrow keys while turning on the power Hold the keys for at least 6 seconds after power is on This reset will erase all calibrations See Section 7 3 7 4 or 8 4 for recalibrating inputs Section 9 4 for recalibrating outputs Section 6 3 for recalibrating load cells Section 13 1 for setting contrast and Section 6 4 or 7 5 for tuning the Spyder WARNING THIS RESET WILL ERASE ALL CALIBRATIONS 13 4 Download Software To download new software hold down the Up and Down arrow keys while turning on power and hold the keys until the display shows Update Software See Section 12 4 for software updating www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 58 of 60 Supply Voltage Fuse F1 Enclosure Climatic Class Temperature Range Operating
7. E POSITION ee ale He 58 3 OFF Tension OFF www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 21 of 60 7 0 DANCER CONTROL 7 2 1 2 SETPOINT POSITION Setpoint Position is set by the voltage on Term 16 When Setpoint Source is Ethernet this screen may be used to enter a desired setpoint by pressing the ENTER key or using the LEFT and RIGHT ARROW keys Note for P or PD type control the dancer position will not be the same as the position setpoint If Proportional Gain is high enough the dancer position will be approximately SETPOINT gt equal to the position setpoint When Setpoint source is Ethernet and control POSITION XXXX type is P or PD the setpoint may exceed 100 7 2 1 3 OUTPUT LEVEL This screen shows the actual output level of the Spyder in numeric form The bar graph also shows actual output level in analog form The lower left character displays the status of the Spyder See Section 7 2 1 1 for description of the status character 7 2 1 4 TENSION This screen shows the actual measured tension in numeric and bar graph form if B TENSION the load cells are enabled in the Configure menu The bar graph shows measured tension and is scaled to the maximum tension set during calibration of the load He 36 9 LB cells The lower left character displays the status of the Spyder See Section 6 3 to calibrate the load cells 7 2 2 CONFIGURE MENU Navigate to the Configure menu Press 4 This section describ
8. In Dancer Torque mode a clutch or brake should be controlled If a motor is used in a dancer system then Dancer Speed should be used For Open Loop Tension system a torque device must be used lt Dancer Input Pos Setpoint gt From Cal Dancer menu Used to select whether the Dancer Input or the Position Setpoint input will be calibrated Derivative Time From the Parameters menu Set the derivative time Derivative time is only used for Control Type Dancer Torque The factory default is 1 25 sec www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 43 of 60 11 0 ALPHABETICAL LIST OF SCREEN DEFINITIONS Error Limit From the Parameters menu Enter a value for the error limit between 10 and 100 The error limit aids the tuning process by setting a boundary for the actual tension position error that the Spyder will recognize during control corrections Smaller values for the error limit will lengthen the amount of time necessary for Spyder to correct large tension position transients The factory default is 100 First at Full Then P at core From the Tuning menu for Unwinds and Rewinds Selects which parameter to optimize The Spyder should be optimized at or near full roll first On rewinds Quick Stab may be needed while a full roll is wound The Spyder should be optimized at core only after it has been optimized at full roll On unwinds Quick Sta
9. MAIN OUT RUN STOP TENSION OFF POSITION SET POSITION SET INPUT POSITION SET SHIELD SHIELD DANCER DANCER INPUT 5 VOLTS Ki a a ak N d kd Ki I Q Q oO L i a DFP or DFP 2 1K TO 10K 24V GND EARTH POSITION OPEN FOR RUN SETPOINT 1K TO 10K OPEN FOR E STOP JUMPERED FROM FACTORY CLOSE FOR TENSION OFF oO OPTIONAL Figure 11 Basic Dancer Wiring www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 20 of 60 7 0 DANCER CONTROL DFP Voltage Change with Dancer Movement Dancer Torque Unwind Dancer Speed Unwind DFP Max Voltage DFP Min Voltage DFP Min Voltage DFP Max Voltage DFP Max Voltage DFP Max Voltage DFP Min Voltage DFP Min Voltage DFP Voltage measured between Term 38 and 39 with Term 39 negative Figure 12 DFP Connections 7 2 SOFTWARE CONFIGURATION FOR DANCER SYSTEM Refer to the Dancer Torque or Dancer Speed screen flowcharts in drawing number 850B327 for a navigation aid 7 2 1 OPERATOR LOOP MENU This section describes all the screens in the Operator Loop menu All OPERATOR LOOP screens are display only bi K 7 2 1 1 POSITION This screen shows the actual measured position in numeric and bar graph form The bar graph shows the dancer arm position and is scaled from 0 to 100 The lower left character displays the status of the Spyder E E Stop H Hold so can
10. The Spyder has configuration jumpers for Control Inputs can be either active high or low Control Inputs can be either 5 VDC or 24 VDC logic levels Main Control Output can be either 0 to 10 VDC 10 VDC to 10 VDC or 4 mADC to 20 mADC G C amp 4 to 20mA 10V to 10V les 0 to 10V J8 J9 Lola HI Vila qT Figure 4 Configuration Jumpers The Spyder is configured from the factory for 0 10 VDC main output and 5 VDC Logic Low control inputs To open the enclosure to provide access to the jumper settings 1 Open the enclosure by inserting a flat blade screwdriver under the retaining tabs in the base See Figure 3 2 Lift and rotate the cover being careful not to unplug the keyboard connector 3 Grasp the display mounting standoffs and pull up while rocking until the shield top is open To Close the enclosure after changing the jumper settings 1 Replace the shield top onto the shield fence Be careful to keep the display cable wires from being pinched 2 Replace the cover 5 2 DIGITAL CONTROL INPUTS J9 configures the control inputs for either 5V or 24V operation J8 configures the control inputs for either logic High or logic Low operation See Figure 4 for jumper settings Make sure to configure the software for the selected logic type See Section 6 2 2 5 or 7 2 2 7 or 8 2 2 7 The Spyder is configured from the factory for 5 VDC logic Low control inputs 5 2 1
11. are unspecified faults Normal Range is 0 00 VDC 0 25 VDC TERM 24 S D M Normal N F One or Both 21 mV Load Cells Could be either load cell or cable CODE Probable Fault TERM 25 P open TERM 26 P open TERM 25 P to TERM 23 S leg open TERM 25 P to TERM 24 S leg open TERM 26 to TERM 23 S leg open P P P P P P I I ke ken ke TERM 26 P to TERM 24 S leg open TERM 25 P and TERM 23 S reversed or TERM 26 P and TERM 24 S reversed TERM 25 P and TERM 24 S reversed or TERM 26 P and TERM 23 S reversed E II nimo ow D gt P is wired to Ground Should be wired to TERM 26 One of Two 21 mV Load Cells Could be either load cell or cable CODE Probable Fault TERM 25 P open TERM 26 P open TERM 25 P to TERM 23 S leg open TERM 25 P to TERM 24 S leg open TERM 26 to TERM 23 S leg open P P P P P P al TERM 26 P to TERM 24 S leg open TERM 25 P and TERM 23 S reversed or TERM 26 P and TERM 24 S reversed TERM 25 P and TERM 24 S reversed or TERM 26 P and TERM 23 S reversed www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 41 of 60 11 0 ALPHABETICAL LIST OF SCREEN DEFINITIONS 11 0 The descriptions of individual screen functi
12. at the core repeatedly appears at some intermediate roll present diameter rather than at core diameter than it is at core www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 38 of 60 10 0 10 3 Problem Tuning Problems Dancer Control Possible Cause TROUBLESHOOTING Solution or Diagnostic Position unstable Control is not optimally tuned Use Quick Stabilize Navigate to the QuickStab menu Press the 4 key and then press If Unstable gt to immediately try to stabilize Review Tuning once stability is obtained See Section 7 5 Cannot be stabilized Appears while using quick stabilize The dancer position sensor is phased incorrectly The dancer position sensor must be set up per Section 7 4 and Figure 12 The DFP or DFP 2 passes through its dead zone The dancer position sensor must be set up per Section 7 3 so that its voltage varies smoothly from min to max as defined in Figure 12 Verify that the dancer position signal varies smoothly using the Position screen in the Operator Loop The messages Re Tune P at core or Re Tune P at full repeatedly appear The system is less stable at some intermediate roll diameter than it is at core or full roll When the message appears retune P at the present diameter rather than at core or full roll Dancer position does not match the Setpoint Low
13. for the 24 VDC power which may be twisted pair Connect cable shields to the terminals provided Maximum shield length and maximum length of wires outside of the shield is 1 5 inches 38 mm The load cell connections and signal inputs and outputs are Earth ground referenced The power input circuit is not isolated since the negative lead of the 24 VDC power input is Earth ground referenced See Figure 9 for complete connections See Figure 8 for connecting two MAGPOWR load cells Other load cells may also be used contact Fife customer service for details 6 2 SOFTWARE CONFIGURATION FOR LOAD CELL SYSTEM Refer to the Load Cell screen flowchart at the end of this manual for a navigation aid 6 2 1 OPERATOR LOOP MENU This section describes all the screens in the Operator Loop menu All OPERATOR LOOP screens are display only except for Percent Taper T K 6 2 1 1 TENSION This screen shows the actual measured tension in numeric and bar graph form The bar graph shows measured tension and is scaled to the maximum tension set during calibration of the load cells The lower left character displays the status of the Spyder E Stop Hold H Start Automatic Run TENS ION Stop Manual mode Tension OFF Hie 36 5 LB znre ertm TH Won pou O F 6 2 1 2 SETPOINT TENSION OR CORE TENSION Setpoint Tension or Core Tension with taper is set by the voltage on Term 16 Setpoint Source Analog or via the Ethernet port Setpoint Sourc
14. maximum 0 to 1 mMADC or 0 to 10 VDC analog TCP IP Web server interface FTP Client Modbus TCP Slave www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 59 of 60 e MAXCESS weBex 9 GD NORTH CENTRAL AND SOUTH AMERICA Tel 1 405 755 1600 Fax 1 405 755 8425 sales maxcessintl com www maxcessintl com INDIA Tel 91 22 27602633 Fax 91 22 27602634 india maxcessintl com www maxcess in EUROPE MIDDLE EAST AND AFRICA Tel 49 6195 7002 0 Fax 49 6195 7002 933 sales maxcess eu www maxcess eu JAPAN Tel 81 43 421 1622 Fax 81 43 421 2895 japan maxcessintl com www maxcess jp CHINA Tel 86 756 881 9398 Fax 86 756 881 9393 info maxcessintl com cn www maxcessintl com cn KOREA TAIWAN AND SE ASIA Tel 65 9620 3883 Fax 65 6235 4818 asia maxcessintl com 2013 Maxcess
15. proportional gain Optimize the proportional gain P This is done at core for torque systems and at full roll for speed systems For P and PD control there must always be an error between the actual position and the setpoint position to produce an output Adjust the position setpoint until the desired dancer position is achieved Use PID torque or PI speed These can be selected on the Configure menu following selection of the Control Type www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 39 of 60 10 4 10 0 Load Cell Calibration Problems Problem Possible Cause TROUBLESHOOTING Solution or Diagnostic Cannot calibrate load cells Load cells wired incorrectly Table 1 below gives voltages for various wiring errors All voltages are measured with respect to Term 21 Opens on Term 23 and Term 24 cannot be found by measuring voltages Remove power from the Spyder and measure resistance between Term 23 and Term 25 and again between Term 24 and Term 25 For one load cell both readings should be about 260 ohms For two load cells both readings should be about 130 ohms Message Sensing roll too heavy The roll supported by the load cells must weigh less than 1 2 of the total load cell rating the sum of the two This message also appears when there are load cell wiring errors See Cannot calibrate load cells above Message O
16. set up is complete Additional features and options are described later in this manual Always use the RUN STOP feature to activate inertia compensation during stopping See Section 9 6 8 www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 5 of 60 TABLE OF CONTENTS Section Description Page 1 0 __Introduction l 7 _2 0 Installation l 8 _ 3 0 Maintenance l 9 4 0 __Keypad Navigation 9 5 0 System Setup 10 5 1 Hardware Configuration l 10 5 2 Digital Control Inputs l 10 5 3 Analog Outputs 11 5 4 Analog Inputs 11 6 0 Tension Control 12 6 1 Electrical Connections 12 6 2 Software Configuration 12 6 3 i Load Cell Calibration l 15 6 4 Tuning 16 6 4 1 Quick Stabilize 17 6 4 2 Optimize Tuning 17 6 5 Load Cell Connections 18 6 6 Load Cell System Complete Wiring 19 6 7 Load Cell Control Diagram b 19 _7 0 _ Dancer Control 7 1 Electrical Connections 20 7 2 Software Configuration l 21 7 3 Dancer Input Setup 23 7 4 Dancer Calibration 23 7 5 l Tuning l 25 7 5 1 Quick Stabilize 26 7 5 2 Optimize Tuning 26 7 6 l Dancer Torque Control Diagram l 27 7 7 Dancer Speed Control Diagram 28 7 8 Dancer Complete System Wiring 28 _ 8 0 Open Loop Tension Control based on Diameter 29 8 1 l Electrical Connections l 29 8 2 i Software Configuration l 29 8 3 Diameter Calibration 32 8 4 Core Full Roll and Taper Setup 32 8 5 Open Loop Tensio
17. 0V output use Normal for the other two ranges See Section 6 2 2 3 or 7 2 2 5 or 8 2 2 5 The Spyder is configured from the factory for 0 10 VDC OUTPUT RANGE OUTPUT RANGE NORMAL 10 TO 10V gt 5 3 2 METER OUTPUT Load cell systems and Dancers with Load Cells Enabled and Open Loop Tension A 0to 1 mADC signal proportional to Tension Scaled to Max Tension is available between Term 33 and Term 34 with Load Cell Systems and Dancers with Load Cells Enabled This signal is a 0 to 1 mADC signal proportional to the Diameter at Core divided by the Present Diameter to provide a relative speed signal to a motor on a rewind to keep the clutch power dissipation small This output is driven by a 0 to 10 VDC source in series with a 10K ohm resistor and can be used as a 0 to 10 VDC output when connected to a high impedance input 5 4 ANALOG INPUTS 5 4 1 SETPOINT TENSION OR POSITION By default the Setpoint Tension or Position is input as a voltage between Term 16 and Term 17 Use the Configuration menu to change the setpoint to remote from the Ethernet port As shipped from the factory the input is calibrated for a pot between Term 15 and Term 17 with the wiper connected to Term 16 5 4 2 MANUAL SETPOINT Load cell systems and Open Loop Tension systems The Manual Setpoint is input as a voltage between Term 20 and Term 21 As shipped from the factory the input is calibrated for a pot between Term 19 and Term 21 with the wiper connected to Term 20
18. 2 4 SETPOINT SOURCE Select the tension setpoint source The tension setpoint is either the tension input Term 16 or the Ethernet The software is factory calibrated for using a 1K to 10K potentiometer on Term 15 through Term 17 with the wiper on Term 16 When using an external 0 10 VDC voltage source see Section 9 3 for recalibrating the tension setpoint input 6 2 2 5 DIGITAL INPUT ACTIVE LEVEL The digital control inputs may be either Active Low or Active High The software is factory configured for Active Low inputs See Section 5 2 and Figure 4 6 2 2 6 INITIAL SCREEN The first screen after power up is the Operator Loop screen This parameter allows the initial power up screen to be changed to either the Tension screen Section 6 2 1 1 or the Output Level screen Section 6 2 1 5 6 2 2 7 NUMERIC UPDATE RATE This parameter controls the filtering for the numeric actual tension and the actual output displays Default values work well in most applications 6 2 2 8 BAR GRAPH UPDATE RATE This parameter controls the filtering for the bar graph actual tension and the actual output displays Default values work well in most applications 6 2 2 9 SCREEN CONTRAST Adjusts the screen contrast See Section 10 1 General Problems when screen shows no characters www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 15 of 60 6 0 TENSION CONTROL 6 3 LOAD CELL CALIBRATION REQUIRED Navigate to the Cal Sensors menu Pres
19. 20 mADC select NORMAL For the 10 to 10 VDC range select 10V to 10V The software is factory calibrated for the 0 10 VDC andthe 10 to 10 VDC output ranges See Section 9 4 for recalibrating the output when using the 4 20 mADC range See Figure 4 for jumper settings 7 2 2 6 SETPOINT SOURCE Select the source for the dancer setpoint When set to ANALOG the Spyder will use voltage on the terminal 16 as the dancer position setpoint When set to ETHERNET the Spyder will use the software value of setpoint position This value may be changed either at the keypad the web page or by Modbus TCP Use the Setpoint Position screen in the Operator Loop to change the software setpoint www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 22 of 60 7 0 DANCER CONTROL 7 2 2 7 DIGITAL INPUT ACTIVE LEVEL The digital control inputs may be either Active Low or Active High The software is factory configured for Active Low inputs See Section 5 2 and Figure 4 7 2 2 8 INITIAL SCREEN The first screen after power up is the Operator Loop screen This parameter allows the initial power up screen to be changed to either the Position screen Section 7 2 1 1 or the Output Level screen Section 7 2 1 3 7 2 2 9 NUMERIC UPDATE RATE This parameter controls the filtering for the numeric actual position and the actual output displays Default values work well in most applications 7 2 2 10 BAR GRAPH UPDATE RATE This para
20. 4E Full Roll Diameter FLOAT Data LC OPT Read 0 0 999 0 in Write 0x50 Diameter Calibration Constant FLOAT Cal LC OPT Read 0 0 99999 0 Write 0x52 Tension Units BYTE Data LC DT DS Read 0 pound Write 1 ounce 2 Kilogram 3 Newton 4 gram 0x53 Distance Units BYTE Data LC OPT Read 0 inch Write 1 feet 2 millimeter 3 centimeter 4 meter 0x54 Proportional Gain Load Cell FLOAT Data LC Read 0 0 999 0 Write 0x56 Integrator Time Load Cell FLOAT Data LC Read 0 0 60 0 seconds Write 0x58 Derivative Time Dancer FLOAT Data DT Read 0 0 60 0 seconds Write Ox5A Error Limit FLOAT Data LC DT DS Read 0 0 100 0 Write 0x5C Start Time FLOAT Data LC Read 0 0 60 0 seconds Write 0x5E Stop Time FLOAT Data LC DT DS Read 0 0 60 0 seconds OPT Write 0x60 Stop Multiplier FLOAT Data LC DT OPT Read 0 0 99 0 Write 0x62 Hold Level FLOAT Data LC DT Read 0 0 100 0 Write 0x64 Torque Output 0 Calibration Point FLOAT Cal LC DT DS Read 0 0 1 0 0 10V 4 20mA OPT Write 0x66 Torque Output 100 Calibration Point FLOAT Cal LC DT DS Read 0 0 1 0 0 10V 4 20mA OPT Write 0x68 Torque Output 0 Calibration Point FLOAT Cal LC DT DS Read 0 0 1 0 10V to 10V OPT Write Ox6A Torque Output 100 Calibration Point FLOAT Cal LC DT DS Read 0 0 1 0 10V to 10V OPT Write Ox6C Tension Meter 100 Calibration Point FLOAT Cal LC D
21. 5 4 3 DANCER POSITION Dancer systems only The actual Dancer Position is input as a voltage between Term 38 and Term 39 As shipped from the factory the input is calibrated for a pot between Term 26 and Term 39 with the wiper connected to Term 38 See Section 7 3 and Figure 12 for proper dancer potentiometer voltage with dancer movement 5 4 4 DIAMETER INPUT Open Loop Tension systems only The actual Diameter is input as a voltage between Term 38 and Term 39 The input can take a voltage proportional to diameter up to 10 VDC An input voltage of 0 volts is equal to a diameter of 0 See Section 8 3 for calibrating diameter www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 11 of 60 6 0 TENSION CONTROL 6 1 ELECTRICAL CONNECTIONS Figure 5 shows the simplest and minimal connections that are required for the basic Spyder load cell tension control system They are 24 VDC power Earth ground One or two MAGPOWR load cells RUN STOP switch using the Spyder internal logic supply E Stop jumper between Term 10 and Term 11 This is supplied by default from the factory Potentiometer 1K to 10K ohm for tension setpoint Alternately Setpoint Tension can be set using the Ethernet port Choose the Setpoint Source from the Configure menu Output to clutch or brake amplifier current to pressure transducer motor controller etc Route power wiring away from sensor and control wiring Run all wiring in shielded cable except
22. A TTN MAXCESS MAGPOWR MAGPOWR Spyder Tension Control Instruction Manual Figure 1 MI 850A320 1 J COPYRIGHT 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 2009 all rights reserved Periodically there will be updates to this manual The latest version is available on our website or by calling the number on the back page of this publication www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 2 of 60 SPYDER LOAD CELL BASIC SET UP This page provides a summary of the basic set up and calibration of the Spyder control in load cell mode Additional features and options of the Spyder control are described later in this manual Refer to the Load Cell screen flowchart drawing number 850B327 for a navigation aid 1 The connections that are required for the basic Spyder system are the following see Sections 2 0 6 0 and Figure 5 for specific wiring requirements e 24 VDC power Term 6 and Term 7 e Earth ground Term 8 e One or two load cells Term 23 through Term 26 e RUN STOP using the Spyder internal logic supply between Term 9 and Term 11 this is typically accomplished by using a switch between these terminals E Stop jumper in p
23. Adjust Setpoint Position Parameter being tuned Press or 4 to reposition the dancer if necessary The position setpoint analog input is not active during tuning For setpoint source equal to Ethernet the setpoint can be changed over Ethernet while in tuning mode Besides P the parameter being tuned can also be I or D The number next to this letter is not the value of the parameter It is there to show the progress of the tuning Its value can be between 00 and 99 00 is displayed when that parameter is as stable as it can be To optimize press lt until the system starts to become unstable Then press until stability is again obtained When finished tuning press to exit the screen The web must be stopped in order to exit back to the Tuning menu when the setpoint source is set to Analog NOTE Applies to Setpoint Source is Analog The position setpoint input is not active during tuning The UP and DOWN arrow keys are used to change dancer position instead For this reason the web must be stopped Run Stop Stop and restarted Run Stop Run to leave the tuning screens A screen is provided to warn the operator of this Since tuning cannot be done while the web is stopped the Spyder automatically returns to the Tuning Menu when the web is stopped Make sure to set the position setpoint potentiometer to the midpoint before restarting after tuning NOTE Applies to Setpoint Source is Ethernet The position setpoint can alway
24. CONTROL 7 1 ELECTRICAL CONNECTIONS Figure 11 shows the basic connections for the Spyder Dancer control system See Figure 15 for complete connections The Tension Off connection is not required The simplest and minimal connections are 24 VDC power Earth ground MAGPOWR DFP or DFP 2 dancer position potentiometer RUN STOP switch using the Spyder internal logic supply E Stop jumper between Term 10 and Term 11 This is supplied by default from the factory Potentiometer 1K to 10K ohm for position setpoint Alternately Setpoint can be set using the Ethernet port or the Setpoint screen Choose the Setpoint Source from the Configure menu Output to clutch or brake amplifier current to pressure transducer motor controller etc Route power wiring away from sensor and control wiring Run all wiring in shielded cable except for the 24 VDC power which may be twisted pair Connect cable shields to the terminals provided Maximum shield length and maximum length of wires outside of the shield is 1 5 inches 38 mm The load cell connections and signal inputs and outputs are Earth ground referenced The power input circuit is not isolated since the negative lead of the 24 VDC power input is Earth ground referenced See Figure 12 and Section 7 3 for connecting the DFP or DFP 2 Dancer Follower Potentiometers according to the Dancer system types CLUTCH POWER OPTIONAL OR AMPLIFIER Gemeen BRAKE CATS OR n SHIELDED MOTOR MAIN OUT
25. E THEN ID AT FULL gt PID Tuning The Spyder should be optimized at or near core first On unwinds Quick Stab may be needed while an initial roll is unwound The Spyder should be optimized at full roll only after it has been optimized at core On rewinds Quick Stab may be needed to keep the system stable while a roll is wound See 7 5 2 3 for a typical tuning screen 7 5 2 2 Dancer Speed Navigate to the Tuning menu and press JL For a Dancer in Speed mode one of the following screens will be displayed depending on the tuning type selected TUNE P AT FULL P Only Tuning FIRST P AT FULL THEN I AT CORE gt SES The Spyder should be optimized at or near full roll first On rewinds Quick Stab may be needed while a full roll is wound The Spyder should be optimized at core PI tuning only after it has been optimized at full roll On unwinds Quick Stab may be needed to keep the system stable while an initial roll is unwound See 7 5 2 3 for a typical tuning screen www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 26 of 60 7 0 DANCER CONTROL 7 5 2 3 Tuning Screens Tuning allows the operator to optimize tuning parameters by using one button to destabilize the system and another button to stabilize the system NOTE The system must be running to perform Tuning A typical tuning screen looks like this E IF UNSTABLE gt Bat lt STABLE P35 lt Bar Graph of econ t Use to exit screen
26. LC DT DS Read 0 0 60 0 seconds OPT Write 0x82 Position Setpoint 0 Calibration Point FLOAT Cal DT DS Read 0 4095 Write 0x84 Position Setpoint 100 Calibration FLOAT Cal DT DS Read 0 4095 Point Write 0x86 Dancer 0 Calibration Point FLOAT Cal DT DS Read 0 4095 Write 0x88 Dancer 100 Calibration Point FLOAT Cal DT DS Read 0 4095 Write Ox8A Tuning Type Dancer Torque BYTE Data DT Read 0 PD Write 1 PID 0x8B Tuning Type Dancer Speed BYTE Data DS Read 0 P Write 1 Pl 0x8C Proportional Gain Dancer FLOAT Data DT DS Read 0 0 999 0 Write 0x8E Integrator Time Dancer FLOAT Data DT DS Read 0 0 60 0 seconds Write 0x90 Initial Screen Load Cell BYTE Data LC Read 0 Operator Menu Write 1 Tension 2 Output Level 0x91 Initial Screen Dancer BYTE Data DT DS Read 0 Operator Menu Write 1 Position 2 Output Level 0x92 Use Taper BYTE Data LC OPT Read 0 No Write 1 Yes 0x93 System State Status UINT16 None LC DT DS Read 0 Hold OPT Only 1 Start 2 Run 3 Stop 4 E Stop 5 Manual 0x94 Tension On Off Status UINT16 None LC DT DS Read 0 Tension Off OPT Only 1 Tension On 0x95 Tension Setpoint FLOAT None LC Read 0 0 99999 0 Ib Only 0x97 Actual Tension FLOAT None LC OPT Read 0 0 99999 0 Ib Only www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 56 of 60
27. Modbus TCP www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 7 of 60 2 0 INSTALLATION The Spyder is intended for installation on a vertical or horizontal panel with a DIN35 rail See Figure 2 for dimensions The Spyder provides an IP 20 environmental degree of protection Wiring to and from the enclosure must be done with double or reinforced insulation or protective screening which provides protective separation All wiring outside of the Spyder should comply with the essential requirements of the appropriate local standard s and is the responsibility of the installer P 157 6 18 _ fe CSSHSSHSSO 35 2 1 39 85 8 3 38 gd 58 4 2 30 ay co l AAAA AA AAA AAA Figure 2 Figure 3 Outline Dimensions Enclosure Top Removal AN WARNING DISCONNECT POWER BEFORE OPENING ENCLOSURE www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 8 of 60 3 0 MAINTENANCE The only maintenance that may be required on Spyder is fuse replacement Replacement of the fuse requires opening the enclosure which circumvents the enclosure IP rating To replace a fuse Disconnect the power supply Open the enclosure by inserting a flat blade screwdriver under the retaining tabs in the base See Figure 3 Lift and rotate the cover being careful not to unplug the keyboard connector Replace the fuse with the recommended fuse typ
28. N DIAMETER 8 2 2 CONFIGURE MENU Navigate to the Configure menu Press 4 This section describes all the screens in the Configure menu This menu contains screens which configure various options CONFIGURE A gt 8 2 2 1 CONTROL TYPE Select the control type Tension Diameter Open Loop Tension systems must use a torque device which can be a clutch or brake or motor in torque mode 8 2 2 2 SYSTEM TYPE Select the appropriate system type for the application rewind or unwind 8 2 2 4 USE TAPER Enables tapering of tension as the roll diameter increases See Section 8 4 for setup of taper 8 2 2 5 OUTPUT RANGE Select the main output range For a main output range of either 0 10 VDC or 4 20 mADC select NORMAL For the 10 to 10 VDC range select 10V to 10V The software is factory calibrated for the 0 10 VDC andthe 10 to 10 VDC output ranges See Section 9 4 for recalibrating the output when using the 4 20 mADC range See Figure 4 for jumper settings 8 2 2 6 SETPOINT SOURCE Select the source for the tension setpoint When set to ANALOG the Spyder will use voltage on the terminal 16 as the tension setpoint When set to ETHERNET the Spyder will use the software value of setpoint tension percent This value may be changed either at the keypad the web page or by Modbus TCP Use the Setpoint Tension screen in the Operator Loop to change the tension setpoint 8 2 2 7 DIGITAL INPUT ACTIVE LEVEL The digital c
29. RUN STOP Connect TERM 9 to TERM 11 to initiate the stopping function During STOP TIME the Spyder continues to control as a closed loop system but STOP MULTIPLIER is also activated During STOP TIME the output is multiplied by STOP MULTIPLIER See Section 9 6 8 for a description of each control type 5 2 2 E STOP E STOP IS AN AUXILIARY FUNCTION NOT INTENDED TO PROVIDE CATEGORY 1 SAFETY PROTECTION Open the connection between Term 10 and Term 11 to initiate E STOP On torque device unwinds the output goes to 100 On all other systems the output goes to zero E STOP overrides Manual mode and Tension Off 5 2 3 AUTO MANUAL Load cell systems and Open Loop Tension systems Connect Term 12 to Term 11 to switch to Manual mode During Manual mode the main output is directly controlled by the Manual setpoint analog input Term 20 www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 10 of 60 5 0 SYSTEM SETUP 5 2 4 TENSION ON OFF Connect Term 13 to Term 11 to set the main output to 0 volts 4mA Tension Off is always allowed for Load Cell and Open Loop Tension systems For Dancer systems Tension Off is only allowed when in Hold mode Run Stop Input Stop Tension Off overrides Manual mode 5 3 ANALOG OUTPUTS 5 3 1 MAIN OUTPUT J6 configures the main output range for 0 10VDC 10 to 10 VDC or 4 20mA DC See Figure 4 for jumper settings When using the 10V to 10V range be sure to configure the software for 10V to 1
30. T DS Read 0 511 OPT Write Ox6E Tension Setpoint 0 Calibration Point FLOAT Cal LC OPT Read 0 4095 Write www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 55 of 60 Starting Parameter Name Parameter Parameter Used with Read Range Modbus Format Type Control Write Register Types 0x70 Tension Setpoint 100 Calibration FLOAT Cal LC OPT Read 0 4095 Point Write 0x72 Manual Setpoint 0 Calibration Point FLOAT Cal LC OPT Read 0 4095 Write 0x74 Manual Setpoint 100 Calibration Point FLOAT Cal LC OPT Read 0 4095 Write 0x76 Load Cell Positive Bias UINT16 Cal LC DT DS Read 0 511 Write 0x77 Load Cell Negative Bias UINT16 Cal LC DT DS Read 0 511 Write 0x78 Load Cell Gain Reference UINT16 Cal LC DT DS Read 0 511 Write 0x79 Load Cell Offset UINT16 Cal LC DT DS Read 0 4095 Write Ox7A Applied Tension Binary UINT16 Cal LC DT DS Read 0 4095 Write 0x7B Digital Input Active State BYTE Data LC DT DS Read 0 Active Low OPT Write 1 Active High 0x7C Security State BYTE None LC DT DS Read 0 Not Locked OPT Only 1 Locked 0x7D Security Code UINT16 None LC DT DS Write 0 9999 OPT Only 0x7E Numeric Display Rate FLOAT Data LC DT DS Read 0 0 60 0 seconds OPT Write 0x80 Bar Graph Display Rate FLOAT Data
31. TE Cal LC DT DS Read 0 255 OPT Write 0x3D Language BYTE Data LC DT DS Read 0 English OPT Write 1 French 2 German 3 Italian 4 Spanish 0x3E Remote Setpoint Tension FLOAT Data LC OPT Read 0 0 99999 0 Ib Write 0x40 Setpoint Source BYTE Data LC DT DS Read 0 Analog OPT Write 1 Ethernet Software 0x41 Taper Percent FLOAT Data LC OPT Read 0 0 100 0 Write 0x43 Is Taper Setup BYTE Cal LC Read 0 No Write 1 Yes www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 54 of 60 IPA COMMUNICATION OPTIONAL Starting Parameter Name Parameter Parameter Used with Read Range Modbus Format Type Control Write Register Types 0x44 System Type Load Cell BYTE Data LC Read 0 Unwind Write 1 Rewind 2 Type 1 3 Type 2 4 Type 3 5 Type 4 0x45 System Type Dancer BYTE Data DT DS Read 0 Unwind Write 1 Rewind 0x46 Control Type BYTE Data LC DT DS Read 0 Load Cell OPT Write 1 Dancer Torque 2 Dancer Speed 3 Tension Diameter 0x47 Output Range BYTE Data LC DT DS Read 0 Normal Write 1 10V to 10V 0x48 Maximum Tension FLOAT Cal LC DT DS Read 0 0 99999 0 lb Write Ox4A Applied Tension FLOAT Cal LC DT DS Read 0 0 99999 0 Ib Write 0x4C Core Diameter FLOAT Data LC OPT Read 0 0 999 0 in Write Ox
32. UICK STAB 4 parameters do not provide a stable closed loop See Section 6 4 1 gt 2 Tuning optimizes the Spyder by first tuning to make the system slightly TUNING n unstable then adjusting the tuning parameters to make it stable By doing so the gt system is tuned to be as responsive as possible and still remain stable throughout its range of operation See Section 6 4 2 www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 16 of 60 6 0 TENSION CONTROL 6 4 1 QUICK STABILIZE FIRST STEP Default tuning parameters are embedded in the Spyder and were selected to minimize instability If the system is exhibiting extreme fluctuations at start up perform the following procedure to quickly stabilize it Fine tuning using Tuning will still be required NOTE The system must be running to Quick Stabilize Navigate to the Quick Stab menu and press JL Press If Unstable to immediately try to stabilize The Spyder automatically steps through three separate stages in an attempt to stabilize the process The Quick Stab screens are all similar to this one E IF UNSTABLE gt Be DONE P35 Bar Graph of tension d t Parameter being tuned Besides P the parameter being tuned can also be E or I The number next to this letter is not the value of the parameter Itis there to show the progress of the tuning Its values can be between 00 and 99 00 is displayed when that parameter is as stable as
33. VDC power Earth ground Diameter sensor with voltage output proportional to diameter Input between Term 38 and 39 For unwinds the diameter sensor should monitor the unwind diameter and for rewinds the rewind diameter RUN STOP switch using the Spyder Plus internal logic supply E Stop jumper between Term 10 and Term 11 This is supplied by default from the factory Potentiometer 1K to 10K ohm for tension setpoint Alternately Setpoint Tension can be set using the Ethernet port Choose the Setpoint Source from the Configure menu Output to clutch or brake amplifier current to pressure transducer motor controller etc Route power wiring away from sensor and control wiring Run all wiring in shielded cable except for the 24 VDC power which may be twisted pair Connect cable shields to the terminals provided Maximum shield length and maximum length of wires outside of the shield is 1 5 inches 38 mm The signal inputs and outputs are Earth ground referenced The power input circuit is not isolated since the negative lead of the 24 VDC power input is Earth ground referenced An inverse diameter output is available on the meter output to control the speed of rewinds to reduce the heat dissipation in a rewind clutch See Figure 16 8 2 SOFTWARE CONFIGURATION FOR OPEN LOOP TENSION SYSTEM Refer to the Open Loop Tension screen flowchart in drawing number 850B327 for a navigation aid 8 2 1 OPERATOR LOOP MENU This section describes all the s
34. _ Complete Load Cell System Wiring l 19 _ Figure 10 _ Load Cell Control Diagram 19 _ Figure 11 _ Basic Dancer Wiring 20 _ Figure 12 DER Connections 21 _ Figure 13 _ Dancer Torque Control Diagram 27 _ Figure 14 _ Dancer Speed Control Diagram 28 _ Figure 15 _ Complete Dancer System Wiring l 28 _ Figure 16 _ Complete Open Loop Tension System Wiring l 30 _ Figure 17 _ Open Loop Tension Control Diagram 32 _ Figure 18 _ Spyder Status Web Page l 52 _ Figure 19 _ Spyder Configuration Web Page 52 _ Figure 20 _ Example Edit Value Web Pages 52 1 0 INTRODUCTION The MAGPOWR Model Spyder is a microprocessor based control designed for precise closed loop control of either web tension or dancer position The Model Spyder Plus also has an Open Loop Tension control proportional to a diameter input for unwinds and rewinds The web tension control is capable of controlling web tension in unwind rewind or point to point applications in any web press The Spyder measures tension from one or more MAGPOWR load cells and outputs a corrective analog signal to control a torque device The tension setpoint for the Spyder is set by an analog voltage signal or by a parameter from an Ethernet port The Spyder provides an analog input for Manual Level setpoint control inputs for Run Stop Auto Manual Tension On Off and E Stop and a 0 1mA or 0 10V DC meter output proportional to measured tension The dancer control is capable of controlling a dancer in unw
35. abilize Integrator Test SIF UNSTABLE Bet NOW STABLE Bar Graph of Position This screen is entered if the system is not yet stable and the integrator was on The integrator was turned off as this screen was entered This checks to see if the integrator is causing the instability If the system is still unstable the integrator is not causing the instability Pressing JL will switch to a screen similar to 7 5 1 2 to stabilize the proportional gain If the system is now stable then the integrator is the cause of the instability it is now off Pressing lt provides a series of screens explaining this INTEGRATOR MODE I IS UNSTABLE I IS NOW OFF TURN ON TO TUNE EXPECT UNSTABLE WHEN I TURNS ON4 Press J to turn on the integrator and quick stabilize I A screen similar to 7 5 1 2 will be used to stabilize I 7 5 1 2 Quick Stabilize Parameter Adjustment If this screen appears press If Unstable to immediately try to stabilize Press or 4 to reposition the dancer if necessary The position setpoint input is not active during tuning The Spyder automatically steps through several separate stages in an attempt to stabilize the process The Quick Stab screens are all similar to this one E IF UNSTABLE gt Be DONE P354 Bar Graph of re L t Use to exit screen Adjust Setpoint Position Parameter being tuned www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 25 of 60 7 0 DANCER CONTROL Bes
36. actory default setting is 2 seconds Use of the integrator is optional on dancer systems IP Address From the Network menu The IP address assigned to the Spyder to connect to a network If DHCP is enabled this address is ignored Load applied wrong way From Cal Sensors menu The load applied to the load cell during calibration and during normal operation should be in the direction shown by arrows on the load cells See load cell manual Load cells are overloaded A load cell calibration error message See Load Cell Calibration Problems in Section 10 4 Load very small Maybe shorted From the Cal Sensors menu This is a warning message during load cell calibration See Load Cell Calibration Problems in Section 10 4 Manual Level In the Operator Loop When Manual Mode is selected by the Auto Manual input Term 12 the Spyder control output is determined solely by the Manual Level input Term 20 to Term 21 This value is display only Maximum Tension From Cal Sensors menu Enter a value to set the upper limit of the tension range as read by the load cells You should choose a value for the max tension that will have room for the highest setpoint tension you plan to run plus any tension errors that may occur during operation within limits of the load cell load rating This setting also determines the scale for the analog displays www maxcessintl com MAGPOWR Spyder Tension Contro
37. applied near the center of the sensing roll using a rope or narrow web Bar Graph Rate From Configure menu Sets the update rate for the bar graphs on both the Tension Position screens and the Output Level screen Cal Dancer 4 One of the top level menu screens Used to calibrate the dancer inputs Cal Diameter 4 One of the top level menu screens Used to calibrate diameter for Open Loop Tension systems Cal Sensors 4 One of the top level menu screens Used to calibrate the load cells Cal Setpoint Input lt Tension gt Or Cal Setpoint Input lt Manual gt From the Recal Inputs menu Used to select whether the Tension input or the Manual input will be calibrated Use lt or gt to select the input to calibrate Calibrate Taper Yes No From Taper Setup menu When 1 is pressed on the Present Dia screen the operator is asked if taper should be calibrated If Yes is selected the present diameter is entered next www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 42 of 60 11 0 ALPHABETICAL LIST OF SCREEN DEFINITIONS Cannot be stabilized From Quick Stab or Tuning menus See Tuning Problems above in Section 10 2 or 10 3 Configure One of the top level menu screens Used to configure various parameters such as System Type Output Range Setpoint Source Digital Input Active Numeric Rate Bar Graph Rate and Screen Co
38. b may be needed to keep the system stable while an initial roll is unwound FTP Address From the Network menu Enter the address of the FTP site that will be used to obtain Spyder update programs Full Roll Diameter From the Taper Setup menu for load cell system and the Parameter menu for Open Loop Tension system Enter the value of the diameter of the full roll Full roll tuning is optimal From the Tuning menu for unwinds and rewinds This screen announces that Integrator Time has been decreased to the minimum allowed during tuning 0 01 seconds Integrator Time can be set lower than this using the Parameters menu but that is not recommended Gateway Address From the Network menu Enter the IP address of the gateway The gateway is normally your router If DHCP is enabled this address is ignored This address is only needed if access to the world wide web is needed for updating the Spyder program Hold Level From the Parameters menu The output level of the Spyder will go to this value in Hold Mode The Spyder switches to Hold Mode when the Run Stop Input is opened Hold Mode only occurs in while in Auto Hold mode is delayed Stop Time seconds after the Run Stop input is opened If Unstable gt From the Tuning menu Stable Pxx Two different screens look like this one They are used to optimize the given parameter by first pressing until the system becomes slightly unstable and then press lt to
39. cessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 53 of 60 A COMMUNICATION OPTIONAL Spyder Data Number Modbus Registers Comments BYTE 8 bit Unsigned Byte 1 High byte forced to 0 UINT16 16 bit Unsigned Integer 1 UINT32 32 bit Unsigned Integer 2 FLOAT 4 byte Floating Point 2 STRING 32 byte Strings 16 Since some data values are contained in multiple Modbus registers the function code 16 Write Multiple Registers must be used to write these data values If a write occurs to only one of the Modbus registers corresponding to a two word parameter then the Spyder will ignore the write If a write to a 16 word string does not write all 16 registers then the Spyder will ignore the write This prevents the Spyder from receiving only part of a data value This could be problematic if Setpoint Tension or other control parameter was corrupted by only writing a portion of the new data value Reads do not have this restriction The Modbus standard specifies data as being transmitted Most Significant Byte first To support master devices which transmit data Least Significant Byte first the Spyder allows switching between the two For multiple register data there is a configuration parameter to specify whether words registers are transmitted Most Significant Word first or last These two configuration parameters are in the Network menu The default is Most Significant Byte first and Most Significant Word first Not
40. control output Term 30 to Term 31 when 0 output is commanded Output 100 CAL From the Recal Outputs menu Used to calibrate the control output Term 30 to Term 31 when 100 output is commanded Output Level In the Operator Loop Actively displays the present output Term 30 to Term 31 of the Spyder Parameters One of the top level menu screens Used to change parameters such as Proportional Gain Integrator Time Error Limit Start Time Stop Time Stop Multiplier and Hold Level Preferences One of the top level menu screens Used to select Language English Francais Deutsche Italiano Espanol Tension Units lb oz Kg N g and Distance Units in ft mm cm m Present Dia In the Taper Setup menu for load cell system Used to calibrate the diameter for use in taper tension Displays the estimated diameter if diameter has been calibrated In Cal Diameter menu for Open loop tension system Used to calibrate the diameter Diameter calibration is required www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 46 of 60 11 0 ALPHABETICAL LIST OF SCREEN DEFINITIONS Primary tuning is optimal From the Tuning menu for point to point systems This screen announces that Integrator Time has been decreased to the minimum allowed during tuning 0 01 seconds Integrator Time can be set lower than this using the Parameters menu but that is not recomme
41. creens in the Operator Loop menu All OPERATOR LOOP screens are display only except for Percent Taper T K 8 2 1 1 TENSION This screen shows the actual tension in numeric and bar graph form This will be different from the setpoint tension when taper is enabled The lower left character displays the status of the Spyder E Stop Hold H Start Automatic Run TENS TON Stop Manual mode OFF Tension OFF Hi 55 4 znre erm 8 2 1 2 PRESENT DIAMETER Present diameter displays the current diameter being input on Term 38 See Section 8 3 for calibrating diameter 8 2 1 3 SETPOINT TENSION OR CORE TENSION Setpoint Tension or Core Tension with taper is set by the voltage on Term 16 Setpoint Source Analog or via the Ethernet port Setpoint Source Ethernet Setpoint Source is set in the Configure menu 8 2 1 3 1 SETPOINT TENSION No taper tension Display only 8 2 1 3 2 CORE TENSION With taper tension Display only This is the setpoint at core diameter only At other diameters the setpoint is less than the core setpoint if Taper Percent gt 0 www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 29 of 60 8 0 OPEN LOOP TENSION CONTROL BASED ON DIAMETER 8 2 1 4 TAPER PERCENT Enter the desired taper percentage This screen will only be shown when taper has been enabled See Section 8 4 Taper Setup Commanded tension at core Core Tension Commanded tension at full roll Core Tension 1
42. d www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 4 of 60 SPYDER PLUS OPEN LOOP TENSION BASED ON DIAMETER BASIC SET UP This page provides a summary of the basic set up and calibration of the Spyder Plus control in Open Loop Tension mode Additional features and options of the Spyder Plus control are described later in this manual Refer to the Open Loop Tension screen flowchart drawing number 850B327 for a navigation aid 1 The connections that are required for the basic Spyder Plus system are the following see Sections 2 0 8 0 and figure 16 for specific wiring requirements e 24 VDC power Term 6 and Term 7 Earth ground Term 8 Diameter signal Term 38 and Term 39 see Section 5 4 4 and Figure 16 for connections Tension setpoint signal Term 15 through Term 17 RUN STOP using the Spyder Plus internal logic supply between Term 9 and Term 11 this is typically accomplished by using a switch between these terminals E Stop jumper in place between Term 10 and Term 11 This is supplied by default from the factory e Analog control output to clutch or brake amplifier current to pressure transducer motor controller etc Term 30 to Term 31 refer to Sections 5 1 and 5 3 for output configuration The Spyder Plus inputs and outputs are referenced to Earth ground and the negative of the 24 VDC power 2 When using a power amplifier set the current range jumper to the proper setting for the clutch o
43. diameter that corresponds to the voltage input Press the J key to finish diameter calibration The Present Diameter screen actively displays the diameter The Present Diameter screen is also available from the Operator menu 8 4 Core Full Roll Diameter and Taper Setup 8 4 1 Core and Full Roll Diameter REQUIRED Navigate to the Parameters menu and Press 4 to get to Core Diameter and Full Roll diameter Enter the diameters Core Diameter is required for the inverse diameter output and Full Roll Diameter is required for normal operation 8 4 2 Taper Setup Navigate to the Configure menu and Press 4 until Use Taper is displayed Select Yes to enable Taper Press 4 Taper percent is set in the Operator menu See Section 8 2 1 4 8 5 Open Loop Tension Control Diagram DIAMETER INPUT _ Dia Deore Dfull Dcore TaperPercent TENSION SETPOINT INPUT MANUAL INPUT CORE OFFSET CAL DIAMETER gt PRESENT DIA t XXXX IN al V XXXX XXX IN CORE DIAMETER XXXX IN V FULL ROLL DIA XXXX IN USE TAPER YES Basic setup of the open loop tension system is now complete See Section 9 0 for optional settings MAIN OUTPUT Figure 17 Open Loop Tension Control Diagram www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 32 of 60 9 0 OPTIONAL FUNCTIONS 9 1 PREFERENCES MENU This section describes all the screens in the Preferences menu Navigate t
44. e Ethernet Setpoint Source is set in the Configure menu 6 2 1 2 1 SETPOINT TENSION No taper tension Display only 6 2 1 2 2 CORE TENSION With taper tension Display only This is the setpoint at core diameter only At other diameters the setpoint is less than the core setpoint if Taper Percent gt 0 www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 12 of 60 6 0 TENSION CONTROL 6 2 1 3 TAPER PERCENT Enter the desired taper percentage This screen will only be shown when taper has been enabled See Section 9 2 Taper Setup Commanded tension at core Core Tension Commanded tension at full roll Core Tension 1 TaperPercent 100 NOTE The desired Taper is dependent on material and machine type and is totally subjective Determination of the correct amount of taper for your application is a trial and error process 6 2 1 4 MANUAL LEVEL This screen shows the manual level being input on Term 20 6 2 1 5 OUTPUT LEVEL This screen shows the actual output level of the Spyder in numeric form The bar graph also shows actual output level in analog form The lower left character displays the status of the Spyder See Section 6 2 1 1 for description of the status character ee POWER BRAKE AMPLIFIER Q CH Ki _ e 2 o MAIN OUT RUN STOP AUTO MANUAL TENSION OFF TENSION TENSION INPUT TENSION MANUAL INPUT S WHITE S BLACK P GREEN Y P RED
45. e See Section 14 0 Specifications Re install cover akRWNM 4 0 KEYPAD NAVIGATION The use of the various keys is generally self explanatory The LEFT RIGHT UP and DOWN arrow keys are used in menus to move to other screens The LEFT and RIGHT arrow keys are used to edit selection choices e g to select system type In the tuning screens for dancer modes the UP and DOWN arrow keys are used to adjust the position of the dancer On these screens appears in the bottom right hand corner of the screen and the ENTER key is used to exit the screen When the setpoint is Analog the position setpoint input is not active during tuning When a numeric screen is shown the value may be edited by pressing the ENTER key to start editing A numeric edit screen will have a cursor under the digit being edited The UP and DOWN arrows will increment and decrement the digit while the LEFT and RIGHT arrows will move the cursor When finished editing the numeric value press the Enter key The DOWN arrow key will generally move to the next screen in a sub menu For example when the Configure menu is displayed press the DOWN arrow key to scroll through System Type Output Range Setpoint Source Digital Input Active Numeric Rate Bar Graph Rate and Contrast The UP arrow key usually returns to the previous screen www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 9 of 60 5 0 SYSTEM SETUP 5 1 HARDWARE CONFIGURATION
46. e Strings are always transmitted left most character first 12 7 MODBUS PARAMETER LIST This table lists all the Spyder parameters and their minimum and maximum values Modbus register addresses are shown in hexadecimal format in the table Control type abbreviations are LC Load Cell Control DT Dancer Torque Control DS Dancer Speed Control OPT Open Loop Tension based on Diameter Control Open Loop Tension control is only available on Spyder Plus Starting Parameter Name Parameter Parameter Used with Read Range Modbus Format Type Control Write Register Types 0x01 Use DHCP BYTE Data LC DT DS Read 0 No OPT Write 1 Yes 0x02 IP Address UINT32 Cal LC DT DS Read 0 0 0 0 255 255 255 255 OPT Write 0x04 Subnet Mask UINT32 Data LC DT DS Read 0 0 0 0 255 255 255 255 OPT Write 0x06 Gateway Address UINT32 Data LC DT DS Read 0 0 0 0 255 255 255 255 OPT Write 0x08 FTP Address UINT32 Data LC DT DS Read 0 0 0 0 255 255 255 255 OPT Write Ox0A FTP Program Number UINT32 Data LC DT DS Read 920Axxx yyy OPT Write xxx yyy 0 999 Xxx High Word yyy Low Word 0x0C FTP Directory STRING Data LC DT DS Read 31 Characters Maximum OPT Write 0x1C FTP User Name STRING Data LC DT DS Read 31 Characters Maximum OPT Write 0x2C FTP Password STRING Data LC DT DS Read 31 Characters Maximum OPT Write 0x3C Screen Contrast BY
47. e Submit button Examples e http 77192 168 1 1007edit alue paramiD 33 Micra File Edit Yiew Favorites Tools Help O O A A H Deny Address fa http 192 168 1 100 editValue paramlD 33 Hold Level fol f D Figure 20 e http 192 168 1 100 edit alue paramlD 15 Mid Eile Edit View Favorites Tools Help Qa O e 2 A Seen Address fa http 192 168 1 100 editV alue paramiID 15 System Type Unwind x Submit Example Edit Value Web Pages www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 52 of 60 A COMMUNICATION OPTIONAL 12 4 UPDATE SOFTWARE VIA FTP SITE The Spyder can update its software from an FTP server WARNING DOWNLOAD OF SOFTWARE IS ONLY REQUIRED FOR SPECIAL SOFTWARE OR SOFTWARE PATCHES CONTACT FACTORY Turn off power to the Spyder Hold down the Up and Down arrow keys while turning on power The display should show the Update Software menu Press the Down arrow The display will show the program number it is about to download To edit the program number Press the Enter key and enter the program number of the software you need to download Press the Down arrow key to start downloading the software When the display shows Update Successful press the Down arrow to reboot the Spyder The Spyder will reboot with the new program The original software remains valid if any download results i
48. ed upon the amount of time it takes your machine to ramp down from steady state operation to a complete stop When this time has expired Spyder will automatically proceed into HOLD mode Subnet Mask From the Network menu Determines the range of addresses in a subnet Consult your system administrator If DHCP is enabled this parameter is ignored Switch to Quick Stab From the Tuning menu When a tuning parameter is adjusted to its most stable value and the system is still unstable the Spyder automatically switches to Quick Stab so that the other parameters are tuned in the correct order Taper Percent From the Operator Loop When REWIND or UNWIND type is selected you may enter a value here that will taper off the output as the roll progresses from core to full This feature is useful for reducing the inward forces that develop in rolls with a large differential between core and full diameters If you are experiencing crushed cores telescoping or starring rolls try increasing taper in steps until you reach a value that works well for your process See Section 6 2 1 3 or 8 2 1 4 Taper Setup One of the top level menu screens Used to calibrate diameter and to edit Core Diameter and Full Roll Diameter Tension In the Operator Loop Displays the actual tension in both numeric and bar graph forms Try larger Max From the Cal Sensors menu The Spyder will suggest a Max Tension that will make sure that the load ce
49. es all CONFIGURE v the screens in the Configure menu This menu contains screens which ba configure various options 7 2 2 1 CONTROL TYPE Select the control type either Dancer Torque or Dancer Speed Dancer Torque is for dancers using using a torque device clutch or brake and Dancer Speed is for dancers using a speed device motor If a motor is used for a dancer system speed mode is recommended If a motor is used on an unwind system for dancers it must be regenerative so that energy is removed from the system 7 2 2 2 TUNING TYPE When controlling a dancer in either torque or speed mode an integrator can optionally be used in the control The integrator will keep the dancer in the same position as the roll builds or as dancer loading is adjusted Many systems do not need the integrator since the gain of the system is very high Systems with integrators are sometimes more difficult to stabilize Integrator control is selected by choosing PID in torque mode or PI in speed mode 7 2 2 3 SYSTEM TYPE Select the appropriate system type for the application either rewind or unwind See Figure 12 and Section 7 3 for proper connection of the dancer potentiometer voltage based on the System Type and Control Type 7 2 2 4 USE LOAD CELLS Enables reading of the load cells while in Dancer mode See Section 6 3 to calibrate load cells 7 2 2 5 OUTPUT RANGE Select the main output range For a main output range of either 0 10 VDC or 4
50. etpoint may be entered on this screen by pressing the ENTER key or using the LEFT and RIGHT keys to increment and decrement the position Setpoint Source In the Configure menu Selects the setpoint source for either Tension or Position The choice is either Analog or Ethernet The Spyder defaults to Analog input as the setpoint source Signal too low at Max Tension From the Cal Sensors menu The Spyder will not calibrate if the loading of the load cells at Maximum Tension is less than 1 8 of the load cell rating Start Time From the Parameters menu Enter a value based upon the amount of time it takes your machine to ramp up from stopped to steady state operation If the tension spikes during this time try increasing this START TIME value www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 48 of 60 11 0 ALPHABETICAL LIST OF SCREEN DEFINITIONS Stop Multiplier From the Parameters menu Enter a value that will dictate the control output during STOP mode Spyder will use the last control output sent during RUN mode before the STOP signal is received and multiply it by the value set here for the duration of the Stop Time The control continues to control tension during the Stop Time When the stop multiplier value is correctly set it will automatically boost output to the braking device during stops to keep the tension constant Stop Time From the Parameters menu Enter a value bas
51. figure menu select Setpoint Source ANALOG if the dancer setpoint will be read from the analog voltage on terminal 16 Selecting Setpoint Source ETHERNET will use a software setpoint position which can be changed either through the Setpoint Position screen or the Web page or Modbus TCP 6 Calibrate the dancer input and the setpoint position input refer to Sections 7 3 and 7 4 The setpoint position input does not need to be calibrated if Setpoint Source ETHERNET 7 Turn tension on by opening the TENSION ON OFF circuit Term 13 and Term 11 and put the Spyder in RUN mode by switching open the RUN STOP circuit Adjust the position setpoint using a potentiometer Term 15 through Term 17 Run the machine at a reduced line speed and observe the system 8 f the system is unstable go to the Quick Stabilize menu Section 7 5 1 and press the 4 down arrow to begin stabilizing Use the lt left arrow and gt right arrow in the following screens to tune the system 9 Refer to Section 7 5 2 for tuning methods that will optimize the responsiveness 10 Basic set up is complete Additional features and options are described later in this manual Always use the RUN STOP feature to put the Spyder into HOLD mode whenever the machine is stopped to avoid a possible high tension condition during start up For Dancer Torque use the Hold Level screen to output a value of torque to prevent the dancer arm from moving during Hol
52. ftware has only been tested on a Windows XP computer The Spyder Configuration Tool allows sending only Data only Calibration or both Data and Calibration type parameters back to the Spyder The column labeled Parameter Type in the Parameter List in Section 12 7 specifies whether a parameter is considered a Data or Calibration parameter 12 66 MODBUS TCP COMMUNICATION The Spyder acts as a Modbus TCP slave device It supports the function codes Read Holding Registers code 03 Read Input Registers code 04 Write Single Register code 06 and Write Multiple Registers code 16 Either Read Holding Registers or Read Input Registers may be used to read data there is no difference between them The Spyder data size on Modbus is 180 Modbus registers of input and output starting at Modbus register address 1 The table in Section 12 7 shows how all the Spyder parameters are mapped onto Modbus registers There are three parameters in the Network menu to configure the Modbus communications Modbus Address Modbus Byte Order and Modbus Word Order Modbus Address specifies the Modbus address of this slave device and ranges from 0 to 255 The Spyder contains data which does not fit into the standard Modbus register size of 16 bits 2 bytes Some Spyder data consists of multiple consecutive Modbus registers The following table shows the correspondence between the Spyder data types and the number of Modbus registers used to represent the data www max
53. ides P the parameter being tuned can also be Il The number next to this letter is not the value of the parameter It is there to show the progress of the tuning Its value can be between 00 and 99 00 is displayed when that parameter is as stable as it can be When the system is stable press lt Done The Spyder will tell you which parameter should be retuned such as RE TUNE P AT CORE A Pressing 4 will automatically take you to the correct parameter to be retuned This particular message needs some comment Retune P at the present diameter not at core or full roll if P was previously tuned at core full roll and this message repeatedly comes up For large roll builds the system may need to be Quick Stabilized a few times while a roll is being wound or unwound for the first time Note that Error Limit is not tuned by the tuning screens Decreasing Error Limit can sometimes stabilize a system but increasing it will not usually cause a system to become unstable If the tuning procedures fail to produce a stable system it may be necessary to manually decrease the Error Limit parameter The system can be made less responsive by decreasing the Error Limit 7 5 2 OPTIMIZE TUNING SECOND STEP 7 5 2 1 Dancer Torque Navigate to the Tuning menu and press 4 For a Dancer in Torque mode one of the following screens will be displayed depending on the tuning type selected FIRST P AT CORE THEN D AT FULL gt PD Tuning FIRST P AT COR
54. ind or rewind applications in any dancer system The dancer control output can be connected to a torque device Brake or Clutch or a speed device Motor The Spyder measures the dancer position using a MAGPOWR DFP potentiometer connected to the dancer arm and outputs a corrective analog signal to control a torque or speed device that keeps the dancer position constant The dancer setpoint for the Spyder is set by an analog voltage signal or by a software setpoint which can be changed on the Spyder or from the Ethernet port The Spyder provides control inputs for Run Stop Tension On Off and E Stop The tension in the web is fixed by the dancer loading Additionally load cells may be read while in Dancer mode and the 0 1mA or 0 10V DC meter output is proportional to measured tension The open loop tension control is capable of controlling the tension on an Unwind or Rewind based on an analog diameter input including Taper tension and inertia compensation during stopping The tension setpoint is set by an analog voltage signal or by a parameter from an Ethernet port The control provides an analog input for Manual Level setpoint control inputs for Run Stop Auto Manual Tension On Off and E Stop and a 0 1mA or 0 10V DC meter output proportional to Diameter at Core divided by Present Diameter to slow down Rewind motors to reduce clutch power dissipation The Spyder provides an Ethernet port for programming and data collection using either a web page or
55. it can be When the system is stable press lt Done The Spyder will tell you which parameter should be retuned such as RE TUNE P AT CORE M Pressing 4 will automatically take you to the correct parameter to be retuned This particular message needs some comment Retune P at the present diameter not at core if P was previously tuned at core and this message repeatedly comes up For large roll builds the system may need to be Quick Stabilized a few times while a roll is being wound or unwound for the first time Note that Error Limit may have been reduced during Quick Stabilize Decreasing Error Limit can sometimes stabilize a system but increasing it will not usually cause a system to become unstable Therefore Optimizing does not work for Error Limit The system can be made more responsive by increasing Error Limit in the Parameters menu 6 4 2 OPTIMIZE TUNING SECOND STEP 6 4 2 1 Unwinds and rewinds Navigate to the Tuning menu and press JL For unwinds and rewinds this yields the screen FIRST I AT FULL THEN P AT CORE gt The Spyder should be optimized at or near full roll first On rewinds Quick Stab may be needed while a full roll is wound before optimizing at full roll The Spyder should be optimized at core only after it has been optimized at full roll On unwinds Quick Stab may be needed to keep the system stable while an initial roll is unwound See Section 6 4 3 for a typical tuning screen 6 4 2 2 Point t
56. ivated by selecting Digital Input Mode Active High when it is wired active low and the other way around See Section 5 2 and Figure 4 Process not running but Spyder is in Auto mode When the process is not running the tension position control system is open loop If the tension position is even slightly above Setpoint the Spyder will turn full off attempting to correct the tension position www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 37 of 60 10 0 TROUBLESHOOTING 10 2 Tuning Problems Load Cell Control Problem Possible Cause Solution or Diagnostic Tension unstable Control not optimally Use Quick Stabilize tuned Navigate to the QuickStab menu Press the 4 key and then press If Unstable gt to immediately try to stabilize Review Tuning once stability is obtained See Section 6 4 Cannot be stabilized To diagnose 1 Go to the Output Level screen to read the Appears while using quick average output while running in AUTO mode stabiliza 2 Set the Manual Level to the average value 3 Go to the Tension screen 4 Toggle between AUTO and MANUAL modes If the tension in MANUAL mode is NOT more stable than the tension in AUTO mode the tension variations being observed are not caused by dynamic instability They are disturbances generated by your process The message Re Tune P at The system is less stable When the message appears retune P
57. l MI 850A320 1 J Page 45 of 60 11 0 ALPHABETICAL LIST OF SCREEN DEFINITIONS Meter 100 CAL From the Recal Outputs menu Used to calibrate the tension meter output Term 33 to Term 34 when the tension is at Maximum Tension Modbus Address From the Network menu Sets the Modbus address of this Spyder Modbus Byte Order From the Network menu Determines whether Modbus data is sent with the most significant byte first or last Modbus Word Order From the Network menu Determines whether Modbus data is sent with the most significant word first or last Network One of the top level menu screens Used to set IP addresses and other network parameters Numeric Rate From the Configure menu Use to adjust the update and filter rate of the numeric displays of tension position and output Operator Loop One of the top level menu screens All screens in this menu are display only except for Taper Percent This menu provides numeric and bar graph displays of setpoint and actual tension position and output level This is the default entry point for all operator displays Out of range at Max Tension Error message during load cell calibration See Load Cell Calibration Problems in Section 10 4 Out of Range at Max Tension From the Cal Sensors menu See Load Cell Calibration Problems in Section 10 4 Output 0 CAL From the Recal Outputs menu Used to calibrate the
58. lace between Term 10 and Term 11 This is supplied by default from the factory e Analog control output to clutch or brake amplifier current to pressure transducer motor controller etc Term 30 to Term 31 refer to Sections 5 1 and 5 3 for output configuration The Spyder inputs and outputs are referenced to Earth ground and the negative of the 24 VDC power 2 When using a power amplifier set the current range jumper to the proper setting for the clutch or brake being used refer to amplifier User s Manual and the clutch or brake User s Manual for proper settings The following is also required e Power amplifier input if used 115 VAC for PS 90 or 24 VAC or VDC for PS 24 e Output from power amplifier to clutch or brake e The Spyder output is referenced to Earth ground and the negative of the 24 VDC power 3 Close the RUN STOP circuit Term 9 and Term 11 to put the Spyder into HOLD mode see Section 5 2 1 4 Using the Configure menu select Control Type Load Cell and appropriate system type See Section 6 2 2 for the Configure menu and Figure 6 for an explanation of the point to point types 5 Calibrate the load cells refer to Section 6 3 6 Turn tension on by opening the TENSION ON OFF circuit Term 13 and Term 11 put the Spyder into AUTO mode by opening the AUTO MANUAL circuit Term 12 and Term 11 and put the Spyder in RUN mode by switching open the RUN STOP circuit Adjust the tension setpoint using a potentiomete
59. lls are loaded to at least 1 8 of their Maximum Tension This may mean that a load cell with too large of a rating has been installed Try smaller Max From the Cal Sensors menu The Spyder will suggest a Max Tension that will keep the load cells from being out of range at Max Tension Tune First Then P second From the Tuning menu for point to point systems The Spyder should be optimized in the order shown www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 49 of 60 11 0 ALPHABETICAL LIST OF SCREEN DEFINITIONS Tuning One of the top level menu screens Used to optimize the dynamic tuning of the system Unload sensing roll From the Cal Sensors menu Load cell calibration happens in two steps In this first step all loading must be removed from the sensing roll mounted on the load cells so that the roll weight can be zeroed out Use DHCP From the Network menu Determines if the Spyder will try to get a dynamic IP address from a DHCP server If NO is selected then IP Address Gateway Address and Subnet Mask must be configured Use Load Cells From the Configure menu Select Yes to enable reading of load cells when the Spyder is configured for a Dancer system Use Taper From the Taper Setup menu for Load Cell control or the Configure menu for Open Loop Tension control Select Yes to enable taper tension www maxcessintl com MAGPOWR Spyder Ten
60. luggish while a value that is too low will make the system unstable or cause the position to overshoot 9 6 4 ERROR LIMIT Load Cell and Dancer only Enter a value for the error limit between 10 and 100 The error limit aids the tuning process by setting a boundary for the actual tension or position error that Spyder will recognize during control corrections Smaller values for the error limit will lengthen the amount of time necessary for Spyder to correct large tension or position transients Decreasing Error Limit can sometimes stabilize a system but increasing it will not usually cause a system to become unstable Therefore Optimizing does not work for Error Limit Load Cell System Error Limit may have been reduced during Quick Stabilize The system can be made more responsive by increasing Error Limit in the Parameters menu Dancer System Error Limit is not tuned by the tuning screens in Dancer mode If the tuning procedures fail to produce a stable system it may be necessary to manually decrease the Error Limit parameter The system can be made less responsive by decreasing the Error Limit 9 6 5 CONTROL PARAMETERS FACTORY DEFAULTS Factory Defaults Load Cell System Dancer Torque System Dancer Speed System Proportional 0 1 0 1 0 Integrator 2 0 Seconds 2 0 Seconds 2 0 Seconds Derivative N A 1 25 Seconds N A Error Limit 100 100 100 9 6 6 START TIME Load Cell Only Enter a value based upon the amoun
61. meter controls the filtering for the bar graph actual position and the actual output displays Default values work well in most applications 7 2 2 11 SCREEN CONTRAST This screen allows adjustment of the screen contrast See Section 10 1 General Problems when screen shows no characters 7 3 DANCER INPUT SETUP REQUIRED 7 3 1 Setup DFP or DFP 2 7 3 1 1 DFP Install the DFP sensor so that its keyway is pointing towards the top cover when the dancer 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 7 3 1 2 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 7 3 1 3 Check DFP or DFP 2 voltage Verify the dancer voltage between Term 38 and Term 39 matches the voltage change with dancer movement as shown in Figure 12 If the dancer voltage is opposite that shown in the figure simply swap the wires on Term 39 and Term 26 This will reverse the dancer voltage change 7 4 DANCER CALIBRATION REQUIRED Navigate to the Cal Dancer menu Press the JL arrow and the screen should show DANCER INPUT POS SETPOINT gt This screen allows the selecti
62. n Control Diagram 32 9 0 Optional Functions 33 9 1 b Preferences Menu l 33 9 2 Taper Tension Load Cell only 33 9 3 i Calibrate Inputs Menu Load Cell and Open Loop Tension Control l 34 9 4 Calibrate Outputs Menu 34 9 5 Security Menu 35 9 6 i Parameters Menu l 35 10 0 __Troubleshooting l 37 10 1 General Problems 37 10 2 i Tuning Problems Load Cell Control 38 10 3 Tuning Problems Dancer Control l 39 10 4 Load Cell Calibration Problems 40 10 5 i Load Cell Diagnostic Voltages l 41 11 0 _ Alphabetical List of Screen Definitions A8 120 Communication l 51 12 1 Network Setup 51 12 2 l Parameters Available Only from the Web Page or Modbus TCP l 51 12 3 Spyder Web Page 51 12 4 Update Software via FTP Site 53 12 5 Spyder Configuration Tool 53 12 6 Modbus TCP Communicatioin i 53 12 7 Modbus Parameter List l 54 12 8 Modbus Master Program l 57 _ 13 0 _ Reset Functions l 58 14 0 _ Specifications l 59 www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 6 of 60 LIST OF FIGURES Figure Description Page _ Figure 1 _ Spyder Picture l 1 _ Figure 2 Outline Dimensions 8 _ Figure 3 _ Enclosure Top Removal 8 _ Figure 4 _ Configuration Jumper 10 _ Figure 5 _ Basic Load Cell System Connections 13 _ Figure 6 __Load Cell System Types l 14 _ Figure 7 _ Applied Calibration Tension 16 _ Figure 8 _ Load Cell Connections for One or Two Load Cells 18 _ Figure 9
63. n an error and an error screen is shown The following parameters must be set up for the software download to work IP Address Subnet Mask Gateway Address FTP Address FTP directory FTP username FTP password and FTP Program Number The factory defaults are as follows FTP Address 192 168 1 200 FTP Username ftpmag ftpusers FTP Password fghj5678 FTP Directory ProductSoftware For downloading Spyder software from a local FTP server running on a local PC you can get the SpyderWare installation kit from the Maxcess website This kit will install an FTP server on a Windows PC which can be used to download software to the Spyder Go to www maxcessintl com Type the keywords spyderware in the Search field and press the Enter key When displayed click on SpyderWare Installation Kit file which links to a zip file Save the zip file to a directory on your computer Unzip this file and follow the directions in the 850A324 user manual to install and use the software This software has only been tested on a Windows XP computer 12 5 SPYDER CONFIGURATION TOOL To get the Spyder Configuration Tool go to www maxcessintl com Type the keywords spyder config in the Search field and press the Enter key When displayed click on Spyder Configuration Tool which links to a zip file Save the zip file to a directory on your computer Unzip this file and follow the directions in the 850A325 user manual to install and use the software This so
64. nded Program Number From the Network menu The number of the program that will be downloaded from the FTP site to update the Spyder software Proportional Gain From the Parameters menu Enter a value for the proportional gain This tuning parameter adds a correction factor that is proportional to the deviation from the tension setpoint A higher value will make the system more responsive but a proportional gain that is too high will result in an unstable system Factory default setting is O for load cell systems and 1 0 for dancer systems Quick Stab One of the top level menu screens Used to quickly stabilize an unstable system After stabilizing the system should be tuned using the Tuning menu Recal Inputs One of the top level menu screens Used to recalibrate the Tension setpoint input Term 16 to Term 17 and the Manual setpoint input Term 20 to Term 21 Recal Outputs One of the top level menu screens Used to recalibrate the control output and the tension meter output Retune now then retune P Part of Quick Stabilize on point to point systems This screen appears when Quick Stabilize has stabilized the system while is being adjusted Immediately retune When is optimum retune P Retune now Then P at core Part of Quick Stabilize on unwinds or on rewinds This screen appears when Quick Stabilize has stabilized the system while is being adjusted Retune the system at the prese
65. nsion Control MI 850A320 1 J Page 18 of 60 6 0 TENSION CONTROL 6 6 Load Cell System Complete Wiring Zoe Feet POWER AMPLIFIER TENSION BRAKE METER cane ETHERNET CAT 5 SHIELDED h d 30 31 32 33 34 a 55 6G oO ZE EE E g E D 3 T 2 a 3 2 T e Z O A zZz 2 2 hm cb E O Hl ei Dog 2O9ag00 0a aaao ZZ WH ES Oo od o o o gd a si zs mg SZ sg oe GC So O 5 Z Z 2 Z Z222 zc DO E r S zB oe HHH ez zz o d ad d 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 T l H VM l l MAGPOWR LOAD l CELL l L MANUAL SETPOINT 1K TO 10K OPEN FOR RUN oo OPEN FOR E STOP elo TENSION SETPOINT CLOSE FOR MANUAL oo Den CLOSE FOR TENSION OFF oo Figure 9 Complete Load Cell System Wiring 6 7 Load Cell Control Diagram UNWIND LOAD CELL p HENT 5 INPUT MAIN NO TAPER OUTPUT MANUAL Dia Dcore TaperPercent Dfull Dcore TENSION SETPOINT INPUT HOLD LEVEL MANUAL INPUT Figure 10 Load Cell Control Diagram www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 19 of 60 7 0 DANCER
66. nt Section 6 2 1 3 must be set to 0 to calibrate taper Enter the present diameter This should be the present diameter of the roll The Spyder must be in Run mode Press to finish the calibration TAPER SETUP A gt USE TAPER NO gt A CORE DIAMETER XXXX IN A FULL ROLL DIA XXXX IN V PRESENT DIA XXXX IN A CALIBRATE TAPER YES gt AM PRESENT DIA XXXX XXX IN www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 33 of 60 9 0 OPTIONAL FUNCTIONS 9 2 2 Taper with Open Loop Tension Control See Section 8 4 9 3 CALIBRATE INPUTS Load cell and Open Loop Tension only RECAL INPUTS 4 Navigate to the Recal Inputs menu Press the 4 arrow Inputs for Dancers are calibrated in Section 7 4 9 3 1 Select Setpoint Tension or Manual Voltage CAL SETPOINT When using an external voltage source for either Tension setpoint or Manual Level the inputs must be calibrated for the external voltage source minimum and maximum These inputs are calibrated at the factory for use with a potentiometer connected across the appropriate terminals of the Spyder Select either Tension or Manual and then Press J key to begin a calibration 9 3 2 Apply Minimum Setpoint Tension or Manual Voltage Apply the minimum Setpoint Tension or Manual voltage Press 4 AE KE 4 V 9 3 3 Apply Maximum Setpoint Tension or Manual Voltage APPLY MAX SET Apply the maximum Setpoint Tension or Manual voltage Pres
67. nt diameter and then retune P when the system is again at core Retune P at core Part of Quick Stabilize on unwinds or on rewinds This screen appears when Quick Stabilize has stabilized the system while P is being adjusted If the present diameter is not the core diameter retune P when the system is at core Rarely the system will be more stable at core than at some other diameter Retuning at core will then cause the system to be unstable again when the less stable diameter is reached In this case retune at the less stable diameter rather than at core Retune P now Part of Quick Stabilize on point to point systems This screen appears when Quick Stabilize has stabilized the system while P is being adjusted Immediately retune P Screen Contrast From the Configure menu Used to adjust the screen contrast Use lt and gt to adjust Secondary tuning is optimal From the Tuning menu for point to point systems This screen announces that Proportional Gain has been increased to the maximum allowed during tuning 50 Proportional Gain can be set higher than this using the Parameters menu but that is not recommended www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 47 of 60 11 0 ALPHABETICAL LIST OF SCREEN DEFINITIONS Secondary tuning is optimal From Cal Sensors menu for point to point systems Informs the operator that the most aggressive value allo
68. ntrast Core Diameter From the Taper Setup menu for load cell system and the Parameter menu for Open Loop Tension system Enter the value for the diameter of the core Core Offset From the Parameters menu for Open Loop Tension system Enter a value to offset the torque output when at core diameter See Section 9 6 10 Core Tension In the Operator Loop with taper tension enabled This is a display only of the tension setpoint at core This is not the setpoint at diameters other than core The setpoint at diameters other than core is reduced by taper tension The tension setpoint at core is set by either the Tension Input Term 16 to Term 17 or by the Ethernet connection The source of the setpoint at core tension is determined by Setpoint Source in the Configure menu Core tuning is optimal From the Tuning menu for unwinds and rewinds This screen announces that Proportional Gain has been increased to the maximum allowed during tuning 50 Proportional Gain can be set higher than this using the Parameters menu but that is not recommended Control Type lt Load Cell gt or Control Type lt Dancer Torque gt or Control Type lt Dancer Gpeed or Control Type lt Tension Diameter From the Configure Menu Used to choose the type of control that will be used When using load cells a torque device must be used The torque device can be a clutch or brake or a motor in regenerative mode
69. o point systems Navigate to the Tuning menu and press 4 For point to point systems this yields the screen TUNE I FIRST THEN P SECOND gt The Spyder should be optimized in the order shown See Section 6 4 3 for a typical tuning screen www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 17 of 60 6 0 TENSION CONTROL 6 4 3 Tuning Screens Tuning allows the operator to optimize tuning parameters by using one button to destabilize the system and another button to stabilize the system NOTE The system must be running to perform Tuning A typical tuning screen looks like this E IF UNSTABLE gt Be lt STABLE P35 Bar Graph of tension t t Parameter being tuned Besides P the parameter being tuned can also be Il The number next to this letter is not the value of the parameter It is there to show the progress of the tuning Its values can be between 00 and 99 00 is displayed when that parameter is as stable as it can be To optimize press lt until the system starts to become unstable Then press gt until stability is again obtained When finished tuning press 4 Basic setup of the load cell control system is now complete See Section 9 0 for optional settings 6 5 Load Cell Connections D e S D e SS Eo it Te oO ff ie Sac Eseu m o amp eno 0 ZS SE Ap 3 kb w fb e ZS 0 G Oo O 0 a a Figure 8 Load Cell Connections for One or Two Load Cells www maxcessintl com MAGPOWR Spyder Te
70. o the Preferences menu and Press 4 9 1 1 LANGUAGE Select the language PREFERENCES A D 9 1 2 TENSION UNITS Load cell systems and Dancer systems with Load Cells Enabled Select the Tension Units 9 1 3 DISTANCE UNITS Load cell and Open Loop Tension systems only Select the Distance units 9 2 TAPER TENSION SETUP This section describes all the screens in the Taper menu Taper Tension is the reduction of tension as the diameter increases on arewind Taper Tension is desired on rewinds to prevent crushed cores and telescoping rolls caused by excess tension build up 9 2 1 Taper with Load Cell Control Diameter is estimated and must be calibrated to use taper tension Taper Percent Section 6 2 1 3 must be set to 0 to calibrate taper Navigate to the Taper Setup menu and Press 4 Select Yes to enable Taper Press 4 Enter the core diameter The operator sets the setpoint tension only at core The tension at all diameters greater than core is less than the Core Tension Press 4 when finished Enter the diameter of the full roll The Core Tension and Percent Taper determine the tension at the full roll diameter Press J when finished This screen actively displays the diameter as estimated by the Spyder when in Run mode Press 1 to calibrate taper Select Yes and press 4 to enter the Present Diameter This screen defaults to No and helps prevent accidentally overwriting a previous calibration Taper Perce
71. on for calibrating either the Dancer Input or the Position Setpoint input The input from the dancer position sensor and from the position setpoint should both be calibrated Both are calibrated in the same way Press either the lt or gt key to begin a calibration www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 23 of 60 7 0 DANCER CONTROL 7 4 1 DANCER INPUT CALIBRATION 7 4 1 1 Apply Minimum Dancer Voltage Move the dancer arm so that it is against the stop in the direction that provides APPLY MINIMUM the minimum voltage Maximum and minimum input voltages are defined as DANCER VOLTAGE 4 shown in Figure 12 Press 4 7 4 1 2 Apply Maximum Dancer Voltage Move the dancer arm so that it is against the stop in the direction that provides APPLY MAXIMUM the maximum voltage Maximum and minimum input voltages are defined as DANCER VOLTAGE 4 shown in Figure 12 Press 4 V 7 4 1 3 Move Dancer Back Move the dancer arm back to the stop with the minimum voltage This step MOVE DANCER BACK verifies that the dancer potentiometer does not move past the end of the TO MINIMUM STOP resistance element When the software determines the pot is wired correctly the Dancer Calibrate Done screen will appear DANCER CALIBRATE DONE 7 4 1 4 Dancer Calibration Done Dancer Input calibration is now complete Press 4 7 4 2 POSITION SETPOINT CALIBRATION During normal operation applying the minimum voltage to the po
72. ons are provided to aid the understanding of the control operation Calibration and tuning procedures included in this manual must be used for proper operation The information contained in this section is not sufficient to allow proper set up Applied Tension From Cal Sensors menu Enter a value corresponding to the amount of known weight to be used to calibrate the load cell s See also Section 6 3 Apply Minimum Dancer Voltage Or Apply Maximum Dancer Voltage From the Cal Dancer menu Calibration of the dancer position signal The voltage must be between 0 VDC and 10 VDC Minimum must be less than Maximum as defined in Figure 12 Apply Min Set Position volts 4 Or Apply Max Set Position volts 4 From the Cal Dancer menu Calibration of the Position Setpoint analog input The voltage must be between 0 VDC and 10 VDC Minimum must be less than Maximum Apply Min Set Tension voltage 4 Apply Max Set Seen voltage 4 Apply Min Set a voltage 4 Apply Min Set cua voltage 4 From Recal Inputs menu Calibration of the Tension Setpoint and Manual Level analog inputs Either input must be between 0 VDC and 10 VDC Min must be less than Max Apply the Min or Max voltage to the appropriate input and press 4 Apply tension and press 4 From Cal Sensors menu Load cell calibration happens in two steps In this second step the weight used to calibrate the load cells should be applied at this time The weight should be
73. ontrol inputs may be either Active Low or Active High The software is factory configured for Active Low inputs See Section 5 2 and Figure 4 8 2 2 8 INITIAL SCREEN The first screen after power up is the Operator Loop screen This parameter allows the initial power up screen to be changed to either the Tension screen Section 8 2 1 1 the Output Level screen Section 8 2 1 6 or the Present Diameter screen Section 8 2 1 2 8 2 2 9 NUMERIC UPDATE RATE This parameter controls the filtering for the numeric actual tension and the actual output displays Default values work well in most applications 8 2 2 10 BAR GRAPH UPDATE RATE This parameter controls the filtering for the bar graph actual tension and the actual output displays Default values work well in most applications 8 2 2 11 SCREEN CONTRAST This screen allows adjustment of the screen contrast See Section 10 1 General Problems when screen shows no characters www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 31 of 60 8 0 OPEN LOOP TENSION CONTROL BASED ON DIAMETER 8 3 DIAMETER CALIBRATION REQUIRED Navigate to the Cal Diameter menu and Press 4 The diameter calibration is a single point diameter calibration Only the large diameter point is calibrated The lower diameter calibration point is implied to be 0 volts input equals 0 diameter Input a voltage into the diameter input and press the key on the Present Diameter screen and enter a
74. oop Tension BYTE Data OPT Read 0 Unwind Write 1 Rewind 0xBE Core Offset FLOAT Data OPT Read 20 0 100 0 Write 0xCO Actaul Tension Setpoint Percent FLOAT None OPT Read 0 0 100 0 Only 0xC2 Actual Tension Percent FLOAT None OPT Read 0 0 100 0 Only 0xC4 Initial Screen Open Loop Tension BYTE Data OPT Read 0 Operator Menu Write 1 Tension 2 Output Level 3 Diameter 12 8 MODBUS MASTER PROGRAM There is a Modbus master program available to test communications with the Spyder that runs on a PC with Windows This program was written as an engineering debugging tool for Modbus software development and is provided as is Go to www maxcessintl com Type the keywords spyder modbus in the Search field and press the Enter key When displayed click on Spyder Modbus TCP Master Software which links to a zip file Save the zip file to a directory on your computer Unzip this file and run the SMM exe file Use the Configure screen to set up IP address of the Spyder update rate and Spyder Program Number The Spyder program number is displayed on the Spyder for a few seconds after applying power www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 57 of 60 LEA RESET FUNCTIONS The Spyder has functions which are activated by holding down keys while turning on power 13 1 Automatic Contrast Adjust The automatic contrast adjustment is activated by holding down the Left and
75. p 192 168 1 100 index html pagelD 0 tel MAGPOWR Status Parameter Name Value Parameter Type Device Name SpyderUnwind Data Program Version 920491 07 None System State Status Hold None Tension On Off Status On None Tension Setpoint 68 9 Ib None Actual Tension 0 0 Ib None Actual Output 0 0 None Actual Diameter Not_Calibrated None MAGPOWR Figure 18 Spyder Status web page File Edit View Favorites Tools Help Microsoft Internet Explorer One x 2 seach se Favorites A i AL Address ja http 4 192 168 1 100 index html pagelD 1 MAGPOWR Configuration Parameter Name Value Parameter Type Screen Contrast 80 Cal Language English Data Control Type Load Cell Data System Type Unwind Data Output Range Normal Data Setpoint Tension Source Analog Data Remote Setpoint Tension O00 lb Data Tension Units Ib Data Distance Units in Data Digital Input Active State Low Data Numeric Display Rate 0 5 sec Data Bar Graph Display Rate 0 1 sec Data Initial Screen Operator Loop Data MAGPOWR Figure 19 Spyder Configuration web page To change the value of a parameter click on the link for the data value The Spyder will return a page with an input box to allow entering a new value When the new value has been entered click on th
76. pliers less than 1 0 are used on Rewinds to decrease the torque to stop the roll and values greater than 1 0 are used on Unwinds to increase the torque to stop the roll 9 6 9 HOLD LEVEL Not used on Dancer Speed or Open Loop Tension The output level of the Spyder will go to this value in Hold Mode The Spyder switches to Hold Mode when the Run Stop Input is closed Hold Mode only occurs while in Auto Hold mode is delayed Stop Time seconds after the Run Stop input is closed 9 6 10 CORE OFFSET Open Loop Tension only The core offset will add or subtract a fixed value of torque from the output to allow adjustment of tension at core diameter If tension is too high at core use a negative value for core offset If tension is too low at core use a positive value for core offset The range of this parameter is from 20 to 100 The default is 0 www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 36 of 60 10 0 TROUBLESHOOTING Separate tables are provided for 10 1 General Problems 10 2 Tuning problems Load Cell Control 10 3 Tuning problems Dancer Control 10 4 Load cell calibration problems 10 5 Load Cell Diagnostic Voltages 10 1 General Problems Problem Possible Cause Solution or Diagnostic Screen blank or all dark Contrast grossly misadjusted Remove power Reapply power while holding down the keys and lt The Spyder will be sweep through the contrast settings When the contrast is at o
77. r Term 15 through Term 17 Run the machine at a reduced line speed and observe the system 7 If the system is unstable go to the Quick Stabilize menu Section 6 4 1 and press the 4 down arrow to begin stabilizing Use the lt left arrow and right arrow in the following screens to tune the system 8 Refer to Section 6 4 2 for tuning methods that will optimize the responsiveness 9 Basic set up is complete Additional features and options are described later in this manual Always use the RUN STOP feature to put the Spyder into HOLD mode whenever the machine is stopped to avoid a possible high tension condition during start up www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 3 of 60 SPYDER DANCER BASIC SET UP This page provides a summary of the basic set up and calibration of the Spyder control in dancer mode Additional features and options of the Spyder control are described later in this manual Refer to either the Dancer Torque or the Dancer Speed screen flowchart drawing number 850B327 for a navigation aid 1 The connections that are required for the basic Spyder system are the following see Sections 2 0 7 0 and Figure 11 for specific wiring requirements e 24 VDC power Term 6 and Term 7 e Earth ground Term 8 e Dancer position signal Term 38 Term 39 and Term 26 see Sections 7 3 and 7 4 and Figures 11 and 12 for connections e Dancer setpoint signal Term 15 through Term 17
78. r brake being used refer to amplifier User s Manual and the clutch or brake User s Manual for proper settings The following is also required e Power amplifier input if used 115 VAC for PS 90 or 24 VAC or 24 VDC for PS 24 e Output from power amplifier to clutch or brake e The Spyder Plus output is referenced to Earth ground and the negative of the 24 VDC power 3 Close the RUN STOP circuit Term 9 and Term 11 to put the Spyder Plus into HOLD mode see Section 5 2 1 4 Using the Configure menu select Control Type Tension Diameter In the Configuration menu select the appropriate system type See Section 8 2 2 for the Configure menu 5 Using the Configure menu select Setpoint Source ANALOG if the tension setpoint will be read from the analog voltage on terminal 16 Selecting Setpoint Source ETHERNET will use a software setpoint tension which can be changed either through the Web page or Modbus TCP 6 Calibrate the diameter input and the setpoint tension input refer to Sections 8 3 and 9 3 The setpoint tension input does not need to be calibrated if Setpoint Source ETHERNET 7 Using the Parameters menu enter the Core diameter and the Full Roll diameter 8 Turn tension on by opening the TENSION ON OFF circuit Term 13 and Term 11 and put the Spyder Plus in RUN mode by switching open the RUN STOP circuit Adjust the tension setpoint using a potentiometer Term 15 through Term 17 9 Basic
79. r near the desired level press 4 The Spyder will sweep through the contrast settings repeatedly until 1 is pressed The contrast can be refined in the Screen Contrast screen See Section 13 1 Power supply is low See Section 14 0 Specifications Screen difficult to read Contrast misadjusted Adjust contrast in the Screen Contrast screen This screen is the last screen in the Configure menu Output always high E Stop Active unwinds For safety reasons E Stop occurs with an open circuit The logic is therefore different than the other digital inputs E Stop can also be mistakenly activated by selecting Digital Input Mode Active High when it is wired active low and the other way around See Section 5 2 and Figure 4 Process not running but Spyder is in AUTO mode rather than in HOLD mode When the process is not running the tension position control system is open loop If the tension position is even slightly below Setpoint the Spyder will turn full ON attempting to correct the tension position Output always low Tension ON OFF set to OFF One or more of the external Tension On Off switches is active Active depends upon the Digital Input Mode See Section 5 2 and Figure 4 E Stop Active All control types except unwind For safety reasons E Stop occurs with an open circuit The logic is therefore different than the other digital inputs E Stop can also be mistakenly act
80. s shown Not Secured or Secured Press J to enter the security code to either enable or disable the security lock SECURITY A NOT SECURED gt This function allows you to lock all tuning calibration and configuration parameters to prevent unauthorized tampering Operators will still have access to tension position setpoint tension on off auto manual manual output and taper percent NOTE When selecting a security code be sure to record it 9 6 PARAMETERS MENU This section describes all the screens in the Parameters menu PARAMETERS A pS Navigate to the Parameters menu and Press 4 9 6 1 PROPORTIONAL GAIN Load Cell and Dancer Only Enter a value for the proportional gain This tuning parameter adds a correction factor that is proportional to the deviation from the tension or position setpoint A higher value will make the system more responsive but a proportional gain that is too high will result in an unstable system 9 6 2 INTEGRATOR TIME Load Cell and Dancer only Enter a value for the integrator time which sets the basic response time of the system A value that is too high will make the system less responsive to tension or setpoint errors while a value that is too low will make the system quick but unstable 9 6 3 DERIVATIVE TIME Dancer Torque only Enter a value for the derivative time which provides a response dependant on the rate of change of the position A value that is too high will make the system s
81. s 4 TENSION VOLTAGEY V 9 3 4 Calibration Done The selected input calibration is now complete Press J This will return to the CALIBRATION Recal Inputs menu DONE A 9 4 CALIBRATE OUTPUTS Navigate to the Recal Outputs menu Press the 4 arrow to begin calibration REGAL OUTPUTS The tension meter output is calibrated at the factory and no adjustment should be required The main output is calibrated at the factory for the 0 10 VDC and 10V to 10V output range The main output will need to be recalibrated when choosing the 4 20 mADC range See Section 6 2 2 3 or 7 2 2 5 or 8 2 2 5 and Figure 4 for configuring the output range 9 4 1 OUTPUT 0 CAL o Use the LEFT and RIGHT arrow keys to adjust the main output on Term 30 ToU Ge CAL and Term 31 to 0 volts or 4 mADC Press when finished E ah 9 O Cc ei 4 2 UTPUT 100 CAL OUTPUT o Use the LEFT and RIGHT arrow keys to adjust the main output on Term 30 USE A 1 dest 6 CAL and Term 31 to 10vdc or 20 mADC Press when finished Ad 9 4 3 METER 100 CAL Load Cell systems and Dancer with Load o Cells Enabled and Open Loop Tension systems TE 1 oe 6 CAL Use the LEFT and RIGHT arrow keys to adjust the meter output on Term 33 USE a and Term 34 to 1 mADC or 10 VDC Press when finished www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 34 of 60 9 0 OPTIONAL FUNCTIONS 9 5 SECURITY LOCK OUT Navigate to the Security menu The present state of security i
82. s J Select YES to calibrate sensors Press 4 Unload the sensing roll Remove all web and weight from the sensing roller before pressing 4 Pressing 4 will overwrite previous calibrations When Maximum Tension appears enter the maximum tension that will be used on this system if different than that displayed by pressing J This is the upper limit of the tension range as read by the load cells You should choose a value for the Max Tension that will have room for the highest setpoint tension you plan to run plus any tension errors that may occur during operation within the limits of the load cell load rating This setting also scales the analog bar graph Usually it is best to set Maximum Tension to approximately twice the value of the normal running tension When finished press 4 Enter the Applied Tension you will use to calibrate the load cells Press 4 Apply the tension to the sensing roll This tension should be applied to the sensing roll using a rope or narrow web that is routed around the sensing roll in the same way as the normal web See Figure 7 This tension is best applied using a weight but a spring scale can also be used Press 4 Calibration has been performed Remove the calibration load from the sensing roll TEMPORARY WEB SENSING ROLL WEIGHT Figure 7 Applied Calibration Tension 6 4 TUNING REQUIRED Two steps are involved 1 Quick Stab to get the control loop stable if upon start up the default Q
83. s be changed during tuning either by Ethernet or by the UP and DOWN arrow keys The dancer does not need to be stopped to exit the Tuning screens 7 6 Dancer Torque Conirol Diagram DANCER INPUT MAIN OUTPUT HOLD LEVEL POSITION SETPOINT INPUT Figure 13 Dancer Torque Control Diagram www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 27 of 60 7 0 DANCER CONTROL 7 7 Dancer Speed Control Diagram Toi E STOP o RUN STOP MAIN S OUTPUT HOLD DANCER INPUT POSITION SETPOINT INPUT Figure 14 Dancer Speed Control Diagram 7 8 Dancer System Complete Wiring CLUTCH POWER TENSION OPTIONAL AMPLIFIER METER ETHERNET 0 1mA CATS D SHIELDED RAED MAIN OUT MAIN OUT METER TENSION OFF POSITION SET POSITION SET INPUT POSITION SET DANCER INPUT S BLACK P GREEN 5 VOLTS RUN STOP DANCER a a an N a Ka a ao Lei L a 24V GND PARTI DFP or DFP 2 1K TO 10K OPEN FOR RUN OPEN FOR E STOP JUMPERED FROM FACTORY EE CLOSE FOR TENSION OFF SETPOINT OPTIONAL 1K TO 10K Figure 15 Complete Dancer System Wiring www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 28 of 60 8 0 OPEN LOOP TENSION CONTROL BASED ON DIAMETER 8 1 ELECTRICAL CONNECTIONS Figure 16 shows the complete connections that are required for the Spyder Plus open loop tension control system The minimum connections are 24
84. sion Control MI 850A320 1 J Page 50 of 60 A COMMUNICATION OPTIONAL The Spyder provides communication over Ethernet using the following methods Spyder provides web pages to a browser to read and change parameters Section 12 3 Spyder can update software by using an FTP server and downloading a new program Section 12 4 Spyder can communicate with the Spyder Configuration Tool PC program which allows all parameters to be retrieved and saved in a PC file Section 12 5 Spyder can communicate as a Modbus TCP slave device Section 12 6 12 1 NETWORK SETUP There are 4 parameters in the Network menu which must be set up Use DHCP IP Address Subnet Mask and Gateway Address If your network contains a DHCP server leave the Use DHCP setting to Yes The IP Address Subnet Mask and Gateway Address will automatically be configured correctly If your network needs the Spyder to have a static address set Use DHCP to No and configure IP Address Subnet Mask and Gateway Address to match your network After changing any of these 4 network parameters the Spyder will need to be restarted for the settings to take effect 12 2 PARAMETERS AVAILABLE ONLY FROM THE WEB PAGE OR MODBUS TCP The following parameters are text strings which are only available from the web page Text strings are limited to 31 characters Parameter Name Description Device Name Name of this Spyder Each Spyder can be given a name This name appears on the lis
85. sition setpoint input will command the dancer to its minimum voltage position Applying the maximum voltage will command the maximum voltage position This calibration is not required when the setpoint source is Ethernet 7 4 2 1 Apply Mini Setpoint Volt Adjust the ies GE Se See voltage Press 4 Ge VETS V APPLY MAX SET 7 4 2 2 Apply Maximum Setpoint Voltage Adjust the position setpoint input to the maximum voltage Press 4 POSITION VOLTS V 7 4 2 3 Setpoint Input Calibration Done POSITION SET Setpoint Input calibration is now complete Press 4 CALIBRATE DONE 4 7 5 TUNING REQUIRED Three steps are involved 1 Set the position setpoint potentiometer to the midpoint 2 Quick Stab to get the control loop stable if upon start up the default QUICK STAB 4 parameters do not provide a stable closed loop See Section 7 5 1 gt 3 Tuning optimizes the Spyder by first tuning to make the system slightly TUNING D unstable then adjusting the tuning parameters to make it stable By doing so the system is tuned to be as responsive as possible and still remain stable throughout its range of operation See Section 7 5 2 NOTE Applies to Setpoint Source is Analog The position setpoint input is not active during tuning The UP and DOWN arrow keys are used to change dancer position instead For this reason the web must be stopped Run Stop Stop and restarted Run Stop Run to leave the tuning screens A screen is pro
86. stabilize See Section 6 4 2 or 7 5 2 Tuning Tuning www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 44 of 60 11 0 ALPHABETICAL LIST OF SCREEN DEFINITIONS If Unstable gt Done Pxx Quick Stab From the Quick Stab menu Three different screens look like this one They are used to quickly stabilize the system by pressing until the system stabilizes The Spyder automatically switches to the next screen if the most stable value of the parameter being tuned has not stabilized the system The parameter being tuned is indicated by either a P or an I If Unstable lt lf Now Stable From the Quick Stab menu dancers only The screen appears if the integrator was originally on and is now off If the system is now stable the instability was caused by the integrator A following series of screens explains this before the integrator is turned back on to stabilize the integrator Integrator mode I is unstable Lis now off Turn on to tune Expect unstable when turns on These message screens explain that the integrator is the cause of the instability Integrator Time From the Parameters menu Enter a value for the integrator time which sets the basic response time of the system A value that is too high will make the system less responsive to tension errors while a value that is too low will make the system quick but unstable F
87. t of available Spyder s in the Spyder Configuration Tool program FTP Username FTP Username for connecting to the FTP site to get software updates FTP Password FTP Password for connecting to the FTP site to get software updates FTP Directory FTP Directory on FTP site where software updates are contained Program Version The program version in this Spyder Also shows on the display for 3 seconds after power up 12 3 SPYDER WEB PAGE The Spyder web page allows all parameters to be viewed and edited using a standard web browser The parameters are grouped into pages that correspond to the main menu items found on the Spyder display Type into the address bar of a browser Error Hyperlink reference not valid followed by the IP Address of the Spyder The Spyder will display the web page index html The index page displays the status parameters and provides a menu on the left hand side to see all the other parameters Parameter values which are editable will be shown with a standard web page link Parameters which are not editable will not have a link Example http 192 168 1 100 www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 51 of 60 2 0 COMMUNICATION OPTIONAL e http 77192 168 1 1007index html pagelD 1 File Edt View Favorites Tools Help 3 http 77192 168 1 1007index html pagelD 0 Microsoft Internet Explorer Czech O 3 D Seach Fame G2 Address E htt
88. t of time it takes your machine to ramp up from stopped to steady state operation If the tension spikes during this time try increasing this START TIME value 9 6 7 STOP TIME Enter a value based upon the amount of time it takes your machine to ramp down from steady state operation to a complete stop When this time has expired Spyder will automatically proceed into HOLD mode www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 35 of 60 9 0 OPTIONAL FUNCTIONS 9 6 8 STOP MULTIPLIER Not used on Dancer Speed Enter a value that will dictate the control output during STOP mode Spyder will use the last control output sent during RUN mode before the STOP signal is received and multiply it by the value set here for the duration of the Stop Time The control continues to control tension during the Stop Time When the stop multiplier value is correctly set it will automatically boost output to the braking device and decrease output to a clutch device during stops to keep the tension constant For Load Cell systems only STOP MULITPLIER values less than 1 0 are used on unwinds when additional torque devices are activated during stop For example if the number of active actuators on a MAGPOWR Double Disk Pneumatic Brake is increased from 1 to 2 during stopping set STOP MULTIPLIER to a value of 0 5 For a dancer system controlling a speed device the STOP MULTIPLIER is not used For an open loop tension system Stop Multi
89. ut of range at Max Tension The Spyder has calculated that the load cell will be overloaded if the Maximum Tension specified is applied to the sensing roll The Spyder will recommend a lower Maximum Tension to avoid this problem Message Signal too small at Max Tension The Spyder has calculated that the load cell will have very light loading even when Maximum Tension is applied The Spyder will recommend a higher Maximum Tension to avoid this problem However there is a strong possibility that a load cell was chosen with too high of a rating Spyder will not calibrate if the force applied to the load cell at Maximum Tension is less than 1 8 of the total load cell rating Message Load cells are overloaded The load applied to the sensing roll during calibration has exceeded the rating of the load cell Message Load very small Maybe shorted The signal read by the Spyder after load was applied is very small There may be a short between Term 23 and Term 24 This message also appears if the calibration load was never applied to the sensing roll www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 40 of 60 10 0 TROUBLESHOOTING 10 5 LOAD CELL DIAGNOSITIC VOLTAGES TABLE 1 LOAD CELL DIAGNOSTICS 21 mV Load Cells Measure all voltages with respect to TERM 21 Voltages are approximate All voltages without a code that are not in the Normal Range
90. vided to warn the www maxcessintl com MAGPOWR Spyder Tension Control MI 850A320 1 J Page 24 of 60 7 0 DANCER CONTROL operator of this Since tuning cannot be done while the web is stopped the Spyder automatically returns to the Tuning Menu when the web is stopped Make sure to set the position setpoint potentiometer to the midpoint before restarting after tuning NOTE Applies to Setpoint Source is Ethernet The position setpoint can always be changed during tuning either by Ethernet or by the UP and DOWN arrow keys The dancer does not need to be stopped to exit the Tuning screens 7 5 1 QUICK STABILIZE FIRST STEP Default tuning parameters are embedded in the Spyder and were selected to minimize instability If the system is exhibiting extreme fluctuations at start up perform the following procedure to quickly stabilize it Fine tuning using Tuning will still be required NOTE The system must be running to Quick Stabilize Navigate to the Quick Stab menu and press JL If the system is unstable then press the arrow key associated with the If Unstable text until the system is stable If the system is stable then press the arrow key associated with the text If Now Stable or Done Two different types of screens will appear while performing the Quick Stabilize tuning E IF UNSTABLE Be lt IF NOW STABLE See 7 5 1 1 Quick Stabilize Integrator Test gt te See 7 5 1 2 Quick Stabilize Parameter Adjustment 7 5 1 1 Quick St
91. wed for secondary manual tuning has been reached Secondary tuning should only be performed after primary tuning is optimized Security Code From the Security menu Use to enter the security code to secure or unsecure the Spyder When secured only Remote Setpoint Tension and Percent Taper can be changed Security Secured One of the top level menu screens This screen also displays the Or present state of security When secured only Remote Setpoint Tension and Percent Taper can be changed Security Not Secured Sensing Roll is too heavy A load cell calibration error message See Load Cell Calibration Problems in Section 10 4 Setpoint Tension In the Operator Loop This is a display only of the tension setpoint The tension setpoint is set by either the Tension Input Term 16 to Term 17 or by the Ethernet connection The source of the setpoint tension is determined by Setpoint Source in the Configure menu Setpoint Tension In the Operator Loop without taper tension This is a display only of the tension setpoint The tension setpoint is set by either the Tension Input Term 16 to Term 17 or by the Ethernet connection The source of the setpoint tension is determined by Setpoint Source in the Configure menu Setpoint Position In the Operator Loop For dancer with Setpoint Analog this is only a display of the current setpoint input between Term 16 and Term 17 For dancer with Setpoint Ethernet the position s

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