Maxcess MAGPOWR DFC-90 User manual

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

CONTENTS
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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
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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
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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
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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
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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
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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
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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
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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
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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.