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INTRODUCTION

www.maxcessintl.com

CYGNUS

MI 850A316 1 B

Page 5 of 66

1.0

Introduction

The MAGPOWR

®

Mo

del CYGNUS™ is a microprocessor-based control designed for precise closed loop tension

control of a moving web. The CYGNUS is capable of controlling web tension in unwind, rewind, or point-to-point
applications in any web press.

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 neither be duplicated nor copied in whole or in part nor
be used for any purpose other than for which disclosed.

Copyright 2004, 2018, all rights reserved.

Periodically there will be updates to this manual. The latest version is available on our website or by calling your
regional office listed on the back page of this publication.

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Содержание Cygnus MAGPOWR

Страница 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...

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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