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XCTRL-2DRV
User Manual
34 pgs8.76 Mb2

Warner Electric XCTRL-2DRV User Manual

P-2097-WE-A4
Tension Control System
XCTRL & XCTRL-2DRV
Installation and Operation Manual
I. INTRODUCTION ...................................................................................................................................................................... 4
II. GENERAL INFORMATION ....................................................................................................................................................... 4
III. XCTRL BLOCK DIAGRAM ...................................................................................................................................................... 5
IV. HARDWARE PIN OUT ............................................................................................................................................................. 6
V. XCTRL- 2DRV ........................................................................................................................................................................... 7
VI. SYSTEM WIRING AND SETTING ............................................................................................................................................7
1. TYPICAL WIRING ................................................................................................................................................................ 7
2. OPERATION PRINCIPLE ...................................................................................................................................................... 7
3. DANCER ARM WIRING ........................................................................................................................................................ 8
4. LOAD CELL WIRING ............................................................................................................................................................ 8
5. POWER SUPPLY WIRING ....................................................................................................................................................9
6. WIRING WITH AN X2DRV .....................................................................................................................................................9
7. (OPTIONAL) AUXILIARY ANALOG SENSOR WIRING .......................................................................................................... 9
A. WIRING THE XPRO INTERFACE TO THE XCTRL ...........................................................................................................11
VII. SOFTWARE INSTALLATION & SETTING ................................................................................................................................12
VIII. XCTRL CONFIGURATION ....................................................................................................................................................... 13
2. PARTITION SETTING ............................................................................................................................................................ 13
• READ/WRITE PARTITION
• IMPORT/EXPORT PARTITION
• FACTORY DEFAULT
• SD CARD
........................................................................................................................................................................... 17
.................................................................................................................................................. 14
........................................................................................................................................... 15
.......................................................................................................................................................... 16
3. INPUT SELECTION AND SETTING ...................................................................................................................................... 18
• CELLS / DANCER INPUT
• CALIBRATION
.................................................................................................................................................................... 18
• RANGE DEFINITION
.................................................................................................................................................. 18
.......................................................................................................................................................... 19
4. PID SETTING ........................................................................................................................................................................ 20
• SELECT THE INPUT
• SET UP THE SETPOINT
• ENTER THE GAINS
• COMPENSATION
• STOP INTEGRAL (STPINT)
.......................................................................................................................................................... 20
.................................................................................................................................................... 20
............................................................................................................................................................ 20
............................................................................................................................................................... 20
................................................................................................................................................ 21
5. SPLICE SELECTION AND HOLD OUT CONFIGURATION ................................................................................................... 22
• SPLICE SELECTION
• HOLD OUT / MAX OUT
.......................................................................................................................................................... 23
..................................................................................................................................................... 24
6. INPUT/OUTPUT CONFIGURATION ...................................................................................................................................... 25
• DIGITAL INPUT SETTINGS
• SYNC INPUT ACTIVATION
• DIGITAL OUTPUT (ERRS1, ERRS2) SETTINGS
• THE ANALOG OUTPUT (OUT1, OUT2) SETTINGS
................................................................................................................................................ 25
................................................................................................................................................ 26
................................................................................................................ 26
........................................................................................................... 26
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7. AUXILIARY SENSOR SETTING (ANA INPUT) .......................................................................................................................26
• AUXILIARY ANALOG INPUT TYPE
• AUXILIARY SENSOR CALIBRATION
.................................................................................................................................... 27
................................................................................................................................. 27
8. OPEN LOOP CONFIGURATION ........................................................................................................................................... 28
• LINEAR CURVE
• X FACTOR
................................................................................................................................................................. 28
.......................................................................................................................................................................... 28
9. DIAGNOSTIC TOOLS ........................................................................................................................................................... 29
• REAL TIME INFORMATION’ WINDOW
• INPUT/OUTPUT’ WINDOW
............................................................................................................................................... 31
.............................................................................................................................. 30
IX. XCTRL FAMILY PART LIST .....................................................................................................................................................33
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I. INTRODUCTION:
This control is a solid state electronic control that receives signal from a Dancer pivot point sensor or 2 Load cells and transmits internally the appropriate signals to the brake power driver to regulate a stable tension. It integrates 2 separate Digital PID controllers and 2 separate Open Loop control. Based on a double board architec­ture, it can integrate a Driver board to control our electromagnetic brakes range. In that particular case, all communi­cation, Input/Output and power signal of the driver board will be made thru an internal connector. All parameters could be saved to an integrated memory and to an SD Card, but can also be uploaded or downloaded thanks to its external communication bus (USB). In case of Load Cell application, when the setpoint needs to be modied, an optional handset is available.
Figure 1: XCTRL Housing Dimensions
II. GENERAL INFORMATION
Control chassis should be kept clear of all areas where foreign material, dust, grease, or all might affect the opera­tion of the control. Installation must be made in accordance with the instructions found in this manual. Failure to do so may damage the Controller. Throughout this manual the PID board will be called the XCTRL board and the Driver board will be called the X2DRV board.
Ratings
Main supply Voltage (V) 24V DC +/- 5%
Output 0-10V and/or 4-20mA
Operating T°C 0°C to 50°C no condensation
Compliance
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III. XCTRL Block Diagram
Figure 2: XCTRL Block Diagram
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IV. Hardware Pin Out
1 SD Card External interface Parameters Savings. Possibility to save up to 8 partitions.
2 USB External interface
Use to setup the controller (Input/Output, PID, splice parameters) and to up­load and download all parameters to a setup partition.
3 A Digital IN
4 B Digital IN
5 C Digital IN
6 Sync Digital IN
7 ErrS1 Digital Out
8 P1 Digital IN
9 P2 Digital IN
10 P3 Digital IN
11 Stplnt Digital IN
12 ErrS2 Digital Out
13 24V
14 Out1 Analog Output
15 Gnd Ground
16 Ana1 Analog Input
17 Gnd Ground
Power supply
OUT
Splice selection inputs. Depending on the A, B, C bit state, select a congu­ration of OUT1, OUT2, between a logical menu of 11 possibilities and select PID1&2 compensation input
NPN, PNP input type Selectable.
Logical input which activate the changes of the A, B, C inputs. Depending on logical setting, it could be activate on edge or on state. NPN, PNP input type Selectable.
Error signal output to inform that Sensor1/Cell1 is out of range. Working range can be programmed in %, Kg, Nm… 0-24VDC
Parameters Partition signal input. Depending on the P1, P2, P3 bit state, it offers a selection to all parameters tables used to setup all Input/Output, PID and Open loop controllers NPN, PNP input type Selectable.
Stop or reset the integral calculation of the PID
NPN, PNP input type Selectable.
Error signal output to inform that Sensor2/Cell2 is out of range. Working range can be programmed in %, Kg, Nm… 0-24VDC
Auxiliary 24VDC Power supply, 100mA
Analog Output of PID1 or Open Loop 1 out depending on ABC selection. Selectable: 0/+10V DC or 4/20mA.
Auxiliary Sensor Input: usually used to compensate the PID Gain versus the roll diameter Selectable: 0/+10V DC or 4/20mA.
18 24V
19 Out2 Analog Output
20 Gnd Ground
21 Ana2 Analog Input
22 Gnd Ground
23 Ex1+ Power Out
24 Ex1- Power Out
25 C1+
26 C1-
27 Shld Shielding Load Cell or Sensor shielding
28 Ex2+ Power Out
29 Ex2- Power Out
30 C2+
31 C2-
32 Shld Shielding Load Cell or Sensor shielding
Power supply
OUT
Differential Analog
Input
Differential Analog
Input
24VDC Power supply, 100 mA
Analog Output of PID2 or OL2 out depending on ABC selection. Selectable: 0/+10V DC or 4/20mA.
Auxiliary Sensor Input: usually used to compensate the PID Gain versus the roll diameter Selectable: 0/+10V DC or 4/20mA.
Sensor power supply & Load Cell excitation Selectable 0-10Vdc or 0-15Vdc, 100mA
Load Cell and/or Dancer Arm sensor input 0-10Vdc, 0-40mVdc
Sensor power supply & Load Cell excitation Selectable 0-10Vdc or 0-15Vdc, 100mA
Load Cell and/or Dancer Arm sensor input 0-10V DC, 0-40mVdc
This installation and Operating Manual has been arranged for the systematic installation and start-up of your Tension Control System. Please check off each step before proceeding to the next step.
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V. XCTRL- 2DRV
When working with the XCTRL-2DRV, no wiring between the XCTRL and the X2DRV control board are needed.
In fact, the power supply as well as the connections between the analog outputs (OUT1 & OUT2) of the XCTRL and the analog inputs of the X2DRV (InBK1 & InBK2) control boards are internally made.
If more information is needed on the standalone X2DRV control, please refer to the ‘X2DRV Installation and Operation Manual’
VI. System wiring and setting
WARNING: Contact with electrical voltages present in the controller covered in this manual can cause injury. To avoid these consequences, make sure all power is off during installation.
These wiring precautions will help you properly install and wire a trouble-free system.
1. Use proper gauge wire for all pin:
- Data input: 0,5mm² (20 AWG) or 0,75mm² (18 AWG)
- Brakes wires: 0,75mm² (18 AWG) or 1mm² (17 AWG)
2. Shielded cable is recommended for all connections
3. Do not use this controller for purposes other than those intended. Such use could damage the controller
1. Typical Wiring
Figure 3: XCTRL Typical Wiring
2. Operation Principle
The closed Loop controls are usually made with using two types of sensors: the dancer arm and the load cell. The XCTRL controller supports both. These two sensors provide a voltage signal proportional to the web ten­sion. This signal is interpreted and the web tension is adjusted accordingly by braking thru one of the integrat­ed PID controller.
Load Cell Applicaiton:
Figure 4: Load Cell Application
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Dancer Arm Application:
Figure 5: Dancer Arm Application
3. Dancer Arm Wiring
Wire Dancer Arm BTCS605-E2 or BTCS 620 to the controller as describe below, use channel 1 or 2. For all generalist wiring refer to gure 2 above. Please refer to the paragraph Input Selection and Setting to setup the XCTRL accordingly.
Figure 6: Dancer Arm Wiring
4. Load Cell Wiring
Wire Load Cell (not amplied or amplied) to the controller as describe below, use channel 1 and/or 2. For all generalist wiring refer to gure 2 above.
Figure 7: Not Amplified Load Cell Wiring Figure 8: Amplified Load Cell Wiring
Note: For all load cell wiring please refer to the corresponding Datasheet
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5. Power Supply Wiring
Wire 24VDC input power to pin 24V as shown below:
CAUTION: Improperly setting the
24VDC can damage the power supply and/or the controller
Figure 9: Power supply wiring
6. Wiring with an X2DRV
If you don’t have an XCTRL-2DRV and you want to get a closed loop control, the XCTRL can be associated with the X2DRV. For all detail about the driver refer to the X2DRV Installation & Operation manual. The XCTRL output and the X2DRV Input are selectable (0-10V or 4-20mA). To wire the XCTRL with an X2DRV follow the procedure below:
Note: 2 Channels available (Out1, Out2, InBK1, InBK2)
Figure 10: XCTRL & X2DRV wiring
Note: When the XCTRL is associated with an X2DRV (XCTRL-2DRV), power supply, input and communica­tion are made by an internal connector. No connection extra connection between the controller and the driver is needed.
7. (Optional) Auxiliary analog sensor wiring
Two auxiliary sensor inputs are available. They can both be programmed in 0-10Vdc or 4-20mA type Inputs. They can also be used with the PID or the Open Loop Controllers input, refer to section 4.d and/or 4.h para­graph II/ Software Installation and Setting. The most popular use is to have them coupled to a roll diameter sensor in order to compensate the PID Gain during unwinding
Figure 11: PID Gain Compensation in linear compensation mode
Figure 11: PID Gain Compensation in linear compensation mode
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8. (Optional) Manual Calibration
The manual calibration of the XCTRL controller allows you to calibrate the sensor Input (Cell1/Cell2) and the auxiliary sensor input (Ana1/Ana2) without the XCTRL Congurator application. The calibrated values will be then applied to the partition selected by P1, P2, P3 inputs.
Use the button above the green LED to start the calibration and follow the procedure. A long press corresponds to 5s and a time out is equal to 10s.
Procedure:
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5. (Optional) Touch Screen Installation and Setting
The optional touch Screen (Xpro) allows you to modify the setpoint easily. It is generally necessary when Load cells are used to change the tension while running.
It’s also offering to display some curves and values in real time.
If customer wants to use its own screen, a set of control code is described in the application note AN_ XPRO_SetOfCommand.pdf.
a. Wiring the XPro Interface to the XCTRL
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