Maxcess MAGPOWR DFC-90 User manual

MAGPOWR DFC-90
Instruction Manual
EN
Dancer-Follower Arm Control
90VDC
MI 850A265 1 G

CONTENTS
www.maxcessintl.com
MAGPOWR DFC-90
MI 850A265 1 G
INTRODUCTION 1-1
About these operating instructions ...................................................................... 1-1
Product overview .................................................................................................. 1-2
Follower arm/dancer options ............................................................................... 1-2
INSTALLATION 2-1
SETUP 3-1
FOLLOWER ARM APPLICATIONS 4-1
Electrical connections........................................................................................... 4-1
Sensor setup ........................................................................................................ 4-1
Control setup ....................................................................................................... 4-2
Operation............................................................................................................. 4-4
DANCER APPLICATIONS 5-1
Electrical connections........................................................................................... 5-1
Sensor setup ........................................................................................................ 5-2
Dancer control setup and tuning.......................................................................... 5-3
Optional dancer optimization............................................................................... 5-5
TROUBLESHOOTING 6-1
Follower arm applications .................................................................................... 6-1
Dancer applications.............................................................................................. 6-2
SPECIFICATIONS 7-1
SERVICE 7-1
Maintenance......................................................................................................... 7-1
Replacement parts ............................................................................................... 7-1

1-1
INTRODUCTION
www.maxcessintl.com
MAGPOWR DFC-90
MI 850A265 1 G
About these
operating
instructions
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 2011, 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 of
this publication.
Language
These are the original instructions, written in English.

1-2
INTRODUCTION
www.maxcessintl.com
MAGPOWR DFC-90
MI 850A265 1 G
Product overview
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.
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.

2-1
INSTALLATION
www.maxcessintl.com
MAGPOWR DFC-90
MI 850A265 1 G
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 75 mm [3.0 inches].
Figure 1. Enclosure dimensions
6.18 [157.0mm]2.30 [58.4mm]
1.39 [35.2mm] 3.38 [85.9mm]

3-1
SETUP
www.maxcessintl.com
MAGPOWR DFC-90
MI 850A265 1 G
Setup
1. Remove the enclosure top by inserting a flat blade screwdriver
under the retaining tabs in the base (See Figure 2).
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 A range.
3. Replace the enclosure top.
Figure 2. Enclosure top removal
Figure 3. JP1 current settings
7 1
JP1

4-1
FOLLOWER ARM APPLICATIONS
www.maxcessintl.com
MAGPOWR DFC-90
MI 850A265 1 G
Follower arm
applications
Electrical connections
Connections required for the basic follower arm system:
115 VAC power input
90 VDC output for clutch/brake
DFP or DFP-2 roll diameter sensor
10kΩtension 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.
See Figure 4.
Sensor setup
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. (See Figure 4.)
Figure 4. Follower arm setup
(continued)
FULL ROLL DIAMETER
CORE DIAMETER
DFP

4-2
FOLLOWER ARM APPLICATIONS
www.maxcessintl.com
MAGPOWR DFC-90
MI 850A265 1 G
Sensor setup
(continued)
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
multi-meter type ohm meter to measure from the white wire
(wiper) to the red or black wire. Turn the potentiometer shaft
until the meter reads 500Ω. Install the DFP-2 sensor so that at
the 500Ω meter reading, the follower arm is halfway through its
travel.
Figure 5. Follower arm electrical connections
Control setup
The control adjustments marked with an underline on the label
are the only ones needed for follower arm adjustment Stop Time
and Stop Multiplier apply to all operating modes and are not
distinctively marked. (See Figure 6 and settings on next page.)
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 +-
1 2 3 4 5 6 7 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,

4-3
FOLLOWER ARM APPLICATIONS
www.maxcessintl.com
MAGPOWR DFC-90
MI 850A265 1 G
Control setup
(continued)
Figure 6. Control adjustments
1. Set the following switch and 22-turn potentiometers to the
settings given below:
Fswitch PD
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.
(continued)

4-4
FOLLOWER ARM APPLICATIONS
www.maxcessintl.com
MAGPOWR DFC-90
MI 850A265 1 G
Control setup
(continued)
Optional adjustments
Stop Multiplier and Stop Time
Use the STOP MULT pot 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). Rotate the STOP TIME pot to
adjust the length of time the increased torque is applied. The
STOPPED indicator illuminates when the Stop Time expires.
Operation
Adjust tension with the external 10kΩtension pot.
Adjust rewind taper with 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.
Stop multiplier function
Rotate the STOP MULT pot clockwise to increase the stopping
torque.
Rotate the STOP TIME pot clockwise to increase the time that the
stopping torque is applied. The STOP TIME may be adjusted from
0.2 to 60 seconds.

5-1
DANCER APPLICATIONS
www.maxcessintl.com
MAGPOWR DFC-90
MI 850A265 1 G
Dancer
applications
Electrical connections
Connections required for the basic dancer system:
115 VAC 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 ground referenced.
The control inputs are isolated and may be ground referenced.
See Figure 7.
Figure 7. Dancer electrical connections
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)

5-2
DANCER APPLICATIONS
www.maxcessintl.com
MAGPOWR DFC-90
MI 850A265 1 G
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
multi-meter type ohm meter to measure from the white wire
(wiper), to the red or black wire. Turn the potentiometer shaft
until the meter reads 500Ω. Install the DFP-2 sensor so that at the
500Ωmeter reading, the dancer is halfway through its travel.

5-3
DANCER APPLICATIONS
www.maxcessintl.com
MAGPOWR DFC-90
MI 850A265 1 G
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 MULT apply to all operation modes and are not
distinctively marked.
1. Set the following switch and 22-turn potentiometers to the
settings given below:
Fswitch 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. The
direction to adjust D to minimize oscillations is system
dependent.
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.

5-4
DANCER APPLICATIONS
www.maxcessintl.com
MAGPOWR DFC-90
MI 850A265 1 G
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.
1. Set the I pot full clockwise.
2. With the machine stopped, set the switch to PID. This turns
the integrator on.
3. Run the machine near full roll and at a slow speed and use the
POS2 pot to center the dancer. Rotate POS2 clockwise to
move the dancer up towards an empty dancer condition.
4. Turn the I pot counter-clockwise until the dancer begins to
oscillate around the setpoint position. Then, turn the I pot
clockwise until the oscillation stops.
The RUN/STOP input must be used if the integrator is on (switch
in PID 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. Increase Stop
Time by rotating the STOP TIME pot clockwise. The STOPPED
indicator lights when the Stop Time expires. While the STOPPED
indicator is illuminated, the DFC-90 provides a hold level current
to the clutch/brake. This hold level may be adjusted by turning
the HOLD 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.

5-5
DANCER APPLICATIONS
www.maxcessintl.com
MAGPOWR DFC-90
MI 850A265 1 G
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
PD mode
1. With a roll diameter near core and the machine stopped, set the
F 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.
(continued)

5-6
DANCER APPLICATIONS
www.maxcessintl.com
MAGPOWR DFC-90
MI 850A265 1 G
Dancer optimization
(continued)
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 D pot, 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.
PID mode
The next steps complete the tuning of the dancer operating in PID
mode.
1. With a roll diameter near full roll and the machine stopped,
set the F switch to PID.
2. Run the machine and adjust the pot to center the dancer roll.
3. Decrease the pot by rotating counter-clockwise in small steps
checking for dancer overshoot at each step. Do this until
overshoot is obtained.
4. Increase the pot by the amount necessary to eliminate the
overshoot.
Adjustment is now complete for the dancer operating in PID mode.

6-1
TROUBLESHOOTING
www.maxcessintl.com
MAGPOWR DFC-90
MI 850A265 1 G
Follower arm applications
Symptom
Possible cause
Solution or diagnostic
No clutch/brake
output
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 beginning on page 4-2.
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 10kΩ
Use a 10kΩpotentiometer 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 beginning on
page 4-2.
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.
Follower Arm not calibrated
Follow the calibration procedure beginning on
page 4-2.
Clutch/brake
output does not
increase during
stop time
RUN/STOP switch not connected
or not wired properly
Verify RUN/STOP switch wiring.
STOP MULTiplier potentiometer
not set properly
Turn STOP MULT potentiometer clockwise to
increase the stopping torque.
Remote meter not
working
Incorrect type of meter
Meter should be a current meter with 1 mA
full scale and no more than 3kΩresistance.
Meter wires shorted or open
Disconnect meter wiring at the DFC-90 and
check for proper meter resistance between the
wires.

6-2
TROUBLESHOOTING
www.maxcessintl.com
MAGPOWR DFC-90
MI 850A265 1 G
Dancer applications
Symptom
Possible Cause
Solution or Diagnostic
No clutch/brake
output
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.
Jumper not installed between
20 and 21
Install jumper between terminals 20 and 21.
Clutch/brake output
full on or full off
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 on page
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.
Dancer not calibrated
Follow the calibration procedure on page 5-3.
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.
Clutch/brake output
does not increase
during stop time
RUN/STOP switch not
connected or not wired
properly
Verify RUN/STOP switch wiring.
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
page 5-4.
Remote meter not
working
Incorrect type of meter
Meter should be a current meter with
1 mA full scale and no more than
3kΩresistance.
Meter wires shorted or open
Disconnect meter wiring at the DFC-90 and
check for proper meter resistance between the
wires.

7-1
SPECIFICATIONS
www.maxcessintl.com
MAGPOWR DFC-90
MI 850A265 1 G
Specifications
Supply voltage
115 VAC, +/- 10%, 50/60 Hz, 1.1 A maximum, sinusoidal
Fuses: F1, F2
1.6 A slow-blow, Littelfuse Part No. 21501.6, or
Cooper-Bussmann Part No. S505-1.6-R
Enclosure
IP 20
Climatic class
3K3 (EN60721)
Temperature range
Operating: 0° C to 50° C [0° F to 122° F]
Storage: -30°C to 80°C [-22° F to 176° F]
Relative humidity
5% to 85%
Pollution degree
2 (IEC664-1)
Altitude
0 to 2000 m [0 to 6562 ft]
Compatible residual
current
Device types: A or B (IEC755)
Worst case fault current
1.6 A AC
Inputs
Signal
DFP or DFP-2 potentiometer: 1 to 10kΩ, 1/4 W minimum
Tension potentiometer: 10kΩminimum, 1/4 W minimum
RUN/STOP
Contact closure, 30Ωmaximum, 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 3kΩmaximum
DFP or DFP-2
reference voltage
10 V +/-2%, 10 mADC maximum

7-1
SERVICE
Maintenance
The only maintenance that may be required on the DFC-90 is
fuse replacement.
1. Shut off AC power to the DFC-90 unit.
2. Remove the enclosure top by inserting a flat blade
screwdriver under the retaining tabs in the base
(See Figure 2, page 3-1).
3. Replace fuse(s).
4. Reinstall the enclosure to maintain the IP rating.
Service requests and
replacement parts
To request service or to get replacement parts, contact one of
the following addresses:
Fife Corporation
222 West Memorial Rd.
Oklahoma City, OK, 73114,
USA
Phone: [phone]
Fax: [phone]
Web: www.maxcessintl.com
Fife-Tidland GmbH
Max-Planck-Strasse 8
65779 Kelkheim OR
Deutschland
Telefon: [phone]
Fax: [phone]
Web: www.maxcess.eu
Siemensstrasse 13-15
48683 Ahaus
Deutschland
AMERICAS
Tel [phone]
Fax [phone]
[e-mail]
www.maxcessintl.com
EUROPE, MIDDLE EAST
AND AFRICA
Tel [phone]
Fax [phone]
[email protected]
www.maxcess.eu
CHINA
Tel [phone]
Fax [phone]
[email protected].cn
www.maxcessintl.com.cn
INDIA
Tel [phone]
Fax [phone]
[e-mail]
www.maxcess.in
JAPAN
Tel [phone]
Fax [phone]
[e-mail]
www.maxcess.jp
KOREA, TAIWAN,
AND SE ASIA
[e-mail]
www.maxcess.asia
© 2018 Maxcess