Warner Electric X2DRV User manual

X2DRV
Installation & Operation Manual
Introduction:
The x2DRV
is a solid state electronic control that will accept a variety of input signals and provides to the brake an output current a
proportional to the input. This double channel driver can be operated by a remote potentiometer, a voltage or a current
The x2DRV is a
2 VDC double channel driver, Amps current capability.
When associated with an xCTRL, power supply, Input and (Communication) will be made by the internal connector.
This manual has been designed to cover the full range of
Tension control system X2DRV
Installation & Operation Manual
Installation & Operation Manual
is a solid state electronic control that will accept a variety of input signals and provides to the brake an output current a
proportional to the input. This double channel driver can be operated by a remote potentiometer, a voltage or a current
2 VDC double channel driver, Amps current capability.
When associated with an xCTRL, power supply, Input and (Communication) will be made by the internal connector.
This manual has been designed to cover the full range of
installation, start-
up and operation of your tension control system.
Figure 1:x2DRV housing dimensions
29/08/2012
Page 1 of 5
is a solid state electronic control that will accept a variety of input signals and provides to the brake an output current a
nd voltage
proportional to the input. This double channel driver can be operated by a remote potentiometer, a voltage or a current
loop input.
When associated with an xCTRL, power supply, Input and (Communication) will be made by the internal connector.
up and operation of your tension control system.

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X2DRV Installation & Operation Manual Page 2 of 5
Ratings:
Main Supply Voltage (V)
2 V DC
+/
-
5%
Output
A with Anti Residual
Operating T°
-
10°C to 50°C no
Condensation
ompliance
General information:
Control chassis should be kept clear of all areas where foreign material, dust, grease, or all might affect the operation of the control.
Installation must be made in accordance with the instructions found in this manual. Failure to do so may damage the Driver.
This driver supports the following Warner brakes : TB’s, ATT’s, MPB’s, MPC’s. POB’s, POC’s and MTB’s brakes cannot be driven by this device.
Installation instructions:
Hardware Pin Out:
1 BK1+ Power Output
Brake
1
Output +
Integrated Anti-residual control. Voltage or Current controlled.
2 BK1- Power Output
Brake
1
Output
–
3 BK2+ Power Output
Brake
2
Output +
Integrated Anti-residual control. Voltage or Current controlled.
BK2- Power Output
Brake
2
Output
–
5 ON1 Analog input
F
ull
power :
2 VDC
applied
to brake
1
Active low / GND: NPN type Input
6 OFF1 Analog input
Power Off
brake
1 : 0
V
applied
to brake
1
with anti
-
residual
Active low /GND: NPN type Input
7
Gnd
Ground
8 ON2 Analog input
Full power : 2 VDC applied to brake 2
Active low /GND: NPN type Input
9 OFF2 Analog input
Power Off brake 2 : 0V applied to brake 2 with anti
-
residual
Active low /GND: NPN type Input
10
Gnd
Ground
11 InBK1 Analog input
Brake 1
Input signal control.
Selectable: 0/+10V DC or /20mA.
12
Gnd
Ground
13 Ana1 Analog input
Brake 1 Auxiliary input : T
o compensate
Brake1 signal in Open Loop control
Selectable: 0/+10V DC or /20mA.
Teachable Span (item 9 page ).
1
Gnd
Ground
15 10V Power out
External
interface P
ower Supply.
1
0VDC, 100mA Output
Used to Power an external potentiometer to get an Open Loop control (local torque
adjust)
16
Gnd
Ground
17 InBK2 Analog input
Brake 2 Input signal control.
Selectable: 0/+10V DC or /20mA.
18
Gnd
Ground
19 Ana2 Analog input
Brake 2 Auxiliary input : To compensate Brake2 signal in Open Loop control
Selectable: 0/+10V DC or /20mA.
Teachable Span (item 9 page ).
20
Gnd
Ground
21 10V Power out
External
interface Power Supply. 10VDC, 100mA.
Used to Power an external potentiometer to get an Open Loop control (local torque
adjust)
22
Gnd
Ground
23
2 V
Power supply
2 V
DC
Power supply
Input
2
GND
Ground
GROUND

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X2DRV Installation & Operation Manual Page 3 of 5
This installation and Operating Manual has been arranged for the systematic installation and start-up of your Tension Control System. Please
check off each step before proceeding to the next step.
System Wiring and setting:
WARNING: Contact with electrical voltages present in the driver covered in this manual can cause injury. To avoid these consequences, make
sure all power is off during installation.
These wiring precautions will help you properly install and wire a trouble-free system.
1. Use proper gauge wire for all pin :
-Data input : 0,5mm² (20AWG) or 0,75mm² (18AWG)
-Brakes wires : 0,75mm² (18AWG) or 1mm² (17AWG)
2. Shielded cable is recommended for all connections
3. Do not use this driver for purposes other than those intended. Such use could damage the driver
Wiring:
1. Wire 2 V DC input power to pin 2 V as shown figure 3
24V
GND
2. Connect wiring from brake magnets to Pin BK1 and/or BK2 of the x2DRV as shown figure 2
3. Select the Input type with the red switches located along the bottom of the control:
Off: -20mA INPUT
On: 0-10V INPUT (Default)
. Select the Output type with the red switches located along the bottom of the control:
V/I Off: Output controlled in Voltage: 0-10VDC or -20mA IN => 0-2 VDC OUT (Default)
V/I On: Output controlled in Current: 0-10VDC or -20mA IN => 0- A OUT
BK2+
BK2
-
ON2
OFF2
Gnd
InBK2
Gnd
Ana2
Gnd
10V
Gnd
BK1+
BK1-
ON1
OFF1
Gnd
InBK1
Gnd
Ana1
Gnd
10V
Gnd
InBK1 InBK2 An1 An2
V/I F1 F2
Not
used
Power Supply +2 VDC
Power
Supply Ground
Figure 3: Power supply wiring
Default
: 0
-
10V INPUT
Default
: 0
-
2 V OUTPUT
CAUTION: Improperl
y setting the
2 VDC can damage the power
supply and/or the driver
On
Off
Figure 2: x2DRV wiring – one or two brakes
Brake 1 or 2
Brake Input signal control
Brake Auxiliary input
External interface Power Supply
ON: Full power: 2 VD
C applied to brake, NPN type Input
OFF: Power Off brake 1: 0V applied to brake with anti-residual, NPN type Input
GND
GND
GND
Connected to an
External
Control
or PLC
Connected to an
External
Control or PLC
Connected to a
Potentiometer 1 or 2, others
On
Off

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X2DRV Installation & Operation Manual Page of 5
5. Wire Controller or PLC (0-10V or -20mA Input) to pin InBK1 or InBK2 as shown figure
6. Set the Anti-residual with the white screw as shown figure as describe below:
. (Optional): Pins ON1, OFF1, ON2, OFF2 are NPN type Input:
-When ON (1 or 2) is set to Ground => 24V is applied on BK (1 or 2) output
-When OFF (1 or 2) is set to Ground => 0V with Anti-residual is applied on BK (1 or 2) output
8. (Optional): To get an Open Loop control use the external interface power supply (10V DC) as shown figure 2 to supply a
potentiometer or others as describe figure 5.
9. Auxiliary Analog Sensor (Teac able Span)
In case of use an analog sensor or two, wire them to Pin Ana1 or Ana2 and teach their voltage or current span with starting the
calibration as describe below (for this use the button Cal as shown figure 6). If no calibration is done, Ana1 or Ana2 are ignored.
The Analog Input (Ana) compensates the Brake Input signal control (InBK) between 20-100%.
To Disable Ana1 or Ana2 compensation, please calibrate Ana 1 or 2 wit out any connection (unplugged).
Figure 5
:
Typical Open Loop application with
diameter compensation
a.
Apply the brake at 0V or mA on InBK (1 or 2) or
activate the Brake
-
Off (OFF1 or
OFF2)
b. Check the Brake armature floats away from the Brake magnet with no sticking
c. If the armature sticks to the magnet, set the Anti-Residual (AntiR1 or AntiR2) as
shown below until the armature is free with no sticking
d. Reapply the Brake at 10V or 20mA on InBK (1 or 2) or by returning the Brake-Off
(OFF1 or 2) Pin to its normal position and activating the Brake-On input (ON1 or
2)
e. If Brake releases freely, make no further adjustments as the Anti-Residual is
now set
X2DRV
InBK Gnd 10VDC
Ana
Potentiometer
Modulation
between 20-100%
Turn the trim pot clockwise to
increase the Anti-Residual
Turn the trim pot Counterclockwise to
decrease the Anti-Residual
Figure 4: Anti-residual calibration
AntiR
(1 or 2)
Potentiometer for Anti-residual setting
Anti
-
residual adjustment
Voltage Output versus anti
-
residual co
ntrol
24V
10V
or
20mA
Vout 0-2 V
Vin
0-10V or -20mA
AntiR

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X2DRV Installation & Operation Manual Page 5 of 5
10. (Optional): The frequency adjustment changes the modulation frequency to eliminate brake “hum” or “howl” when the brake is
stationary. The frequency is factory set and normally requires no adjustments. Set the frequency as describe below with the red
switches below the chassis:
11. Double check all wiring connections per figure 2 and insure all terminals are tight
Note: If an over-load occurs (current A more) the Driver output will shut down and the red LED will turn ON. To reset the system remove
power to the Driver and turn it on again.
X2DRV Block Diagram:
“Teachable Span” calibration procedure
Step 1
With the Auxiliary wired to Ana1
or Ana2
Press Cal button >5s.
Step 2
Put Min to Ana1 or Ana2
Short press to valid: Min is learnt
Step 3
Put Max to Ana1 or Ana2
Short press to valid: Max is
learnt and calibration is done
Set 0: Between 250 and 750 HZ
Set 1: Between 1000 and 3000 HZ
Set 2: Between 2500 and 7500 HZ
Set 3: Between 250 and 10
K
HZ
(default)
V/I F1 F2
(rd)
Red LED on
(rd)
Slow flashing
F1
F
2
F1
F
2
F1
F
2
F1
F
2
Figure 6: Anti-residual setting and calibration
Short press
Cal
Cal
Short press
Cal
>5s
(rd)
Quick flashing
On
Off
Turn the trim pot clockwise
to increase the frequency
Turn the trim pot
counterclockwise to decrease
Digital
0
-
10V or
-
20mA
Input
Selectable
Power Layers
OUTPUT ontrol:
Pulse width modulated 4 Amps
with Anti-residual Mode
Brake 1
0
-
2 V
or 0
-
A
Brake 2
0
-
2 V
or 0
-
A
Brake 2 ON
Brake 2 OFF
Brake 1 ON
Brake 1 OFF
LED1 State Brake
LED2 State Brake
AntiR1 Anti
-
Res
Potentiometer
AntiR2 Anti
-
Res
Potentiometer
POWER SUPPLY
2 V DC +/- 5%, A
10 VDC out
Tension/Current
Output Control
Frequency
Ana2 0
-
10V
or -20mA
(Teach In)
Ana1 0
-
10V
or -20mA
(Teach In)
InBK2 0
-
10V
or -20mA
InBK1 0
-
10V
or -20mA
Open Loop Digital Control
InBK2
X Gain
Ana2
Prop.2
Calibration
Open Loop Digital Control
In
BK1
X Gain
Ana1
Prop.1
Calibration
Hardware interface
Digital Input (Active low)
Analog Input
Analog Output
Setting
Cal
AntiR
LED
Potentiometer for Anti-residual setting
State LED
Auxiliary Input alibration: Ana1 & Ana2