Magpowr DFC-90 User manual

6.18 [157.0mm]2.30 [58.4mm]
1.39 [35.2mm] 3.38 [85.9mm]
222 W. Memorial Road, Oklahoma City, OK 73126-0508
Phone: [phone] Fax: [phone]
www.magpowr.com E-mail: [e-mail]
INSTRUCTION MANUAL
MODEL DFC-90
DANCER-FOLLOWER ARM CONTROL 90 VDC
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, all rights reserved.
Periodically there will be updates to this manual. The latest version is available at www.magpowr.com or by calling
1-800-MAGPOWR (624-7697).
1.0 Introduction
The MAGPOWR Model DFC-90 is a complete solution for follower arm or dancer control applications. The DFC-90
provides a 90 vdc current regulated output to control electromagnetic clutches and brakes. The DFC-90 also
provides a small reverse current to minimize the drag torque of the clutch / brake.
The Model DFC-90 has four jumper selectable current ranges. Maximum outputs for the individual ranges are
0.125, 0.25, 0.5 and 1.0 adc. The appropriate range is determined by the current rating of the clutch or brake to be
controlled. For best torque control resolution, the lowest current range providing sufficient current for maximum
operating torque should be selected.
Connections are provided for an external 1 madc current meter. The meter display will indicate clutch / brake
output current as a percentage of the output range selected.
The control circuits are electrically isolated from the power circuits.
2.0 Installation
The DFC-90 is intended for installation on a vertical panel using a DIN 35 rail with the wiring terminals facing down.
Figure 1 shows the enclosure dimensions.
Wiring to and from the DFC-90 must be done with double or reinforced insulation or protective screening which
provides protective separation. All wiring should comply with the essential requirements of the appropriate
standard(s) and is the responsibility of the installer.
Route control signal wiring away from AC wiring. Connect shields of shielded cable to the terminals indicated as
“SHIELD”. Maximum shield length and maximum length of wires outside of the shield is 3 in. (75 mm).
Figure 1
Enclosure Dimensions
850A265-1
10/04Rev. D

2
71
JP1
FULL ROLL DIAMETER
CORE DIAMETER
DFP
3.0 Setup
Remove the enclosure top by inserting a flat blade screwdriver under the retaining tabs in the base (See
figure 2). Set the JP1 current range selection jumpers to the range appropriate for the clutch / brake
connected to the DFC-90 (See figure 3 for current range settings). The factory setting is 1/8 amp range.
Replace the enclosure top.
Figure 2 Figure 3
Enclosure Top Removal JP1 Current Range Settings
4.0 Maintenance
The only maintenance that may be required on the DFC-90 is fuse replacement. Replacement of the
fuse(2) requires first removing ac power, then opening the enclosure. The enclosure must be re-installed
to maintain the IP rating. The enclosure may be opened by inserting a flat blade screwdriver under the
retaining tabs in the base (See figure 2).
5.0 Follower Arm Applications
5.1 Electrical Connections
Figure 5 shows the connections that are required for the basic follower arm system. They are:
115 vac power input
90 vdc output for clutch / brake
DFP or DFP-2 roll diameter sensor
10 kohm tension potentiometer
The clutch / brake output and the remote meter output are not isolated from the AC line and must not be
ground referenced. The control inputs are isolated and may be ground referenced.
5.2 Sensor Setup (See Figure 4)
The DFP or DFP-2 position sensor should be at the center of rotation when the follower arm is halfway
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.
Figure 4

3
INCREASING
DFP OR DFP2
1817
STOP
RUN
( OPEN FOR RUN )
INCREASING
10K
DIAMETER
TENSION
TENSION
OPEN FOR RUN
RUN/STOP
CW
L1
OUTPUT METER
L2 +-
90V 1mA POSITION
SHIELD +-
1234567 23
VAC
115
-+
24 25 26
TENSION
SHIELD
19 20 21
+
22
-
OPTIONAL OTHERWISE)
ALLOWED IN
(OPTIONAL)
CLUTCH/
BRAKE
METER
REMOTE
0-1 madc
D.C. OUTPUT
115 vac
50/60 Hz
SWITCH NOT
(REQUIRED FOR
STOP MULTIPLIER,
DFP
Install the DFP sensor so that its keyway is pointing towards the top cover when the follower arm is
half way through its travel.
DFP-2
To find the electrical center point of pot rotation, use a digital multimeter type ohm meter to measure
from the white wire (wiper), to the red or black wire. Turn the potentiometer shaft until the meter
reads 500 ohm. Install the DFP-2 sensor so that at the 500 ohm meter reading, the follower arm is
halfway through its travel.
Figure 5
Follower Arm Electrical Connections
5.3 Follower Arm Control Setup
The control adjustments marked with an underline on the label are the only ones needed for follower arm
adjustment (see Figure 6). Stop time and Stop multiplier apply to all operating modes and are not
distinctively marked.
Figure 6

4
1) Set the following switch and 22-turn potentiometers to the settings given below:
switch F
ZERO full Counter Clockwise
FULL full Clockwise
Dfull Counter Clockwise
CORE full Counter Clockwise
STOP TIME full Counter Clockwise
STOP MULT full Counter Clockwise
2) Set the external TENSION pot full Clockwise.
3) Position the follower arm on an empty core.
4) Adjust the CORE pot to obtain zero on the remote meter.
5) Adjust the ZERO pot until the meter just starts to increase, and then reverse adjustment direction to
just return the meter to zero.
6) From published torque versus current curves adjust the CORE pot for the desired output current at
core. (Example: y madc to provide xx ft.-lb. at core)
7) Place the follower arm at the full roll position, and adjust the FULL pot to the desired output current at
full roll.
Setup is complete, and the DFC-90 is ready for operation.
Optional adjustments:
Stop Multiplier and Stop Time. The STOP MULT pot can be used to increase the torque while the
machine is stopping. The increased torque is applied when the RUN/STOP input is closed (terminals 17
and 18). The length of time the increased torque is applied is adjusted by the STOP TIME pot. The
STOPPED indicator illuminates when the Stop Time expires.
5.4 Operation
Tension is adjusted using the external 10 kohm tension pot.
Rewind taper can be adjusted using the FULL pot. The tension will decrease as the roll diameter
increases without changing the remote TENSION pot setting. Counter Clockwise rotation of the FULL
pot will decrease the tension at full roll, thereby increasing the amount of taper.
If the stop multiplier function is used, Clockwise rotation of the STOP MULT pot will increase the
stopping torque. Clockwise rotation of the STOP TIME pot will increase the time that the stopping torque
is applied. The STOP TIME may be adjusted from 0.2 to 60 seconds.

5
INCREASING
DFP
1817
STOP
RUN
( OPEN FOR RUN )
LOAD CURRENT
OPEN FOR RUN
RUN/STOP
POSITION
SHIELD +-
23 24 25 26
TENSION
SHIELD
19 20 21
+
22
-
0-1 madc
REMOTE
METER
BRAKE
CLUTCH/
50/60 Hz
115 vac
1mA
METER
L2
115
1
L1
2
VAC
90V
OUTPUT
3
+
4
-
5
+
6
-
7
(OPTIONAL FOR PD)
(OPTIONAL)
SWITCH NOT
ALLOWED IN
D.C. OUTPUT
(REQUIRED FOR PID)
(REQUIRED FOR STOP MULTIPLIER)
6.0 Dancer Applications
6.1 Electrical Connections
Figure 7 shows the connections that are required for the basic dancer system. They are:
115vac power input
90 vdc output for clutch / brake
DFP or DFP-2 dancer position sensor
Install jumper between terminals 20 and 21.
The clutch / brake output and the remote meter output are not isolated from the AC line and must not be
referenced to ground. The control inputs are isolated and may be ground referenced.
Figure 7
Dancer Electrical Connections
6.2 Sensor Setup
The DFP or DFP-2 position sensor should be at the center of rotation when the dancer is halfway
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.
DFP
Install 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.
DFP-2
To find the electrical center point of pot rotation, use a digital multimeter type ohm meter to measure from
the white wire (wiper), to the red or black wire. Turn the potentiometer shaft until the meter reads 500
ohm. Install the DFP-2 sensor so that at the 500 ohm meter reading, the dancer is halfway through its
travel.

6
PID
6.3 Dancer Control Setup and Tuning
The controls marked on the label without an underline or box are the only ones needed for dancer
adjustment (see Figure 6). Stop time and Stop multiplier apply to all operation modes and are not
distinctively marked.
1) Set the following switch and 22-turn potentiometers to the settings given below:
switch PD
Pfull Clockwise
Dmid rotation (approximately 11 turns)
CORE full Counter Clockwise
STOP TIME full Counter Clockwise
STOP MULT full Counter Clockwise
2) With the machine running with web, adjust the POS1 pot to center the dancer roll.
3) Adjust the D pot to minimize dancer arm oscillations.
4) If dancer arm oscillations cannot be eliminated, turn the P pot Counter Clockwise and repeat step 3.
Calibration is complete, and the DFC-90 is ready for operation.
Optional Adjustments:
Integrator. Many machines run quite successfully after the above adjustments have been made. If the
dancer arm moves too much while the roll changes size, the integrator can be turned on to keep the
dancer centered.
The control adjustments marked with a box apply to a dancer with integrator.
5) Set the pot full Clockwise.
6) With the machine stopped, set the switch to . This turns the integrator on.
7) Run the machine near full roll and at a slow speed and use the pot to center the dancer.
Clockwise rotation of moves the dancer up, towards an empty dancer condition.
8) Turn the pot Counter Clockwise until the dancer begins to oscillate around the setpoint position.
Then, turn the pot Clockwise until the oscillation stops.
The RUN/STOP input must be used if the integrator is on (switch in position). The RUN/STOP input
should be closed (terminals 17 and 18) when the machine starts its deceleration. The DFC-90 keeps the
integrator on until Stop Time expires. Stop Time may be increased by Clockwise rotation of the STOP
TIME pot. The STOPPED indicator lights when the Stop Time expires. While the STOPPED indicator is
lit the DFC-90 provides a hold level current to the clutch / brake. This hold level may be adjusted by
turning the pot.
Stop Multiplier and Stop Time. Even if integrator mode is not used, the STOP MULT pot can be used to
increase the torque while the machine is stopping. The increased torque is applied when the RUN/STOP
input is closed (terminals 17 and 18). The length of time the increased torque is applied is adjusted by
the STOP TIME pot. Using the stop multiplier feature in dancer mode could cause the dancer to oscillate
while the machine is stopping.
POS2
POS2
I
I
PID
HOLD
I

7
7.0 Optional Dancer Optimization
After tuning of the dancer, the following method will usually optimize the stability and responsiveness of
the dancer. The method begins by placing the dancer in PD mode with a roll diameter near core and
reducing the gain to a level which the user may consider unacceptable. Gain will subsequently be
increased to a more desirable level. If using PID mode, the dancer is placed in PID mode with a roll
diameter near full roll and the integrator is reduced to a level which the user may consider unacceptable.
Then, the integrator will be increased to a more desirable level. Sometimes, it may be necessary to first
make the PD mode adjustment at a larger roll diameter, and then refine the adjustment near core.
Do not switch between PD/ PID while the machine is running since this may result in a large transient
jump in the output.
1) With a roll diameter near core and the machine stopped, set the switch to PD mode.
2) Run the machine and adjust the POS1 pot to center the dancer arm.
3) Decrease the P pot by rotating Counter Clockwise until the dancer stabilizes. The POS1 pot may
require readjustment several times in order to keep the dancer roll centered.
DEFINITION: In the following steps the user will have to determine if the dancer is overshooting. To do
this, move the stable dancer away from its set position by pushing on the dancer, by bumping the
unwind/rewind roll, or by some similar means. If the dancer goes past the set position before settling to
the set position, it is overshooting. If the dancer goes straight to the stable position without going past it,
the dancer is not overshooting.
4) Increase the P pot by rotating Clockwise in small steps checking for dancer overshoot at each step.
Do this until overshoot is obtained.
5) Adjust the D pot in small steps checking for dancer overshoot at each step. Do this until the
overshoot is eliminated. The direction to adjust D for no overshoot is system dependent.
6) Repeat steps (4) and (5) until the overshoot cannot be eliminated using the Dpot, or until the P pot is
full Clockwise.
7) Decrease the P pot by the amount necessary to eliminate the overshoot.
Adjustment is now complete for the dancer operating in PD mode. The next steps complete the tuning of
the dancer operating in PID mode.
8) With a roll diameter near full roll and the machine stopped, set the mode switch to PID.
9) Run the machine and adjust the pot to center the dancer roll.
10) Decrease the pot by rotating Counter Clockwise in small steps checking for dancer overshoot at
each step. Do this until overshoot is obtained.
11) Increase the pot by the amount necessary to eliminate the overshoot.
Adjustment is now complete for the dancer operating in PID mode.
POS2
I
I

8
8.0 Follower Arm/ Dancer Options
The DFC-90 is factory adjusted to provide full reverse current with 0 vdc input. If some other current is
desired with 0 vdc input, the minimum current potentiometer may be adjusted by cutting out the hole
shown on the label and then using a trimpot adjustment tool. Modifying this setting will cause the clutch /
brake drag torque to be higher than expected and is not recommended.
9.0 Troubleshooting
9.1 Follower Arm Applications
Symptom Possible Cause Solution or Diagnostic
No AC power. Verify incoming power is correct
voltage and frequency.
Fuses blown. Clutch / Brake wires shorted together
or shorted to ground.
Clutch / Brake wires open
circuit. Disconnect clutch / brake wires at the DFC-90 and check for proper clutch /
brake resistance between the wires.
Remote tension adjust
potentiometer turned full
counter clockwise or not
wired properly.
Verify tension pot wiring, turn tension
adjust pot full clockwise and follow
the calibration procedure in section
5.3.
Voltage between terminals 20(+) and
22(-) should be greater than zero and
should change as the DFP or DFP-2
is moved through its travel.
Remote tension
potentiometer resistance is
less than 10 kohms.
Use a 10 kohm potentiometer for the
Remote tension control.
DFP, DFP-2 position sensor
not wired properly or wires
shorted.
Verify position sensor is wired
properly and follow the calibration
procedure in section 5.3.
Voltage between terminals 24 and 26
should be 10 vdc.
Voltage between terminals 25 and 26
should change as the DFP or DFP-2
is moved through its travel.
No clutch / brake
output.
Follower Arm not calibrated. Follow the calibration procedure in
section 5.3.
RUN/STOP switch not
connected or not wired
properly.
Verify RUN/STOP switch wiring.
Clutch / Brake
output does not
increase during
stop time. STOP MULTiplier
potentiometer not set
properly.
Turn STOP MULT potentiometer
clockwise to increase the stopping
torque.
Incorrect type of meter. Meter should be a current meter with
1 ma full scale and no more than 3
Kohm resistance.
Remote meter
not working.
Meter wires shorted or open. Disconnect meter wiring at the DFC-
90 and check for proper meter
resistance between the wires.

9
9.2 Dancer Applications
Symptom Possible Cause Solution or Diagnostic
No AC power. Verify incoming power is correct
voltage and frequency.
Fuses blown. Clutch / Brake wires shorted together
or shorted to ground.
Clutch / Brake wires open
circuit.
Disconnect clutch / brake wires at the
DFC-90 and check for proper clutch /
brake resistance between the wires.
No clutch / brake
output.
Jumper not installed
between 20 and 21.
Install jumper between terminals 20
and 21.
DFP or DFP-2 sensor not
wired properly or wires
shorted.
Verify DFP or DFP-2 sensor is wired
properly and follow the calibration
procedure in section 6.3.
Voltage between terminals 24 and 26
should be 10 vdc.
Voltage between terminals 25 and 26
should change as the DFP or DFP-2
is moved through its travel.
Dancer not calibrated. Follow the calibration procedure in
section 6.3.
Clutch / Brake
output full on or full
off.
DFC-90 in PID mode and
RUN/STOP switch is not
wired properly.
Verify RUN/STOP switch wiring. PID
mode needs a RUN/STOP switch for
proper operation.
RUN/STOP switch not
connected or not wired
properly.
Verify RUN/STOP switch wiring.Clutch / Brake
output does not
increase during
stop time. STOP MULTiplier
potentiometer not set
properly.
Turn STOP MULT potentiometer
clockwise to increase the stopping
torque.
Dancer arm hunting
during stopping.
STOP MULTiplier is being
used.
Turn STOP MULT potentiometer
counter clockwise to decrease the
hunting during stopping. See Stop
Multiplier note at end of section 6.3.
Incorrect type of meter. Meter should be a current meter with
1 ma full scale and no more than
3 kohm resistance.
Remote meter not
working.
Meter wires shorted or
open.
Disconnect meter wiring at the DFC-
90 and check for proper meter
resistance between the wires.

10.0 Specifications
Supply Voltage: 115vac, +/- 10%, 50/60 Hz, 1.1 amp maximum, sinusoidal
Fuses: F1, F2 1.6 amp, Littelfuse Part No. 21601.6, or
Wickmann Part No. 19194-053-FS
Enclosure: IP20
Climatic Class: 3K3 (EN60721)
Temperature Range:
Operating: 0° C to 50° C
Storage: -30° C to 80° C
Relative Humidity: 5% to 85%
Pollution Degree: 2 (IEC664-1)
Altitude: 0 to 2000 m
Compatible Residual Current
Device Types: A or B (IEC755)
Worst Case Fault Current: 1.6 amp ac
Inputs:
Signal: DFP or DFP-2 Potentiometer: 1 to 10 kohm, ¼ watt minimum
Tension Potentiometer: 10 kohm minimum, ¼ watt minimum
RUN/STOP: Contact closure, 30 ohm maximum, 0.2 vdc maximum
Outputs:
Clutch / Brake: Voltage: -3 to 90 vdc, full wave, phase controlled
Current: Adjustable in four ranges:
-0.004 to 0.125 adc
-0.008 to 0.25 adc
-0.016 to 0.5 adc
-0.032 to 1.0 adc
Regulation: < 1% of range
Meter Signal: 0 to 1 madc, +/-2% into 3 kohm maximum
DFP or DFP-2 Reference Voltage: 10v +/-2%, 10 madc maximum