Maxcess MAGPOWR Spyder-Plus-S1 Instruction Manual
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Maxcess MAGPOWR Spyder-Plus-S1 Instruction Manual

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MAGPOWR TENSION CONTROL
Spyder-Plus-S1
Tension Control
Instruction Manual

Figure 1. Spyder-Plus-S1

EN
MI 850A351 1 C

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Summary of Contents for Maxcess MAGPOWR Spyder-Plus-S1

  • Page 1: Figure 1. Spyder-Plus-S1

    MAGPOWR TENSION CONTROL Spyder-Plus-S1 Tension Control Instruction Manual Figure 1. Spyder-Plus-S1 MI 850A351 1 C...

  • Page 3: About The Spyder-Plus-S1

    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.

  • Page 4: Table Of Contents

    Taper Tension Setup ....................... 39 Calibrate Inputs (Load cell and Open Loop Tension only) ............40 Calibrate Outputs ........................40 Security Lockout ........................41 Parameters Menu ........................41 www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 4 of 68...
  • Page 5 13.2 Reset All Parameters Except Calibrations to Defaults ............67 13.3 Reset All Parameters to Defaults (Including Calibrations) ............67 13.4 Download Software ......................... 67 14.0 SPECIFICATIONS www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 5 of 68...
  • Page 6 Figure 18. Open Loop Tension Control Diagram ..................38 Figure 19. Spyder Status web page......................59 Figure 20. Spyder Configuration web page ....................59 Figure 21. Example Edit Value Web Pages ....................59 www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 6 of 68...

  • Page 7: Spyder-Plus-S1 Basic Setup

    9. Basic set-up is complete. Additional features and options are described later in this manual. Always use the RUN/STOP feature to put the Spyder into HOLD mode whenever the machine is stopped to avoid a possible high-tension condition during start-up. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 7 of 68...

  • Page 8: Dancer

    For Dancer, Torque use the Hold Level screen to output a value of torque to prevent the dancer arm from moving during Hold. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 8 of 68...

  • Page 9: Open Loop Tension Based On Diameter

    9. Basic set-up is complete. Additional features and options are described later in this manual. Always use the RUN/STOP feature to activate inertia compensation during stopping. See Section 9.6.8. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 9 of 68...

  • Page 10: Installation

    5 8 .4 [2 .3 0 ] 1 5 7 [6 .1 8 ] 3 5 .2 [1 .3 9 ] 8 5 .8 [3 .3 8 ] Figure 2. Outline Dimensions www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 10 of 68...

  • Page 11: Maintenance

     (down) arrow key to scroll through System Type, Output Range, Setpoint Source, Digital Input Active, Numeric Rate, Bar Graph Rate, and Contrast. The  (up) arrow key usually returns to the previous screen. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 11 of 68...

  • Page 12: System Setup

    100%. On all other systems the output goes to zero. E-STOP overrides Manual mode and Tension Off. 5.2.3 AUTO/MANUAL (Load cell systems and Open Loop Tension systems) www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 12 of 68...

  • Page 13: Analog Outputs

    10 VDC. An input voltage of 0 volts is equal to a diameter of 0. See Section 6.6 (Load Cell), 7.4.3 (Dancer) or 8.3 (Open Loop Tension) for calibrating diameter. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 13 of 68...

  • Page 14: Tension Control

    CORE TENSION (With taper tension) Display only. This is the setpoint at core diameter only. At other diameters the setpoint is less than the core setpoint if Taper Percent > 0. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 14 of 68...

  • Page 15: Figure 5. Basic Load Cell System Connections

    The lower left character displays the status of the Spyder. See Section 6.2.1.1 for description of the status character. Figure 5. Basic Load Cell System Connections www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 15 of 68...
  • Page 16 –10 to +10 VDC range, select –10 V to +10 V. The software is factory calibrated for the 0-10 VDC and the -10 to +10 VDC output ranges. See Section 9.4 for recalibrating the output when using the 4-20 mADC range. See Figure 4 for jumper settings. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 16 of 68...

  • Page 17: Figure 6. Load Cell System Types

    This parameter controls the filtering for the bar graph actual tension and the actual output displays. Default values work well in most applications. 6.2.2.12 SCREEN CONTRAST Adjusts the screen contrast. See Section 10.1, General Problems, when screen shows no characters. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 17 of 68...

  • Page 18: Load Cell Calibration (Required)

    By doing so the system is tuned to be as responsive as possible and still remain stable throughout its range of operation. See Section 6.4.2. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 18 of 68...
  • Page 19 Navigate to the Tuning menu and press . For point to point systems this yields the screen: The Spyder should be optimized in the order shown. See Section 6.4.3 for a typical tuning screen. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 19 of 68...

  • Page 20: Diameter Calibration

    Press the  key to finish diameter calibration. The Present Diameter screen actively displays the diameter. The Present Diameter screen is also available from the Operator menu. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 20 of 68...

  • Page 21: Inertia Compensation

    Inertia Set-up menu. The calibration for output versus torque does not need to be calibrated again. 6.7 LOAD CELL CONNECTIONS Figure 8. Load Cell Connections for One or Two Load Cells www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 21 of 68...

  • Page 22: Load Cell System Complete Wiring

    6.0 TENSION CONTROL 6.8 LOAD CELL SYSTEM COMPLETE WIRING Figure 9. Complete Load Cell System Wiring 6.9 LOAD CELL CONTROL DIAGRAM Figure 10. Load Cell Control Diagram www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 22 of 68...

  • Page 23: Dancer Control

    24 VDC power input is Earth ground referenced. See Figure 12 and Section 7.3 for connecting the DFP or DFP-2 (Dancer Follower Potentiometers) according to the Dancer system types. Figure 11. Basic Dancer Wiring www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 23 of 68...

  • Page 24: Software Configuration For Dancer System

    0 to 100%. The lower left character displays the status of the Spyder. = E-Stop = Hold = Start = Automatic (Run) = Stop = Tension OFF www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 24 of 68...
  • Page 25 Enables Inertia Compensation in Dancer, Torque mode. Dancer, Speed does not have inertia compensation. See section 9.6.12 for calibrating inertia compensation. Inertia compensation can be used with and without a diameter input signal. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 25 of 68...

  • Page 26: Dancer Input Setup (Required)

    Figure 12. If the dancer voltage is opposite that shown in the figure, simply swap the wires on Term. 39 and Term. 26. This will reverse the dancer voltage change. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 26 of 68...

  • Page 27: Dancer Calibration (Required)

    Diameter input CALIBRATION (Required for Diameter options) Diameter must be calibrated when using the Diameter based options of inertia, hold level changes with, and gain compensated control. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 27 of 68...

  • Page 28: Tuning (Required)

    If Unstable text until the system is stable. If the system is stable then press the arrow key associated with the text If Now Stable or Done. Two types of screens will appear while performing the Quick Stabilize tuning: See 7.5.1.1 Quick Stabilize, Integrator Test www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 28 of 68...
  • Page 29 If the tuning procedures fail to produce a stable system it may be necessary to manually decrease the Error Limit parameter. The system can be made less responsive by decreasing the Error Limit. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 29 of 68...
  • Page 30 The Spyder should be optimized at core (PI tuning) only after it has been optimized at full roll. On unwinds Quick Stab may be needed to keep the system stable while an initial roll is unwound. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 30 of 68...

  • Page 31: Tuning (Dancer, Torque With Diameter)

    The Spyder should be optimized at or near full roll first. Press  to optimize P at full roll. The Spyder should be optimized at core only after it has been optimized at full roll. Press  to optimize Mc, (Stop Torque Ratio) at core. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 31 of 68...

  • Page 32: Control Diagram - Dancer, Torque With No Diameter

    There is a table in section 9.6.6 showing default values of proportional, integrator, derivative, error limit and stop torque ratio for each type control type. 7.7 CONTROL DIAGRAM – DANCER, TORQUE WITH NO DIAMETER Figure 13. Dancer, Torque with No Diameter Control Diagram www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 32 of 68...

  • Page 33: Control Diagram - Dancer, Torque With Diameter

    7.8 CONTROL DIAGRAM – DANCER, TORQUE WITH DIAMETER Figure 14. Dancer, Torque with Diameter Control Diagram 7.9 CONTROL DIAGRAM – DANCER, SPEED Figure 15. Dancer, Speed Control with or without Diameter Diagram www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 33 of 68...

  • Page 34: Figure 16. Complete Dancer System Wiring

    7.0 DANCER CONTROL 7.10 Dancer System Complete Wiring Figure 16. Complete Dancer System Wiring www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 34 of 68...

  • Page 35: Open Loop Tension Control Based On Diameter

    CORE TENSION (With taper tension) Display only. This is the setpoint at core diameter only. At other diameters the setpoint is less than the core setpoint if Taper Percent > 0. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 35 of 68...

  • Page 36: Figure 17. Complete Open Loop Tension System Wiring

    The lower left character displays the status of the Spyder. See Section 8.2.1.1 for description of the status character. Figure 17. Complete Open Loop Tension System Wiring www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 36 of 68...
  • Page 37 This parameter controls the filtering for the bar graph actual tension and the actual output displays. Default values work well in most applications. 8.2.2.11 SCREEN CONTRAST This screen allows adjustment of the screen contrast. See Section 10.1, General Problems, when screen shows no characters. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 37 of 68...

  • Page 38: Diameter Calibration (Required)

    Basic setup of the open loop tension system is now complete. See Section 9.0 for optional settings. 8.5 OPEN LOOP TENSION CONTROL DIAGRAM Figure 18. Open Loop Tension Control Diagram www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 38 of 68...

  • Page 39: Optional Functions

    Percent (Section 6.2.1.3) must be set to 0 (zero) to calibrate taper. Enter the present diameter. This should be the present diameter of the roll. The Spyder must be in Run mode. Press  to finish the calibration. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 39 of 68...

  • Page 40: Calibrate Inputs (Load Cell And Open Loop Tension Only)

    METER 100% CAL Use the  and  keys to adjust the meter output on Term.33 and Term.34 to 1 mADC or 10 VDC. Press  when finished. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 40 of 68...

  • Page 41: Security Lockout

    System System Proportional Integrator 2.0 Seconds 2.0 Seconds 2.5 Seconds 2.0 Seconds Derivative 1.25 Seconds 0.625 Seconds Error Limit 100% 100% 100% 100% Stop Torque Ratio 1.0% www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 41 of 68...
  • Page 42 9.6.17 FULL ROLL DIAMETER (Dancer Torque and Open Loop Tension only) In the parameters menu, enter the full roll diameter of the roll. Used by the control loop and for taper tension. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 42 of 68...

  • Page 43: Troubleshooting

    Spyder is in Auto mode. tension/position control system is open loop. If the tension/position is even slightly above Setpoint, the Spyder will turn full off attempting to correct the tension/position. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 43 of 68...

  • Page 44: Tuning Problems (Load Cell Control)

    When the message appears retune P at the core” repeatedly appears at some intermediate roll present diameter rather than at core. diameter than it is at core. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 44 of 68...

  • Page 45: Tuning Problems (Dancer Control)

    For Dancer, Torque with Diameter systems (gain compensated dancer) the control is always in PID mode. Increase the stop torque ratio if position does not correct near core diameter. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 45 of 68...

  • Page 46: Load Cell Calibration Problems

    There may be a short between Term.23 and Term.23. This message also appears if the calibration load was never applied to the sensing roll. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 46 of 68...

  • Page 47: Load Cell Diagnostic Voltages

    TERM.26 (P-) to TERM.24 (S-) leg open (TERM.25 (P+) and TERM.23 (S+) reversed) or (TERM.26 (P-) and TERM.24 (S-) reversed) (TERM.25 (P+) and TERM.24 (S-) reversed) or (TERM.26 (P-) and TERM.23 (S+) reversed) www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 47 of 68...

  • Page 48: Screen Definitions, Alphabetical List

    Used to select whether the Tension input or the Manual input will be calibrated. Use  or  to select the input to calibrate. Cal Setpoint Input  Manual  www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 48 of 68...
  • Page 49 Parameters menu, but that is not recommended. Core WK^2 From the Inertia Setup menu for load cell systems. Enter the core inertia used for inertia setup. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 49 of 68...
  • Page 50 Spyder switches to Hold Mode when the Run/Stop Input is opened. Hold Mode only occurs in while in Auto. Hold mode is delayed Stop Time seconds after the Run/Stop input is opened. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 50 of 68...
  • Page 51 See load cell manual. A load cell calibration error message. See Load Cell Calibration Load cells are overloaded. Problems in Section 10.4. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 51 of 68...
  • Page 52 See Load Cell Calibration Problems in Section 10.4. Output 0% CAL From the Recal Outputs menu. Used to calibrate the control output (Term.30 to Term.31) when 0% output is commanded. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 52 of 68...
  • Page 53 Quick Stabilize has stabilized the system while I is being adjusted. Retune the system at the present diameter and then retune P when the system is again at core. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 53 of 68...
  • Page 54 Tension Input (Term.16 to Term.17) or by the Ethernet connection. The source of the setpoint tension is determined by Setpoint Source in the Configure menu. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 54 of 68...
  • Page 55 When a tuning parameter is adjusted to its most stable value and the system is still unstable, the Spyder automatically switches to Quick Stab so that the other parameters are tuned in the correct order. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 55 of 68...
  • Page 56 DHCP server. If NO is selected, IP Address, Gateway Address and Subnet Mask must be configured. Use Inertia Comp From the Configure menu. Select “Yes” to enable inertia compensation during the stop time. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 56 of 68...
  • Page 57 Open Loop Tension control. Select Yes to enable taper tension. Velocity Units From the Preferences menu for Load Cell control. Select the desired units for Maximum Velocity. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 57 of 68...

  • Page 58: Communication (Optional)

    Parameter values that are editable will be shown with a standard web page link. Parameters which are not editable will not have a link. Example: http://192.168.1.100 www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 58 of 68...

  • Page 59: Figure 19. Spyder Status Web Page

    When the new value has been entered click on the Submit button. Examples: Figure 21. Example Edit Value Web Pages www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 59 of 68...

  • Page 60: Update Software Via Ftp Site

    For downloading Spyder software from a local FTP server running on a local PC you can get the SpyderWare installation kit from the Maxcess website. This kit will install an FTP server on a Windows PC which can be used to download software to the Spyder.

  • Page 61: Modbus/Tcp Communication

    These two configuration parameters are in the Network menu. The default is Most Significant Byte first and Most Significant Word first. Note: Strings are always transmitted left most character first. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 61 of 68...

  • Page 62: Modbus Parameter List

    FLOAT { 0.0 - 99999.0 } lb. DTD, DS Write LC, DTND, Read / 0x4A Applied Tension FLOAT { 0.0 - 99999.0 } lb. DTD, DS Write www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 62 of 68...
  • Page 63 Load Cell Offset UINT16 { 0 - 4095 } DTD, DS Write LC, DTND, Read / 0x7A Applied Tension Binary UINT16 { 0 - 4095 } DTD, DS Write www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 63 of 68...
  • Page 64 Only xxx = High Word yyy = Low Word LC, DTND, Read / 0xB3 Modbus Address UINT16 Data { 0 - 255 } DTD, DS, OPT Write www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 64 of 68...
  • Page 65 Read/ { 0.0 – 99999.0 } 0xDA Inertia Core WK^2 FLOAT Data Write Read/ { 0.0 – 9999.0 } 0xDC Inertia Full Roll Diameter FLOAT Data Write www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 65 of 68...

  • Page 66: Modbus Master Program

    5. Unzip this file and run the SMM.exe file. Use the Configure screen to set up IP address of the Spyder, update rate and Spyder Program Number. The Spyder program number is displayed on the Spyder for a few seconds after applying power. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 66 of 68...

  • Page 67: Reset Functions

    To download new software hold down the  and  keys while turning on power and hold the keys until the display shows "Update Software". See Section 12.4 for software updating. www.maxcessintl.com MAGPOWR Spyder-Plus-S1 Tension Control MI 850A351 1 C Page 67 of 68...

  • Page 68: Specifications

    AND AFRICA AND SE ASIA Tel +1.405.755.1600 Tel +86.756.881.9398 Tel +91.22.27602633 Tel +81.43.421.1622 Tel +49.6195.7002.0 asia@maxcessintl.com Fax +1.405.755.8425 Fax +86.756.881.9393 Fax +91.22.27602634 Fax +81.43.421.2895 Fax +49.6195.7002.933 www.maxcess.asia sales@maxcessintl.com info@maxcessintl.com.cn india@maxcessintl.com japan@maxcessintl.com sales@maxcess.eu www.maxcessintl.com www.maxcessintl.com.cn www.maxcess.in www.maxcess.jp www.maxcess.eu © 2020 Maxcess...

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