Maxcess Cygnus MAGPOWR Instruction Manual Download Page 40 | Manualshive

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TROUBLESHOOTING

www.maxcessintl.com

CYGNUS

MI 850A316 1 B

Page 40 of 66

9.4

Load cell diagnostics

The CYGNUS features diagnostic tools for

load cells. The values displayed in the “Diagnose Load Cell” screens

may aid in diagnostics. Refer to Table 1 for possible faults.

(Home Screen)

Refer to Table 1

for faults

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Summary of Contents for Cygnus MAGPOWR

Page 1: ...CYGNUS S3TM Special Readout and Control Instruction Manual CYGNUS ES3 CYGNUS DINS3 EN Digital Tension Readout and Control MI 850A316 1 B MAGPOWR TENSION CONTROL...

Page 2: ......

Page 3: ...Precision calibration 14 6 3 2 Weightless calibration 15 6 4 Optional input device calibration 16 6 4 1 Web velocity calibration 16 6 4 2 Rpm calibration 17 6 4 3 Diameter calibration 18 6 5 Output ca...

Page 4: ...ain scheduling theory 43 9 7 Auto tune and gain scheduling 44 10 0 SCREEN DEFINITIONS ALPHABETICAL 45 11 0 SPECIFICATIONS 65 12 0 SERVICE 66 LIST OF FIGURES Figure 1 System types 57 Figure 2 Fieldbus...

Page 5: ...1 1 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 neith...

Page 6: ...nt strength to support the weight of the CYGNUS DIN as well as insure the integrity of the environmental seal The CYGNUS DIN maintains a degree of protection of IP65 over its front panel It also meets...

Page 7: ...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 Power amplifier input if used 115 v...

Page 8: ...YGNUS E 1 Disconnect the supply mains 1 Disconnect the supply mains 2 Remove the four screws on the rear of 2 Open the door of the CYGNUS E by loosening the CYGNUS which retain the top cover the two r...

Page 9: ...power to the CYGNUS E control 2 Set JP1 on the power amplifier for the desired output current range to match the specific clutch or brake model to be controlled 3 Connect 115 VAC input as instructed...

Page 10: ...ke you back to Press Setpoint key to reach this screen Home Screen one step at a time Numeric values are input using keys next to corresponding number Decimal point Example shown would input a 1 in th...

Page 11: ...inputs 5 or 24 VDC 6 1 2 E stop E stop is an auxiliary function not intended to provide category 1 safety protection Not applicable for readout only operation Open the connection between TB3 3 and TB...

Page 12: ...ic type Toggle activates keypad level requires logic input Logic can be active either high or low Select desired input Select desired isolated control output type The CYGNUS has two control outputs On...

Page 13: ...2 TB5 1 and TB5 3 on the CYGNUS and 5 possible inputs If you are using Remote Setup Select Remote Setpoint Web Velocity and Roll RPM you must use Velocity RPM Method to calculate diameter 2 Remote Set...

Page 14: ...fer to Figure 1 Enter maximum tension This will scale the analog meter and bar graph Usually Confirm load it is best to set max tension cell type approx twice the value of See Figure 4 the normal runn...

Page 15: ...and sensor performance will not be affected Home Screen Confirm system type See Figure 1 Enter combined load cell rating If two load cells are used that is the sum of the rating Enter web wrap angle...

Page 16: ...ou are using a velocity sensor Configure I O must be configured to accept the appropriate signal before proceeding Home Screen Toggle to select appropriate sensor type Back space two times to return t...

Page 17: ...must calibrate the output of the sensor so the CYGNUS can recognize actual RPM Home Screen Press Home after calibration is complete Enter current Rewind RPM Actual RPM will be displayed Press to calib...

Page 18: ...me Screen Displayed if single point is used Enter current diameter Enter calibration setpoint Displays actual diameter Press to calibrate After calibration Displays actual sensor signal Two point cali...

Page 19: ...SYSTEM SETUP www maxcessintl com CYGNUS MI 850A316 1 B Page 19 of 66 6 5 Output calibration optional Home Screen Select output to be calibrated and follow screen prompts...

Page 20: ...is Optimization using one of two methods In each method the system is optimized by first tuning to make the system slightly unstable then adjusting the tuning parameters to make it stable By doing so...

Page 21: ...e system unstable then re stabilizing it NOTE System must be running to Manually Tune Home Screen Select design method PI or PID Optimization must be done at both full roll and core If tension is unst...

Page 22: ...oose different design methods without Auto Tuning again Example if PID is too aggressive you can change to PI Select design method NOTE Will automatically return to previous screen Press start to begi...

Page 23: ...cessed for re entry of data Home Screen Enter I value Enter D value Enter P value Enter error limit Direct access to tuning parameters is intended for easy input of previously recorded values generate...

Page 24: ...YGNUS MI 850A316 1 B Page 24 of 66 8 0 Optional functions 8 1 Changing units of measure or language Home Screen Select language Select units NOTE Conversion of existing units is automatically made No...

Page 25: ...s caused by excess tension build up Taper can be achieved by either estimating diameter using the optional diameter input or calculating diameter based on roll RPM and Velocity inputs see Section 6 4...

Page 26: ...cel Comp option is used Select when Inertia Comp option is used during stopping Requires Diameter NOTE Accel Comp can Calibration be used for both acceleration and deceleration Enter calibration roll...

Page 27: ...setpoint to change with diameter or to change with tension and diameter Home Screen Enter Hold Level as a percent of output Used only when hold level changes with output is selected Set to 1 0 otherw...

Page 28: ...hese type must be methods you must selected and tune at full roll and calibrated see core See Section Section 6 4 7 3 After tuning at each roll size you must follow these screens to store each value O...

Page 29: ...f round roll Calibrate RPM sensor per Section 6 4 2 of this manual NOTE The system must be dynamically tuned before enabling this function If system is unstable reduce the gain Select yes to enable ou...

Page 30: ...o an outside device It is typically used for Web Break Detection Home Screen Select Maximum output current Set whether Alarm is used of alarm signal Typically 5 mADC for 5 VDC logic and 100 mADC for 2...

Page 31: ...sients typically experienced during a splice Typically input the inverse of the build ratio Selecting yes will take If the new roll feature is used each time the last running output and the tension is...

Page 32: ...motor drive input RPM to a clutch as a rewind roll builds This minimizes the slip watts required to be dissipated by the clutch and extends clutch life This connection is labeled 1 D and is connected...

Page 33: ...IT manual for function address locations Select HMS to activate communication Indicated communication status This will also be displayed on the HOME screen Bus protocol will be displayed here Indicate...

Page 34: ...setups can include different tuning parameters hold levels and tension set points Each is independent of the other setup but can be copied if many parameters are similar 8 11 1 Changing from one set...

Page 35: ...ion on off auto manual manual output and set up changes NOTE When selecting a security code be sure to record it in the space provided below Home Screen Record Security Code Here 1 Enter 4 digit secur...

Page 36: ...was not successful Gain Scheduling configured incorrectly See Section 8 5 Message Out of Round Roll compensation has been turned off Quick Stabilize always turns off Out of Round Roll compensation as...

Page 37: ...ound If it is difficult to change the Digital Input Mode to the correct position try switching to Manual mode on the Home screen Process not running but Cygnus is in Auto mode When the process is not...

Page 38: ...or Diagnostic Tension unstable To Quick Stabilize Navigate to Home More Program Quick Stabilize Press until stable to immediately try to stabilize To diagnose Navigate to Home More Program Quick Stabi...

Page 39: ...RPM 9 3 Auto tune diagnostics Oscillations should start within 10 sec if oscillations do not stop within 15 cycles Both of these problems can occur if there is an oscillation in the tension while in M...

Page 40: ...6 1 B Page 40 of 66 9 4 Load cell diagnostics The CYGNUS features diagnostic tools for load cells The values displayed in the Diagnose Load Cell screens may aid in diagnostics Refer to Table 1 for pos...

Page 41: ...TB6 4 P and TB6 2 S reversed or TB6 3 P and TB6 1 S reversed H TB6 4 P and TB6 1 S reversed or TB6 3 P and TB6 2 S reversed I P is wired to Ground Should be wired to TB6 3 CODE 21 mv Load Cells Could...

Page 42: ...s Not Successful See Gain Scheduling Theory section 9 6 For Gain Scheduling to work properly the following are all needed 1 A properly calibrated diameter signal voltage velocity RPM or Fieldbus are a...

Page 43: ...ameter as read by the diameter sensor The core and full roll PID values can be edited directly at Home More Program Calibrate Dynamic Parameters Gain Sched Parameters Or at Home More Program Calibrate...

Page 44: ...librate Calibrate Dynamics Gain Scheduling and press Store Values for Tuned at Core or for Tuned at Full R 5 Repeat steps 1 to 3 for full roll 6 Select Use Gain Scheduling Yes The above store operatio...

Page 45: ...to correct it Bar graph rate Enter a value for the rate in seconds that the bar graph display updates Default value 0 1 sec Basic Select to enter system type selection Unwind Rewind etc and load cell...

Page 46: ...e prompted to select a setup number to copy to the current setup number You will then be prompted to choose either a complete copy of all settings a copy of sensor calibrations only or to exit without...

Page 47: ...select the input voltage for digital control inputs See also RUN STOP INPUT SPLICE INPUT and TENSION ON OFF MODE Digital out alarm tension on off state Select to enter digital output configuration sc...

Page 48: ...parameters for full roll and core CYGNUS will then create the values for all points in between See also USE GAIN SCHEDULING STORE VALUES and RECOVER VALUES Hold Display indicates the present mode of...

Page 49: ...rol corrections 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 Factory default setting is 2 secon...

Page 50: ...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 settin...

Page 51: ...ult is 1 and it is not normally recommended that you modify this unless you are using the GAIN SCHEDULING feature In this case the overall gain can be manipulated to improve stability at mid roll Perc...

Page 52: ...ters if GAIN SCHEDULING is deactivated or if parameters are manually modified It can also be used to recover AUTO TUNE measurements Rewind Toggle this selection for applications where CYGNUS is contro...

Page 53: ...e automatic mode special condition options Start Display indicates the present mode of operation is starting activated when TB3 1 and TB3 2 are opened See also START TIME___SEC Start time ___ sec Ente...

Page 54: ...DELAY ___ Tension alarm delay ___sec Enter a value to set an amount of time the actual tension must remain below the TENSION ALARM LEVEL ___ before the web break alarm is activated See also TENSION AL...

Page 55: ...s The same four digit code must be entered to unlock and grant access to these settings When UNSECURED is displayed any four digit code may be used regardless of the last code used see also SECURED Un...

Page 56: ...FIGURE I O Web Width___ Select to edit the current web width for use in tension setpoint calculation when TENSION UNITS of PLI kg cm gm mm oz in or N cm are selected Also used for changing INERTIA val...

Page 57: ...FIGURES AND TABLES www maxcessintl com CYGNUS MI 850A316 1 B Page 57 of 66 Figure 1 System types Figure 1 SYSTEM TYPES 52...

Page 58: ...TABLES www maxcessintl com CYGNUS MI 850A316 1 B Page 58 of 66 Figure 2 Fieldbus card installation COMMKIT PB Profibus COMMKIT DN DeviceNet Figure 2 Fieldbus Card COMMKIT EN Ethernet Fieldbus Card Ins...

Page 59: ...MI 850A316 1 B Page 59 of 66 Figure 3 CYGNUS wiring diagram FENTON MO 63026 USA CYGNUS WIRING DIAGRAM L1 115 230 VAC L2 P E 0 10V COM OUTPUT LOAD CELL OPEN FOR RUN OPEN FOR E STOP FENTON MO 63026 USA...

Page 60: ...ND Two Half Bridge 500mv Load Cells BLACK WHITE RED GREEN WHITE RED BLACK GREEN 1 2 3 4 BLACK S WHITE S 1 GREEN RED 3 2 P 4 P One Magpowr Load Cell TB6 GREEN WHITE BLACK RED P 1 S P 2 S 3 4 4 1 500mv...

Page 61: ...FIGURES AND TABLES www maxcessintl com CYGNUS MI 850A316 1 B Page 61 of 66 Figure 5 Wiring diagram for use of digital inputs...

Page 62: ...or P OR Desired Tension Shield TB6 4 5 vdc Ground 5 vdc Tension Sensor P 1K 200 200 200 200 200 200 200 200 200 200 200 200 10 vdc External Power Supply Power Supply OR Analog Ground Analog Output 0 t...

Page 63: ...MI 850A316 1 B Page 63 of 66 Figure 8 CYGNUS E wiring layout CYGNUS E WIRING LAYOUT FENTON MO 63026 USA TENSION SENSORS AUXILLARY WIRING POWER CYGNUS E WITH DOOR CLOSED CYGNUS E WITH DOOR OPEN PS90 P...

Page 64: ...67 144mm 3 88 98 6mm 5 28 134mm A Maxcess International Company 4 9 8mm Recommended Panel Cutout 5 35 136mm 5 35 136mm 5 28 134mm 10 0 254mm 11 5 292mm 1 1 28mm 6 0 152mm 10 25 260mm 10 75 273mm 88 22...

Page 65: ...n parallel or 100 mVDC using 5 volts across one 120 ohm full bridge or 0 to 10 VDC analog Diameter 0 to 10 VDC analog Velocity RPM 0 to 10 volts analog or 0 01 to 50 000 pulses per second 5 VDC or 24...

Page 66: ...t is necessary to return the product for service take care to properly package the unit to prevent damage during shipment If possible use the original shipping containers AMERICAS Tel 1 405 755 1600 F...

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