Magnetic Power Systems, Inc. 1626 Manufacturers Drive. Fenton, MO 63026 Tel: 636.343.5550 Fax: 636.326.0608 magpowr@magpowr.com INSTRUCTION MANUAL EZ-TRAC Digital Tension Readout and Control Table of Contents Section Title Page Figure Title Page 1 Introduction...1 Specifications... 12 2 Installation...1 1 System Types... 13 3 Electrical Connections...2 2 Power Amp Installation... 14 4 Set-Up & Calibration...2 3 Wiring Diagram... 15 5 Power Amp Installation...5 4 Outline Dimensions... 16 6 Optional Features...6 Screen Flow Chart... 17 7 Trouble Shooting...10 8 Reset Procedures...11 850A249-1 3/02 Rev. C
1.0 INTRODUCTION The MAGPOWR EZ-TRAC is a microprocessor-based control, designed for precise closed loop tension control of a moving web. The EZ-TRAC is capable of controlling web tension in unwind, rewind, or point-to-point applications. Through this manual, bold words or symbols represent keystrokes. All data entry and calibration is done through the touch pad keyboard. In some numerical data screens, pressing or moves a cursor below the digits. The underlined digit can be changed with the + or keys. 2.0 INSTALLATION The EZ-TRAC Model EZE and its variants are intended for mounting on any flat vertical surface capable of supporting it. See Figure 4 for dimensions. The EZE meets the environmental and mechanical requirements of EN50178 with the exception of the degree of protection provided by the EZE enclosure is IP65, which is more stringent than the standard. If the IP65 rating is required in final installation, sealing type cable grips should be used for cable entry. Four mounting holes are provided for attachment of the EZE to the mounting surface. The means of attachment should comply with the essential requirements of the appropriate standard(s) and is the responsibility of the installer. The EZ-TRAC Model EZ and its variants are intended for installation through a DIN panel opening. The panel itself should exhibit sufficient strength to support the weight of the EZ as well as insure the integrity of the environmental seal. The EZ maintains a degree of protection of IP65 over its front panel. It also meets the environmental and mechanical requirements of EN50178. The EZ mounting clips found on both sides of the enclosure behind the front panel will accommodate panel thickness of 0.06 inches (1.5mm) to 0.5 inches (12mm). Wiring to and from the enclosure must be done with double or reinforced insulation or protective screening which provides protective separation. All wiring outside either the EZ-TRAC enclosures should comply with the essential requirements of the appropriate standard(s) and is the responsibility of the installer. If using a magnetic particle clutch or brake, see Section 5 to install the Model PA-2 or PA-90 Power Amplifier. WARNING: DISCONNECT MAINS BEFORE OPENING ENCLOSURE MAINTENANCE The only maintenance that may be required on the EZ-TRAC is fuse replacement. Replacement of any fuse requires opening the enclosure, which circumvents the enclosure IP rating. To replace a fuse: On Model EZ and its variants: On Model EZE and its variants: 1. Disconnect the supply mains. 1. Disconnect the supply mains. 2. Remove the two screws on the rear of the EZ 2. Open the door of the EZE by loosening the which retain the top cover. two retaining screws. 3. Remove the top cover. 3. Remove the PA-2 / PA-90 power amplifier 4. Remove the PA-2 / PA-90 power amplifier if present. if present. 5. Remove and replace the blown fuse. 4. Remove and replace the blown fuse. 6. Reinstall the PA-2 / PA-90 power amplifier 5. Re-install the PA-2 / PA-90 power amplifier. 7. Reconnect supply mains. 6. Close the door and re-tighten the retaining screws. 7. Reconnect supply mains. 1
3.0 ELECTRICAL CONNECTIONS Figure 3 shows the connections that are required for the basic EZ-TRAC system. They are: 115 or 230 vac power One or two MAGPOWR tension sensors RUN/STOP using the EZ-TRAC internal logic supply OUTPUT to clutch, brake, motor controller, etc. Power Amplifier input (if used) 115 vac for 90 vdc clutch or brake, or 24 vdc for a 24 vdc clutch or brake. See Section 6 for other options and connections. Route AC power away from sensor and control wiring. MAGPOWR sensor cables are color coded on the nameplate. Run all wiring in shielded cable. Connect shields to the enclosure using the standoffs provided. Maximum shield length and maximum length of wires outside of the shield is 3 inches (75mm). 4.0 SETUP AND CALIBRATION Apply power. Screen contrast can be adjusted by pressing PROGRAM, and then using the + and keys. Press PROGRAM and use or to display Preferences. Press to select language and units. Factory default is English and pounds. The home screen (below) always appears at power up. HOME always returns you to this screen from any other screen. Automatic mode: Manual mode: Stopping: Hold Mode: E-Stop: Off: The output automatically adjusts to correct for changes in tension. Switch to Manual mode anytime using the AUTO/MANUAL key. The output is now fixed at the level set in the MANUAL LEVEL screen. Switch back to Automatic mode using the AUTO/MANUAL key. During the Stop Time, the EZ-TRAC is still in Automatic mode, but the output is momentarily changed by Stop Multiplier. At the end of Stop Time, the EZ-TRAC switches to HOLD mode. In Hold mode the output is fixed at the Hold Level. During Emergency Stop, the output goes to full on for unwind systems and to zero output for all other systems. The output is zero when tension is turned off either by the TENSION ON/OFF key or by a remote connection. 2
4.1 Operator Screens The operator screens (shown in the figure) are those normally used during machine operation and are accessed using and from the HOME screen. A complete flow chart is shown in the back of this manual. The SETPOINT TENSION screen sets the desired tension for AUTOMATIC mode. The CORE TENSION screen sets the desired tension at CORE DIAMETER for a TAPER REWIND system. The WEB WIDTH screen sets the width of the web, and only appears when TENSION/WIDTH units are selected. The TAPER PERCENT screen is used on rewinds to decrease the web tension as the diameter increases. This screen is displayed only for a TAPER REWIND system. The TAPER MUST BE SETUP screen appears if the taper setup parameters have not been set and the present diameter has not been calibrated. See Section 4.5, TAPER SETUP. The MANUAL LEVEL screen sets the desired output when in Manual mode. The OUTPUT LEVEL screen shows the present output when in Automatic or Manual mode. Enter Operator Screen values here: Setpoint Tension Web Width Taper Percent Manual Level 4.2 System Setup Basic setup cannot be performed if E-Stop input is open, or if RUN/STOP input is open. Press PROGRAM and use and to enter the CONFIGURATION menu. Use to access the SYSTEM screen. Use or to select unwind, rewind, taper rewind, or one of the point-to-point types NORMAL, or REVERSE. See Figure 1 for a description of system types. Then continue through the flow chart at right entering the desired data in each screen. See 6.15 for description of screens. Enter System Setup values here: System Start Time Stop Time Stop Multiplier Hold Level Output Range 3
4.3 Tension Sensor Calibration NOTE: Continuing past the for SENSOR CALIBRATE screen will erase any previous sensor calibration. Press PROGRAM and use or to display CAL SENSORS. Press. Follow the steps at the right to calibrate the tension sensors. Maximum tension should be set to a value greater than the highest tension expected in the application. This value is also the 100% level of the analog bar graph. Applied tension is the known forced used in the diagram below. If any error screens are displayed during calibration see Section 7.0, TROUBLESHOOTING. Sensor calibration will require loading the sensor roll with a known force. The known force will be applied using a weight and a temporary web as shown below. The temporary web should be threaded as the web would normally be threaded in the machine to ensure the same wrap angles. In wide web applications, the known force should be applied near the center of the sensing roll using a narrow web such as a rope. Enter Tension Sensor Calibration here: Maximum Tension Applied Tension 4.4 Tuning Enter the desired SETPOINT TENSION. Press PROGRAM and or to access the TUNING screen. Press to access the first tuning screen. The procedure for optimizing tuning in any of the screens shown at the right is listed below: 1. Press and hold the key until the tension becomes unstable. 2. Press and hold the + key until the tension is again stable. System stability can be observed on the bar graph. Run the machine at a moderate speed, with the control in AUTOMATIC mode and perform dynamic calibration using the above procedure in the indicated sequence. STABility is normally optimized at full roll. COMPensation is normally optimized at core. If the tension becomes unstable at some other roll diameter see Tension Oscillates in Section 7, TROUBLESHOOTING. 4
4.5 Taper Setup Taper tension is used on rewinds to make better rolls by reducing full roll tension compared to core tension. Taper tension is selected by setting the SYSTEM type to TAPER REWIND. Press PROGRAM and or to access the TAPER SETUP screen. Press and enter the CORE and FULL ROLL diameters. Next, the present diameter must be calibrated, since the EZ-TRAC estimates diameter from the running torque and tension. The diameter must be calibrated with TAPER PERCENT set to zero. Press to access the ENTER PRESENT DIA screen, and enter the present diameter with the machine running. Press HOME and use to access the TAPER PERCENT screen. Enter the desired taper percent. Enter Taper Setup values here: Core Diameter Full Roll Diameter Enter Present Diameter 5.0 INSTALLATION OF POWER AMPLIFIERS (IF USED) 5.1 PA-90 Install the PA-90 before applying power to the control. Remove the EZ cover or open the EZE door. Set JP6 on the EZ-TRAC p.c. board to 0-10v. Set JP1 on the power amplifier for the desired output current range. On model EZ, unplug TB6 and remove the knockout from the rear of the enclosure. Mount Power Amplifier per Figure 2 using the standoffs provided with the PA-90. Resecure cover or door. When using the PA-90, the 0 to 10 vdc control output is still active but no longer isolated, and is referenced to the AC line. 5.2 PA-2 Install the PA-2 before applying power to the control. Remove the EZ cover or open the EZE door. Set JP6 on the EZ-TRAC p.c. board to 0-10v. Set JP1 and JP2 on the power amplifier for the desired output voltage and current range. On model EZ unplug TB6 and remove the knock-out from the rear of the enclosure. Mount Power Amplifier per Figure 2 using the standoffs provided with the PA-2 Resecure cover or door. When using the PA-2, the 0 to 10 vdc control output is still active but no longer isolated, and is referenced to the AC line. 5
6.0 OPTIONAL CONNECTIONS, FUNCTIONS AND OTHER TECHNICAL INFORMATION TABLE OF CONTENTS ALTERNATE TENSION INPUTS... 6.1 RUN/STOP... 6.2 E-STOP... 6.3 REMOTE TENSION ON/OFF... 6.4 SELECTING OUTPUT VOLTAGE/CURRENT... 6.5 OPERATOR SCREENS... 6.6 UNITS OF MEASURE... 6.7 LANGUAGE... 6.8 MANUAL MODE... 6.9 TAPER TENSION... 6.10 STOP MULTIPLIER... 6.11 HOLD LEVEL CONTROL... 6.12 SECURITY... 6.13 RECALIBRATIE OUTPUT... 6.14 SCREEN DESCRIPTIONS... 6.15 6.1 Alternate Tension Inputs 100 mv/v TENSION SENSORS On the main PCB cut jumpers JP11 and JP12. Connect wires to TB2 and TB3 as shown using shielded wiring. Only one full bridge can be used. 10vdc TENSION SIGNAL On the main PCB cut jumpers JP10, JP11, JP12 and JP13. Connect signal between terminals TB2.1(+) and TB2.2(-) using shielded wiring. Connect TB2.2 to TB3.1 (GND). 6.2 RUN/STOP Connect TB3.4 to TB3.3 to initiate the stopping function. During STOP TIME the EZ-TRAC continues to control tension as a closed loop system and STOP MULTIPLIER is also activated. When using the internal 5 vdc supply (set JP8-7)OPTO SUPPLY) to INT (internal)), 2 madc flows in the switch. See Section 6.4 to use isolated logic inputs (5 to 24 vdc). 6.3 E-STOP (E-STOP is an auxiliary function not intended to provide category 1 safety protection) Open the connection between TB3.2 and TB3.1 to initiate E-STOP. On unwinds the output goes full on. On all other systems the output goes to zero. When using the internal 5 vdc supply (set JP8-7)OPTO SUPPLY) to INT (internal)), 2 madc flows in the switch. See Section 6.5 to use isolated logic inputs (5 to 24 vdc). 6.4 REMOTE TENSION ON/OFF TENSION OFF sets the output to zero for all types of systems. For type REVERSE system OUTPUT LEVEL will display 100% since these systems are reverse acting (i.e. tension decreases with increasing output). REMOTE TENSION ON/OFF duplicates TENSION ON/OFF on the keypad. A momentary connection made between TB3.5 and TB3.3 will toggle between TENSION ON and OFF. The TENSION ON/OFF key remains functional. When using the internal 5 vdc supply (set JP8-7)OPTO SUPPLY) to INT (internal)), 2 madc flows in the switch. See Section 6.5 to use isolated logic inputs (5 to 24 vdc). 6
6.5 ISOLATED LOGIC INPUTS If it is desired to isolate the logic inputs on TB4 to interface with other equipment or for increased noise immunity, an external power supply can be used as shown in the diagram below. On the main PCB set JP8-7 (OPTO SUPPLY) to EXT (external). 6.6 SELECTING OUTPUT VOLTAGE/CURRENT Then output voltage/current at TB4.1(+) and TB4.2(-) is set by positioning jumpers on JP6 as shown below. JP6 must be set for 0 to 10vdc when the PA-2 or PA-90 Power Amplifier is used. The 10vdc to +10vdc output is normally used with regenerative drives in torque mode. If the drive is wired so that +10vdc creates torque in the first quadrant, use SYSTEM TYPE normal. Otherwise use SYSTEM TYPE REVERSE. In either case tension can now increase or decrease from T1 to T2. See Figure 1. If the PA-2 or PA-90 Power Amplifier is used, select current and voltage per Figure 2. 6.7 OPERATOR SCREENS The operator screens are those normally used during machine operation and are accessed using or from the HOME screen. These are the only screens which are accessible when security is set per Section 6.14. The operator screens are TENSION, SETPOINT TENSION, MANUAL LEVEL, OUTPUT LEVEL, TAPER PERCENT, (if TAPER REWIND is selected), and WEB WIDTH (if TENSION/WIDTH UNITS are selected). 6.8 UNITS OF MEASURE PREFERENCES can be used to select units of measure from: LB Kg N/cm OZ N G/mm PLI G(grams) OZ/IN Kg/cm 7
6.9 LANGUAGE PREFERENCES can be used to select different languages. The available languages are: ENGLISH (factory default) FRANCAIS DEUTSCH ESPANOL ITALIANO 6.10 MANUAL / AUTOMATIC MODE Use the key to toggle between AUTOMATIC and MANUAL mode. In MANUAL MODE the output level is fixed at the level set in the MANUAL LEVEL screen. 6.11 TAPER TENSION Taper tension is used on rewinds to make better rolls by reducing full roll tension compared to core tension. Percent taper is defined as the percent decrease in tension from core to full roll. The EZ-TRAC estimates diameter from the running torque and tension. Diameter must be calibrated while running before taper tension can be used. When calibrating diameter, TAPER PERCENT must be set to zero. 6.12 STOP MULTIPLIER Extra torque is often needed to help stop large unwind rolls. STOP MULTIPLIER is available to increase the output as a multiple of the present running torque. 6.13 HOLD LEVEL CONTROL During normal automatic operation the output changes to correct for changes in SETPOINT TENSION, roll diameter, etc. During the STOP TIME the EZ-TRAC is still in automatic mode, but the output is momentarily changed by STOP MULTIPLIER to help stop the unwind roll. At the end of STOP TIME the EZ-TRAC switches to HOLD mode. In HOLD mode the output is fixed at the HOLD LEVEL. 6.14 SECURITY The UNLOCKED LOCK screen can be used to prevent changes to all the programming parameters. When secured, only values in the operator screens can be changed. Enter code number, record here press. 6.15 RECALIBRATE OUTPUT The output is calibrated at the factory and adjustment is not normally required. The RECALibrate OUTPUT screen allows fine adjustment of the output voltage/current at 0% and 100%. Use the + or keys to adjust the actual output with a meter on TB4.2 and TB4.1. 8
6.16 SCREEN DESCRIPTIONS OPERATOR SCREENS TENSION SETPOINT TENSION CORE TENSION MANUAL LEVEL OUTPUT LEVEL TAPER PERCENT WEB WIDTH Displays current measured tension and operating mode. The tension set point for AUTOMATIC mode and STOPPING mode. (Does not appear when taper tension is used). This is the SETPOINT TENSION at CORE DIAMETER when taper tension is used. The output percent when in MANUAL MODE. Current output as a percent of maximum. Appears only when taper tension is used. The core tension is reduced by this percentage as the rewind roll increases to FULL ROLL DIAMETER. Appears only when TENSION/WIDTH UNITS are used. Enter the width of the present web to enable TENSION/WIDTH calculations. PARAMETER SCREENS ERROR LIMIT HOLD LEVEL INTEGRATOR TIME PROPORTIONAL GAIN START TIME STOP MULTIPLIER STOP TIME This value limits the percent of error that is acted upon. The output will stay at this percent level while in HOLD mode. This time adjusts the response to errors. Larger values slow down the response to rapidly changing error. Generates an output adjustment proportional to the error. Provides a soft-start when starting with a slack web. The output is limited to the HOLD LEVEL at start, but the limit level is increased with time. This is the time taken to increase the limit to full output. A longer start time will provide a softer start. Upon receipt of a stop signal, the output is increased by this multiplier (1 creates no increase). Since the output is proportional to roll diameter, this is a simple adjustment for roll inertia. This is the time that EZ-TRAC stays in STOPPING (automatic) mode after the stop signal is received. At the end of this time the control goes to HOLD mode. Stop time should be slightly longer than actual machine stopping time. CONFIGURE SCREENS OUTPUT RANGE SYSTEM SCREEN CONTRAST Normal, -10 vdc to +10 vdc UNWIND, REWIND, TAPER REWIND, NORMAL, REVERSE. Select TAPER REWIND to enable taper tension. NORMAL and REVERSE are for point-to-point applications. See Figure 1 for description of each type. Adjusts the readability of the screen. PREFERENCES SCREENS LANGUAGE UNITS CORE DIAMETER FULL ROLL DIA ENTER PRESENT DIA Selects display language. ENGLISH, FRANCAIS, DEUTSCH, ESPANOL or ITALIANO Selects display units. LB, OZ, PLI, OZ/IN, KG, N, G, KG/CM, N/CM, G/MM. TAPER SETUP SCREENS CORE TENSION is commanded at this diameter. At this diameter the tension will be reduced by the taper percent. This screen is used to calibrate the estimated diameter. Enter the present diameter while running to calibrate diameter. 9
7.0 TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION OR DIAGNOSTIC Screen blank or hard to read Contrast misadjusted Press PROGRAM,, and then use + or keys to adjust. Output always low Power select switch improperly set. TENSION ON/OFF set to OFF Set 115/230 vac power select switch to the appropriate voltage. Press TENSION ON/OFF on the keypad once. Output always high E-STOP is active (except unwind). E-STOP is wired incorrectly. E-STOP is active (unwinds only). If the internal logic is being used (the factory default) TB3.2 must be connected to TB3.1 to disable E-STOP. Also verify JP8-7 set to INT. See above. Cannot enter PROGRAMMING or CALIBRATION screens. EXCESSIVE ROLL WEIGHT E-STOP is wired incorrectly. Not in HOLD mode. RUN/STOP not wired correctly. Sensor(s) misapplied. If the internal logic supply is being used (the factory default) TB3.4 must be connected to TB3.3 to be in HOLD mode. Also verify JP8-7 set to INT. The total weight of the sensor idler roll and shaft must be less than ½ of sensor rating. When two sensors are used this is the combined rating of both (i.e. 100 lbs for two 50 lb sensors). MAXIMUM TENSION TOO HIGH Selected maximum tension is out of sensor range. Calibration can be completed by using a small maximum tension. See Maximum tension is out of range below. SENSOR SIGNAL TOO LOW Maximum tension is out of sensor range. 1. This problem is often caused by loading the sensor in the wrong direction. It can be corrected by reversing +SIG and SIG (TB2-1 and TB2-2). Maximum tension is out of sensor range. 2. If signal direction is correct, calibration can often be completed by using a larger maximum tension. See Maximum tension is out of range below. 3. When maximum tension is applied the load on the sensors must be less than the total sensor rating and greater than 1/8 of total sensor rating. When two sensors are used this is the combined rating of both (i.e. 100 lbs for two 50 lb sensors). Calculate this load from: LOAD = 2*MAX*SIN(WRAP/2) Where: MAX=maximum tension entered during sensor calibration. WRAP=wrap angle.
Tension oscillates DIAGNOSTIC: 1. From the HOME screen use or to go to OUTPUT LEVEL. 2. While the machine is running record the approximate output level. 3. Enter this value in the MANUAL LEVEL. 4. Switch to MANUAL mode. 5. If the tension continues to oscillate there is an out of round roll or other machine generated tension variation. 6. If the oscillation stops the control may be mistuned. See ERROR LIM needs adjustment. ERROR LIM needs adjustment 1. Go to OPTIMIZE ERROR LIM. 2. Press and hold until the oscillation stops. 3. If ERROR LIM is max go to COMP needs adjustment. Front panel TENSION ON/OFF does not work COMP needs adjustment STAB needs adjustment STAB is max E-STOP is active E-STOP is wired incorrectly 1. Go to OPTIMIZE COMP (ignore reference to core) 2. Press and hold until oscillation stops. 3. If oscillations cease, optimize ERROR LIMIT. 4. If COMP is max go to STAB needs adjustment. 1. Go to OPTIMIZE STAB (ignore reference to full roll). 2. Press and hold until the oscillation stops. 3. If oscillations cease, optimize COMP and then optimize ERROR LIM. 4. If STAB is max go to STAB is max. This is extremely rare. You have a system that needs more than 150 sec integrator to be stable. Verify this result by performing the diagnostic under Tension Oscillates. If verified this system may need to use PID for the OPTIMIZE METHOD. Consult the factory. If the internal logic is being used (the factory default) TB3.2 must be connected to TB3.1 to disable E-STOP. 8. RESET PROCEDURES If it is desired to reset parameters to factory default values perform the following reset procedure: 1. Simultaneously press and and hold for 2 seconds. RESETTING PARAMETERS will appear on the screen for 1 second. 2. Program reset is complete. The basic (tension sensor) calibration has not been erased, and all other programming has been reset to factory default values. Begin at Section 4.0 to reprogram. 11
EZ-TRAC SPECIFICATIONS Supply Voltage: 115 or 230 volts rms, ± 10% Supply Frequency: 50 or 60 cycles per second, sinusoidal Fuses: F1, F2 1.6 amp, Littelfuse Part No. 21606.6, or Wickmann Part No. 19194-053-FS Enclosure EZ Front Panel IP65 (IEC529) IP20 (IEC529) EZE Enclosure IP65 (IEC529) Climate Class: 3K3 (EN60721) Temperature Range: Operating 0 C to 40 C Storage -30 to +80 C Relative Humidity 5% to 85% Pollution Degree 2 (IEC664-1) Altitude: 0-2000 meters Compatible Residual Current Device Types: Worst Case Fault Current: Inputs: Tension Sensor E-Stop Run/Stop Tension Off Outputs: Torque A or B (IEC755) 1.6 amperers 2.1 millivolts/volt using +5 and 5 volts (10 volts) across one 350 ohm sensor or two 350 ohm sensors in parallel, or 100 millivolts/volt, using 5 volts across one 100 ohm full bridge, or 0 to +10 volts analog switch closure or 5 volt or 24 volt logic switch closure or 5 volt or 24 volt logic switch closure or 5 volt or 24 volt logic 0 to +10 vdc, 1 milliamp maximum 4 to 20 madc., 500 ohms maximum -10 to +10 vdc, 1 milliamp maximum 12
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