Magpowr DIGITRAC 2 Instruction Manual
Magnetic Power Systems, Inc.
1626 Manufacturers Drive. Fenton, MO 63026
Tel: 636.343.5550 Fax: 636.326.0608 magpowr@magpowr.com
INSTRUCTION MANUAL
DIGITRAC
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2
DIGITAL TENSION READOUT AND CONTROL
TABLE OF CONTENT S
Section Title
1 Introduction........................... 2 Specifications.......................20
2 Installation............................. 2 1 Wiring Isolated Inputs ..........15
3 Electrical Connections..........3 2 Sy stem Types.......................16
4 Setup and Calibration...........3 3 PA-2 Installation...................17
5 PA-2/PA-90 Installation......... 5 4 Wiring Diagrams...................18
6 Optional Features................. 6 5 Outline Dimensions..............19
7 Trouble Shooting ................12 6 Screen Flow Chart................21
8 Reset Procedures...............15
All of the information herein is the exclusive proprietary property of Magnetic Power Systems, Inc., 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 2002, all rights reserved.
850A154-1
8/02 Rev. D
Page Figure Title Page
1. INTRODUCTION
The MAGPOWR
%
Model DIGITRAC% 2 is a microprocessor based control, designed for precise closed loop
tension control of a moving web. All data entry and calibration is done through the touch pad keyboard. The
DIGITRAC 2 is capable of controlling web tension in unwind, rewind, or point-to-point applications. Throughout
this manual, bold words or symbols represent keystrokes.
2. INSTALLATION
INSTALLATION
The DIGITRAC 2, Model D2E and its variants are intended for mounting on any flat vertical surface capable of
supporting it. See Figure 4 for dimensions. The D2E meets the environmental and mechanical requirements of
EN50178 with the exception that the degree of protection provided by the D2E enclosure is IP65 which is more
stringent than the standard. If the IP65 rating is required in the final installation, sealing type cable grips should
be used for cable entry. Four mounting holes are provided for attachment of the D2E 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 DIGITRAC 2, Model D2 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 D2 as well as insure the integrity of the
environmental seal. The D2 maintains a degree of protection of IP65 over its front panel. It also meets the
environmental and mechanical requirements of EN50178. The D2 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 of the DIGITRAC 2 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 DIGITRAC 2 is fuse replacement. Replacement of any fuse
requires opening the enclosure, which circumvents the enclosure IP rating. To replace a fuse:
On Model D2 and its variants: On Model D2E and its variants:
1. Disconnect the supply mains. 1. Disconnect the supply mains.
2. Remove the two screws on the rear of the D2 2. Open the door of the D2E by loosening the
which retain the top cover. two retaining screws.
3. Remove the top cover. 3. Remove the PA-2 or PA-90 power amplifier
4. Remove the PA-2 or PA-90 power amplifier if present.
if present 4. Remove and replace the blown fuse.
5. Remove and replace the blown fuse. 5. Re-install the PA-2 or PA-90.
6. Re-install the PA-2 or PA-90 and the top cover. 6. Close the door and re-tighten the retaining screws.
7. Reconnect supply mains. 7. Reconnect supply mains.
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3. ELECTRICAL CONNECTIONS
Figure 3 shows the connections that are required for the basic DIGITRAC 2 system. They are:
115 or 230 vac power
One or two MAGPOWR tension sensors
RUN/STOP using the DIGITRAC 2 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 (75 mm).
4. SETUP AND CALIBRATION
Apply power.
Screen contrast can be adjusted using SHIFT,B and é orê.
SETUP #
STATUS
A = AUTOMATIC
S = STOPPING
H = HOLD
M = MANUAL
E = E-STOP
OFF
ANALOG
BAR GRAPH
OF TENSION
DIGITAL
READOUT
OF TENSION
USE
CONFIGURE
TO SELECT
UNITS &
LANGUAGE
The home screen (above) always appears at power up. HOME also returns you to this screen.
Keyboard Layout and Programming See Cover for keypad layout.
CLEAR clears numeric inputs and other keystrokes.
SHIFT selects the shifted (white) functions
NEXT and PRIOR change to next or prior screens. é or ê change the value of the parameter displayed on the
screen. See Figure 6 for a complete programming flow chart.
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4.1 System Set up
Basic calibration cannot be performed if E-STOP is open,
or if RUN/STOP is in run mode.
A complete flow chart is shown in Figure 6.
To begin basic calibration, do the following:
Press SHIFT,
Press PROGram,
or to select )PROGRAM: CALIBRATE(,
Use
Press NEXT to select
Press NEXT to display
)CALIBRATE BASIC(,
)SELECT SYSTEM(.
Use é or ê to select desired system type. See Figure 1 for a
description of system types. If using a regenerative drive, see
Section 6.9 to determine system type.
Then continue through the flow chart at right entering the
desired data in each screen.
4.2 Tension Sensor Calibration
NOTE: Continuing beyond this point will erase any
previous sensor calibration in this setup.
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.
Follow the steps at the right to calibrate the tension
sensors.
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4.3 Dynamic Tuning
Use NEXT or PRIOR to enter the DESIRED TENSION screen and enter the
desired value. Follow the flow chart, Figure 6, to enter CALIBRATE DYNAMICS.
When asked to OPTIMIZE in any of the following steps do the following:
1. Press and hold
unstable.
2. Press and hold é 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
5. INSTALLATION OF MODEL PA-90 or PA-2 Power Amplifier (if used)
5.1 PA-90
Install the PA-90 before applying power to the control
Remove the D2 cover, or open the D2E door.
Set JP6 on the D2 p.c. board to “0-10V” and “voltage”.
Set JP1 on the power amplifier for the desired output current range.
On Model D2, 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.
ê until the tension becomes
)Tension Oscillates( in Troubleshooting, Section 7.
When using the PA-90, the DIGITRAC 2’s 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 D2 cover, or open the D2E door.
Set JP6 on the main PCB to
Set JP1 and JP2 on the power amplifier per Figure 2 for the desired output voltage and current range.
On model D2 unplug TB7 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.
When using the PA-2, the DIGITRAC 2’s 0 to 10 vdc control output is still active but no longer isolated, and is
referenced to the AC line.
)0-10V( and )VOLTAGE(.
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6. OPTIONAL CONNECTIONS, FUNCTIONS AND OTHER TECHNICAL INFORMATION
TABLE OF CONTENTS
HARDWARE
ALTERNATE TENSION INPUTS ............................................................... 6.1
DIAMETER INPUT ..................................................................................... 6.2
WEB SPEED INPUT................................................................................... 6.3
RUN/STOP ................................................................................................. 6.4
E-STOP ...................................................................................................... 6.5
REMOTE TENSION ON/OFF..................................................................... 6.6
ISOLATED LOGIC INPUTS (RUN/STOP, ETC.)....................................... 6.7
SELECTING OUTPUT VOLTAGE/CURRENT........................................... 6.8
+5 vdc SUPPLY.......................................................................................... 6.9
PROGRAM OPTIONS
OPERATOR SCREENS ............................................................................. 6.10
UNITS OF MEASURE ................................................................................ 6.11
LANGUAGE................................................................................................ 6.12
MANUAL MODE......................................................................................... 6.13
TAPER TENSION....................................................................................... 6.14
INERTIA COMPENSATION ....................................................................... 6.15
HOLD LEVEL CONTROL........................................................................... 6.16
OPTIMIZE METHOD .................................................................................. 6.17
SETUPS AND COPY SETUPS .................................................................. 6.18
SECURITY.................................................................................................. 6.19
ITEM NUMBERS AND SCREEN DESCRIPTIONS.................................... 6.20
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.
10 vdc TENSION SIGNAL
On main PCB cut jumpers JP10, JP11, JP12 and JP13.
Connect signal between terminals TB2.1(+) and TB2.2(-)
using shielded wiring. TB2.2(-) should also be connected to
TB3.1 (GND).
6.2 DIAMETER INPUT
The DIGITRAC 2 uses the diameter of the roll on unwinds and rewinds for inertia compensated stopping and on
rewinds for providing taper tension. When no diameter input is provided the DIGITRAC 2 estimates diameter.
Using a diameter input gives more accurate results.
Select the DIAMETER INPUT TYPE under PROGRAM-CONFIGURE. Connect a diameter sensor between
TB3.7(+) and TB3.6(-) using shielded wiring.
VOLTAGE (0 to 10 vdc) Voltage must be proportional to diameter (i.e. the output at core cannot be 0 vdc).
Select )VOLTAGE( on JP15 on the main PCB.
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PULSE (0 to 5 vdc, 0 to10,000 pps) Diameter is calculated by dividing web speed by this signal, which is
proportional to unwind/rewind RPM. Select )PULSE( on JP15 on main PCB. TB3.5 can be used to supply 5vdc
to the pulse generator. See current limitation in Paragraph 6.9. A web speed signal must be provided if the
diameter signal is
)PULSE(.
6.3 WEB SPEED INPUT
The DIGITRAC 2 needs a web speed input if a PULSE type input is used to calculate diameter of the roll on
unwinds and rewinds.
Select the SPEED INPUT TYPE under PROGRAM-CONFIGURE. Connect a web speed sensor between
TB3.8(+) and TB3.6(-) using shielded wiring.
VOLTAGE (0 to 10 vdc) Select
PULSE (0 to 5vdc, 0 to 10,000 pps) Select )PULSE( on JP9 on main PCB. TB3.5 can be used to supply 5 vdc to
the pulse generator. See current limitation in Paragraph 6.9.
)VOLTAGE( ON JP9 on main PCB.
6.4 LOGIC INPUTS
The logic inputs may be isolated with an external (5 to 24 vdc) power supply to interface with other equipment or
for increased noise immunity. Set JP7-8 (OPTO SUPPLY) to EXT (external) for an external isolated 5 to 24 vdc
power supply as shown in Figure 5. The current flowing in the logic inputs switches is 2 madc.
6.4.1 RUN/STOP
Connect TB4.4 to TB4.3 to initiate the stopping function. During STOP TIME the DIGITRAC 2 continues to
control tension as a closed loop system but INERTIA COMP and STOP MULTIPLIER are also activated.
See Section 6.7 to use isolated logic inputs (5 to 24vdc).
6.4.2 E-STOP (E-STOP IS AN AUXILIARY FUNCTION NOT INTENDED TO PROVI DE
CATEGORY 1 SAFETY PROTECTION)
Open the connection between TB4.2 and TB4.1 to initiate E-STOP. On unwinds the output goes full on. On all
other systems the output goes to zero.
See Section 6.7 to use isolated logic inputs (5 to 24vdc).
6.4.3 REMOTE TENSION ON/OFF
TENSION OFF sets the output to zero for all types of systems. For Type 2 and 3 systems OUTPUT LEVEL will
display 100% since these systems are reverse acting (i.e. tension decreases with increasing output).
Either of two optional modes of operation are selected using PROGRAM-CONFIGURE.
TOGGLE duplicates TENSION ON/OFF on the keypad. A momentary connection should be made between
TB4.5 and TB4.3 will toggle between TENSION ON and OFF. The TENSION ON/OFF key remains functional.
LEVEL turns TENSION OFF when TB4.5 is connected to TB4.3. The TENSION ON/OFF key is disabled.
See Section 6.7 to use isolated logic inputs (5 to 24vdc).
6.5 ISOLATED LOGIC I NPUTS
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 Figure 15. On the main PCB set JP8-7 (OPTO SUPPLY) to
EXT (external).
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