Maxcess MAGPOWR Spyder-Plus Instruction Manual Download

Page: 38 / 60

10.0

TROUBLESHOOTING

www.maxcessintl.com

MAGPOWR Spyder-Plus

MI 850A320 1 M

Page 38 of 60

10.2

Tuning Problems (Load Cell Control)

Problem

Possible Cause

Solution or Diagnostic

Tension unstable

Control not optimally
tuned.

Use Quick Stabilize.

Navigate to the

QuickStab

menu. Press the



key and then press

If Unstable



to immediately try to stabilize.

Review “

Tuning

” once stability is obtained.

See Section 6.4.

“Cannot be stabilized.”
Appears while using quick
stabilize.

To diagnose:

1) Go to the

Output Level

screen to read the

average output while running in AUTO mode.

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

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
core” repeatedly appears

The system is less stable
at some intermediate roll
diameter than it is at core.

When the message appears retune P at the
present diameter rather than at core.

Summary of Contents for MAGPOWR Spyder-Plus

Page 1: ...MAGPOWR Spyder Plus Tension Control Instruction Manual Figure 1 EN Spyder Plus MI 850A320 1 M MAGPOWR TENSION CONTROL ...

Page 2: ...sed 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 2016 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 ...

Page 3: ... or brake User s Manual for proper settings The following is also required Power amplifier input if used 115 VAC for PS 90 or 24 VAC or VDC for PS 24 Output from power amplifier to clutch or brake 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 Configu...

Page 4: ...d 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 ...

Page 5: ...he 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 VAC for PS 90 or 24 VAC or 24 VDC for PS 24 Output from power amplifier to clutch or brake The Spyder output is referenced to Earth ground and the negative of the 24 VDC power 3 Close the RUN STOP circuit Term 9 an...

Page 6: ...Complete System Wiring 28 8 0 Open Loop Tension Control based on Diameter 29 8 1 Electrical Connections 29 8 2 Software Configuration 29 8 3 Diameter Calibration 32 8 4 Core Full Roll and Taper Setup 32 8 5 Open Loop Tension Control Diagram 32 9 0 Optional Functions 33 9 1 Preferences Menu 33 9 2 Taper Tension Load Cell only 33 9 3 Calibrate Inputs Menu Load Cell and Open Loop Tension Control 34 9...

Page 7: ...n 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 unwind 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 me...

Page 8: ...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 Figure 2 Outline Dimensions Figure 3 Enclosure Top Removal WARNING DISCONNECT POWER BEF...

Page 9: ...hoices 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 ...

Page 10: ...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 RUN STOP ...

Page 11: ...is 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 ...

Page 12: ...ive 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 ...

Page 13: ... 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 ...

Page 14: ...nt 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 Figure 6 Load Cell Sy...

Page 15: ...actory 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...

Page 16: ...ximum Tension to approximately twice the value of the normal running tension When finished press Enter the Applied Tension you will use to calibrate the load cells Press 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...

Page 17: ...ge 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 ...

Page 18: ... parameter being tuned can also be I 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 until the system starts to become unstable Then press until stability is again obtained When finished tuning press Basic setup of the l...

Page 19: ... RUN OPEN FOR E STOP MAGPOWR LOAD CELL 26 25 24 23 22 9 10 11 12 13 14 15 16 17 18 19 20 21 CLOSE FOR TENSION OFF RUN STOP E STOP GND AUTO MANUAL TENSION OFF SHIELD TENSION TENSION INPUT TENSION SHIELD MANUAL MANUAL INPUT MANUAL SHIELD S WHITE S BLACK P GREEN P RED TENSION SETPOINT 1K TO 10K 30 MAIN OUT MAIN OUT 31 SHIELD 32 METER 33 METER 34 AMPLIFIER POWER CLUTCH OR BRAKE CLOSE FOR MANUAL 1K TO ...

Page 20: ...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 maxi...

Page 21: ...ERATOR LOOP MENU This section describes all the screens in the Operator Loop menu All screens are display only 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 s Start A Automatic Run S Stop OFF Tension OFF F...

Page 22: ...n 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 Contro...

Page 23: ...l 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 wipe...

Page 24: ...ltage 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 Minimum Setpoint Voltage Adjust the position setpoint input to the minimum voltage Press 7 4 2 2 Apply Maximum Setpoint Voltage Adjust the position setpoint input to the maximum voltage Press 7 4 2 3 Setpoint Input Calibration Don...

Page 25: ...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 See 7 5 1 1 Quick Stabilize Integrator Test See 7 5 1 2 Quick Stabilize Parameter Adjustment 7 5 1 1 Quick Stabilize Integrator Test This screen is entered if the system is not yet stable and the integrator was on The integrator was turned off as...

Page 26: ...oduce 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 For a Dancer in Torque mode one of the following screens will be displayed depending on the tuning type selected PD Tuning PID Tuning The Spyder sho...

Page 27: ...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...

Page 28: ...OL www maxcessintl com MAGPOWR Spyder Plus MI 850A320 1 M Page 28 of 60 7 7 Dancer Speed Control Diagram Figure 14 Dancer Speed Control Diagram 7 8 Dancer System Complete Wiring Figure 15 Complete Dancer System Wiring ...

Page 29: ...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 navigat...

Page 30: ...sired 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 analo...

Page 31: ...s 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 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 8 2 2 8 INITIAL SCREEN The first screen after power up...

Page 32: ...rcent is set in the Operator menu See Section 8 2 1 4 Basic setup of the open loop tension system is now complete See Section 9 0 for optional settings 8 5 Open Loop Tension Control Diagram Figure 17 Open Loop Tension Control Diagram Navigate to the Cal Diameter menu and Press The diameter calibration is a single point diameter calibration Only the large diameter point is calibrated The lower diam...

Page 33: ...er 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 Select Yes to enable Taper Press 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 when finished Enter the diameter of the...

Page 34: ...etpoint Tension or Manual voltage Press 9 3 4 Calibration Done The selected input calibration is now complete Press This will return to the Recal Inputs menu 9 4 CALIBRATE OUTPUTS Navigate to the Recal Outputs menu Press the arrow to begin calibration 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...

Page 35: ... 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...

Page 36: ... system controlling a speed device the STOP MULTIPLIER is not used For an open loop tension system Stop Multipliers 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 Hol...

Page 37: ...e 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 slightl...

Page 38: ...sing quick stabilize To diagnose 1 Go to the Output Level screen to read the average output while running in AUTO mode 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 disturb...

Page 39: ...age 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 co...

Page 40: ...ells above Message Out 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 Th...

Page 41: ...le Fault A TERM 25 P open B TERM 26 P open C TERM 25 P to TERM 23 S leg open D TERM 25 P to TERM 24 S leg open E TERM 26 P to TERM 23 S leg open F TERM 26 P to TERM 24 S leg open G TERM 25 P and TERM 23 S reversed or TERM 26 P and TERM 24 S reversed H TERM 25 P and TERM 24 S reversed or TERM 26 P and TERM 23 S reversed I P is wired to Ground Should be wired to TERM 26 CODE One of Two 21 mV Load Ce...

Page 42: ...t Manual voltage 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 Apply tension and press From Cal Sensors menu Load cell calibration happens in two steps In this second step the weight used to calibrate the load cells shou...

Page 43: ...put 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 t...

Page 44: ...r 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 y...

Page 45: ...s while a value that is too low will make the system quick but unstable Factory 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...

Page 46: ...y 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 control output Term 30 to Term 31 when 0 output is commanded Output 100 CAL ...

Page 47: ...e tension meter output Retune I now then retune P Part of Quick Stabilize on point to point systems This screen appears when Quick Stabilize has stabilized the system while I is being adjusted Immediately retune I When I is optimum retune P Retune I 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 I is bein...

Page 48: ...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 ...

Page 49: ... 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 f...

Page 50: ...ensing 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 Dance...

Page 51: ...AMETERS 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 list of available Spyder s in the Spyder Configuration Tool program FTP Username FTP Username for conn...

Page 52: ...Status web page 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 the Submit button Examples Figure 20 Example Edit Value Web Pages ...

Page 53: ... 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 the results are displayed filter for Software in the list on the left do not click Search a second time When displayed click on Spyder Configuration To...

Page 54: ...ngs 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 Starting Modbus Regi...

Page 55: ... 2 Kilogram 3 Newton 4 gram 0x53 Distance Units BYTE Data LC OPT Read Write 0 inch 1 feet 2 millimeter 3 centimeter 4 meter 0x54 Proportional Gain Load Cell FLOAT Data LC Read Write 0 0 999 0 0x56 Integrator Time Load Cell FLOAT Data LC Read Write 0 0 60 0 seconds 0x58 Derivative Time Dancer FLOAT Data DT Read Write 0 0 60 0 seconds 0x5A Error Limit FLOAT Data LC DT DS Read Write 0 0 100 0 0x5C St...

Page 56: ...T DS OPT Read Write 0 0 60 0 seconds 0x80 Bar Graph Display Rate FLOAT Data LC DT DS OPT Read Write 0 0 60 0 seconds 0x82 Position Setpoint 0 Calibration Point FLOAT Cal DT DS Read Write 0 4095 0x84 Position Setpoint 100 Calibration Point FLOAT Cal DT DS Read Write 0 4095 0x86 Dancer 0 Calibration Point FLOAT Cal DT DS Read Write 0 4095 0x88 Dancer 100 Calibration Point FLOAT Cal DT DS Read Write ...

Page 57: ... this value by 100 to get percent 0xBB Setpoint Tension Percent FLOAT Data OPT Read Write 0 0 100 0 0xBD System Type Open Loop Tension BYTE Data OPT Read Write 0 Unwind 1 Rewind 0xBE Core Offset FLOAT Data OPT Read Write 20 0 100 0 0xC0 Actaul Tension Setpoint Percent FLOAT None OPT Read Only 0 0 100 0 0xC2 Actual Tension Percent FLOAT None OPT Read Only 0 0 100 0 0xC4 Initial Screen Open Loop Ten...

Page 58: ... 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 calib...

Page 59: ...to 10K ohm potentiometer Manual Setpoint 0 to 10 VDC 0 25 mADC maximum or 1K to 10K ohm potentiometer Position Setpoint 0 to 10 VDC 0 25 mADC maximum or 1K to 10K ohm potentiometer Dancer Input 0 to 10 VDC 0 25 mADC maximum or 1K to 10K ohm potentiometer Diameter Input 0 to 10 VDC 0 25 mADC maximum E Stop switch closure or 5 VDC or 24 VDC active High Low logic 8 mADC maximum Run Stop switch closur...

Page 60: ...ales maxcess eu www maxcess eu CHINA Tel 86 756 881 9398 Fax 86 756 881 9393 info maxcessintl com cn www maxcessintl com cn INDIA Tel 91 22 27602633 Fax 91 22 27602634 india maxcessintl com www maxcess in JAPAN Tel 81 43 421 1622 Fax 81 43 421 2895 japan maxcessintl com www maxcess jp KOREA TAIWAN AND SE ASIA asia maxcessintl com www maxcess asia 2015 Maxcess ...

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