Tension Control System XCTRL & XCTRL-2DRV Installation and Operation Manual P-2097-WE-A4
I. INTRODUCTION....................................................................................................................................................................... 4 II. GENERAL INFORMATION........................................................................................................................................................ 4 III. XCTRL BLOCK DIAGRAM.........................................................................................................................
7. AUXILIARY SENSOR SETTING (ANA INPUT)........................................................................................................................ 26 • AUXILIARY ANALOG INPUT TYPE..................................................................................................................................... 27 • AUXILIARY SENSOR CALIBRATION.................................................................................................................................. 27 8.
I. INTRODUCTION: This control is a solid state electronic control that receives signal from a Dancer pivot point sensor or 2 Load cells and transmits internally the appropriate signals to the brake power driver to regulate a stable tension. It integrates 2 separate Digital PID controllers and 2 separate Open Loop control. Based on a double board architecture, it can integrate a Driver board to control our electromagnetic brakes range.
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IV. Hardware Pin Out 1 SD Card External interface Parameters Savings. Possibility to save up to 8 partitions. 2 USB External interface Use to setup the controller (Input/Output, PID, splice parameters) and to upload and download all parameters to a setup partition. 3 A Digital IN 4 B Digital IN 5 C Digital IN Splice selection inputs.
V. XCTRL-2DRV When working with the XCTRL-2DRV, no wiring between the XCTRL and the X2DRV control board are needed. In fact, the power supply as well as the connections between the analog outputs (OUT1 & OUT2) of the XCTRL and the analog inputs of the X2DRV (InBK1 & InBK2) control boards are internally made. If more information is needed on the standalone X2DRV control, please refer to the ‘X2DRV Installation and Operation Manual’ VI.
Dancer Arm Application: Figure 5: Dancer Arm Application 3. Dancer Arm Wiring Wire Dancer Arm BTCS605-E2 or BTCS 620 to the controller as describe below, use channel 1 or 2. For all generalist wiring refer to figure 2 above. Please refer to the paragraph Input Selection and Setting to setup the XCTRL accordingly. Figure 6: Dancer Arm Wiring 4. Load Cell Wiring Wire Load Cell (not amplified or amplified) to the controller as describe below, use channel 1 and/or 2.
5. Power Supply Wiring Wire 24VDC input power to pin 24V as shown below: CAUTION: Improperly setting the 24VDC can damage the power supply and/or the controller Figure 9: Power supply wiring 6. Wiring with an X2DRV If you don’t have an XCTRL-2DRV and you want to get a closed loop control, the XCTRL can be associated with the X2DRV. For all detail about the driver refer to the X2DRV Installation & Operation manual. The XCTRL output and the X2DRV Input are selectable (0-10V or 4-20mA).
8. (Optional) Manual Calibration The manual calibration of the XCTRL controller allows you to calibrate the sensor Input (Cell1/Cell2) and the auxiliary sensor input (Ana1/Ana2) without the XCTRL Configurator application. The calibrated values will be then applied to the partition selected by P1, P2, P3 inputs. Use the button above the green LED to start the calibration and follow the procedure. A long press corresponds to 5s and a time out is equal to 10s.
5. (Optional) Touch Screen Installation and Setting The optional touch Screen (Xpro) allows you to modify the setpoint easily. It is generally necessary when Load cells are used to change the tension while running. It’s also offering to display some curves and values in real time. If customer wants to use its own screen, a set of control code is described in the application note AN_ XPRO_SetOfCommand.pdf. a.
VI. SOFTWARE INSTALLATION & SETTING The “XCTRL configurator” is a user friendly software which allows you to easily set-up the XCTRL controller. It gives you access to all parameters which could be modified and save into the integrated memory of the XCTRL. A Digital oscilloscope is available to get an overview of the min parameters and the Inputs/Outputs variations. 1. Software downloading This application is available on our Web site. Please visit our web site http://www.warnerelectric.
VII. XCTRL CONFIGURATION 1. XCTRL Configurator language Selection Two languages are available: English and French. To select a language click on the main rolling menu and select the desired language. By default French is selected. 2. Partition Setting The set of parameters is called a partition. With recording and writing a partition you can easily check and modify all parameters of the controller.
• Read/Write Partition This section allows you to Modify, to Check and to Save to the control all sets of parameters. You will find on the application a section named “Current partition” which represents the complete set of parameters (Cell/ Dancer parameters, PID, Splice, Input/output, Optional Inputs, …) of the partition selected by the number in the box placed before. - To read from XCTRL: 1) Select a number of partitions (P1P2P3). 2) Click on Read from XCtrl.
- How to enable the writing and the ‘Write Current to XCtrl Partition P1P2P3’ button ? To avoid any misuse, writing a partition is by default disabled. To enable it please follow the below steps : 1) Click on ‘XCTRL’ in the main menu, then on ‘Enable Writing’. 2) A Login window pops up. 3) Please enter the following login and password: PARTITION, PARTITION. Both login and password are case sensitive. They need to be entered in Uppercase. 4) Click on the ‘OK’ button.
- To import a partition: 1) In the main menu, Click on ‘Partition’, then on ‘Open from computer’ 2) A file explorer opens to allow you to select the partition you want to import form you computer hard drive or from another drive 3) The partition is then loaded in the Current partition 4) Select the partition number in which you want it to be saved.
• SD Card With an SD Card you can save all your partitions or write to the XCTRL from the SD Card. To write or save the partitions follow the procedure below by using the button above the LED (In and Out). The SD Card is not supplied with the XCTRL. When reading from the SD Card, if only 1 partition has been saved on it, this one needs to have the number 0 and so named ‘PART_0.XML’. After having copied this first partition, the application is searching for the next one.
1. Input Selection and Setting • Cells / Dancer Input In this tab you can select the active input and set-up it. Select your input with the drop down menu. Depending of the Input type the excitation and the input voltage will be changed Two analog inputs are available. Each input can support either a dancer arm (BTCS620 or BTCS 254-06/10) or a load cell. Both can be amplified or not. • Calibration Once the input type selected, it’s necessary to teach the Input voltage span with a calibration.
- Load Cell (Amplified & Not Amplified) calibration: In load cell Mode, the max voltage needs to be calculated depending of the load cell type, the mechanical integration into the customer application and the max resultant load put on the cell. To help you please ask the WARNER Electric the load cell calculation spreadsheet.
4. PID Setting The PID tab is defining all PID controller parameters: PID Input selection, PID Automatic and linear compensation, PID gains. The setpoint as well as the Stop Integral (StpInt) behavior can be also set-up in this menu. • Select the Input With the drop down menu, it could be a dancer arm, one load cell or two load cells. The input could be an auxiliary sensor wired on Ana 1 or 2. • Set up the SetPoint Depending of the unit previously programmed the SetPoint’s unit changes.
- Linear compensation: to adjust its gain between the Big and the Small roller diameter, an external sensor is needed. This sensor will measure the roller diameter and will need to be wired to the Ana1 or Ana2 Inputs. These Inputs will need to be calibrated before being selected and used as compensation. In linear compensation the external compensation input (Ana1 or Ana2) will be selected through the Splice menu of “splice” tab.
5. Splice Selection and Hold Out Configuration This menu allows the user to set-up the roll’s change/splice. Depending on the A, B, C, Sync Inputs state, a PID controller’s output (an Open Loop or a defined level) can be directed to different outputs to control another driver channel, so another brake/roll. The splice activation is linked to the A B C Sync input setup. Their activation can differ depending on their type : NPN or PNP. Please refer to the Input/ Output Configuration tab for more information.
• Splice Selection In this tab you can set up a configuration of OUT1, OUT2 between a logical menu of 11 possibilities.
• Hold Out / Max out Some more configurations are available for the “Max out” and the “hold out” levels. “Max Out” allows you to set up the max voltage or current delivered by the Outputs. The “hold out” feature is a procedure which is commonly used to stop a roll after splicing. This procedure applies the “Max out” level during a certain time and switches automatically to the “hold out” level when this time is over. Both “hold out level” and “Hold out delay” can be set with the application.
6. Input/Output Configuration The “Input/Output” tab allows you to set-up the XCTRL Input/Outputs depending of your application requirements. The XCTRL is able to handle two types of digital Input/Output : the NPN and the PNP type. This hardware set-up defines the activation level of the splice Inputs (A,B,C,Sync), of the partition inputs (P1, P2, P3), as well as the Digital (ErrS1, ErrS2) and Analog (Out1, Out2) outputs.
• Sync Input Activation Active on 1L, active on 0L, active on falling edge or active on rising edge. For each kind of activation a diagram is displayed on the software to explain its working. • Digital Output (ErrS1, ErrS2) settings The ErrS1 and ErrS2 outputs are used to inform the external application (PLC, Computer,…) that the corresponding Cell/Dancer Input is out of range. The “Error Range” is defined in the tab “Cell/Dancer”.
• Auxiliary Analog Input Type Select between 0-10Vdc or 4-20mA Note: Tick this box to invert the Analog Input • Auxiliary sensor calibration For a good behavior, it’s a mandatory to calibrate the voltage/current span of these inputs.
8. Open Loop Configuration The XCTRL also integrates two open loop controls. The aim of these controls is to add a linear compensation curve and/or a simple gain factor. The Input can be a load cell, a dancer arm or other analog sensors (e.g. Ultrasonic Sensor). • Select the Input Note: For all information about control Pinout and Wiring please refer to the Typical Wiring section. • Two types of correction are available: Linear curve and X Factor. Both can also be combined.
9. Diagnostic tools This tab is giving access to 2 diagnostic windows. The first one, named ‘Real time information’, gives an overview of all inputs and outputs state, including the splice selection (A, B, C, Sync), the Stop integral (StpInt), the partition selection (P1, P2, P3), the error state (ErrS1, ErrS2), and offers also a real time oscilloscope allowing to see all inputs, outputs variations. The second, named ‘Input/output’ echoes back the voltage or current applied to all pins.
• ‘Real time information’ window 30 Warner Electric • +33 (0) 2 41 21 24 24 P-2097-WE-A4
• Input/output’ window Warner Electric • +33 (0) 2 41 21 24 24 P-2097-WE-A4 31
10. XCTRL Firmware Update When necessary , it’s possible to update the firmware of the XCtrl controller with using the XCtrl configurator application. To do so, please follow the below steps: 1) Click on ‘XCTRL’ in the main menu, then on ‘Update Firmware’. 2) A Login window pops up. 3) Please enter the following login and password: (Please contact Warner to get it), (Please contact Warner to get it). Both login and password are case sensitive. They need to be entered in Uppercase.
VIII.XCTRL FAMILY PART LIST When necessary, it’s possible to update the firmware of the XCtrl controller with using the XCtrl configurator applicaiton. Part Number Designation BXCTRL XCTRL PID Control. Double controller for Dancer arms and load cells application. BX2DRV X2DRV Double Channel 24Vdc Driver. 4A. 0-10VDC or 4-20mA inputs.
Warranty Warner Electric LLC warrants that it will repair or replace (whichever it deems advisable) any product manufactured and sold by it which proves to be defective in material or workmanship within a period of one (1) year from the date of original purchase for consumer, commercial or industrial use. This warranty extends only to the original purchaser and is not transferable or assignable without Warner Electric LLC’s prior consent. Warranty service can be obtained in the U.S.A.
