Magnetic Power Systems, Inc.1626 Manufacturers Drive. Fenton, MO 63026Tel: 636.343.5550 Fax: 636.326.0608 magpowr@magpowr.com

INSTRUCTION MANUAL

EZ-TRAC™Digital Tension Readout and Control

Table of Contents

Section Title Page Figure Title Page

1 Introduction ................................1 Specifications...................... 122 Installation ..................................1 1 System Types ..................... 133 Electrical Connections ...............2 2 Power Amp Installation ....... 144 Set-Up & Calibration ..................2 3 Wiring Diagram ................... 155 Power Amp Installation ..............5 4 Outline Dimensions............. 166 Optional Features.......................6 Screen Flow Chart .............. 177 Trouble Shooting......................108 Reset Procedures ....................11

850A249-13/02 Rev. C

1.0 INTRODUCTION

The MAGPOWR® EZ-TRAC™ is a microprocessor-based control, designed for precise closed loop tension controlof a moving web. The EZ-TRAC is capable of controlling web tension in unwind, rewind, or point-to-pointapplications. Through this manual, bold words or symbols represent keystrokes.

All data entry and calibration is done through the touch pad keyboard. In some numerical data screens, pressing� or � moves a cursor below the digits. The underlined digit can be changed with the + or – keys.

2.0 INSTALLATION

The EZ-TRAC Model EZE and its variants are intended for mounting on any flat vertical surface capable ofsupporting it. See Figure 4 for dimensions. The EZE meets the environmental and mechanical requirements ofEN50178 with the exception of the degree of protection provided by the EZE enclosure is IP65, which is morestringent than the standard. If the IP65 rating is required in final installation, sealing type cable grips should beused for cable entry. Four mounting holes are provided for attachment of the EZE to the mounting surface. Themeans of attachment should comply with the essential requirements of the appropriate standard(s) and is theresponsibility of the installer.

The EZ-TRAC Model EZ and its variants are intended for installation through a DIN panel opening. The panel itselfshould exhibit sufficient strength to support the weight of the EZ as well as insure the integrity of the environmentalseal. The EZ maintains a degree of protection of IP65 over its front panel. It also meets the environmental andmechanical requirements of EN50178. The EZ mounting clips found on both sides of the enclosure behind thefront panel will accommodate panel thickness of 0.06 inches (1.5mm) to 0.5 inches (12mm).

Wiring to and from the enclosure must be done with double or reinforced insulation or protective screening whichprovides protective separation. All wiring outside either the EZ-TRAC enclosures should comply with the essentialrequirements of the appropriate standard(s) and is the responsibility of the installer.

If using a magnetic particle clutch or brake, see Section 5 to install the Model PA-2 or PA-90 Power Amplifier.

WARNING: DISCONNECT MAINS BEFORE OPENING ENCLOSURE

MAINTENANCE

The only maintenance that may be required on the EZ-TRAC is fuse replacement. Replacement of any fuserequires opening the enclosure, which circumvents the enclosure IP rating. To replace a fuse:

On Model EZ and its variants: On Model EZE and its variants:

1. Disconnect the supply mains. 1. Disconnect the supply mains.2. Remove the two screws on the rear of the EZ 2. Open the door of the EZE by loosening the

which retain the top cover. two retaining screws.3. Remove the top cover. 3. Remove the PA-2 / PA-90 power amplifier4. Remove the PA-2 / PA-90 power amplifier if present. if present.5. Remove and replace the blown fuse. 4. Remove and replace the blown fuse.6. Reinstall the PA-2 / PA-90 power amplifier 5. Re-install the PA-2 / PA-90 power amplifier.7. Reconnect supply mains. 6. Close the door and re-tighten the retaining

screws.7. Reconnect supply mains.

1

3.0 ELECTRICAL CONNECTIONS

Figure 3 shows the connections that are required for the basic EZ-TRAC system. They are:

115 or 230 vac powerOne or two MAGPOWR tension sensorsRUN/STOP using the EZ-TRAC internal logic supplyOUTPUT to clutch, brake, motor controller, etc.Power Amplifier input (if used) 115 vac for 90 vdc clutch or brake,or 24 vdc for a 24 vdc clutch or brake.

See Section 6 for other options and connections.

Route AC power away from sensor and control wiring. MAGPOWR sensor cables are color coded on thenameplate. Run all wiring in shielded cable. Connect shields to the enclosure using the standoffs provided.Maximum shield length and maximum length of wires outside of the shield is 3 inches (75mm).

4.0 SETUP AND CALIBRATION

Apply power.Screen contrast can be adjusted by pressing PROGRAM, � and then using the + and – keys.Press PROGRAM and use � or � to display Preferences. Press � to select language and units. Factory defaultis English and pounds.The home screen (below) always appears at power up. HOME always returns you to this screen from any otherscreen.

Automatic mode: The output automatically adjusts to correct for changes in tension.

Manual mode: Switch to Manual mode anytime using the AUTO/MANUAL key. The output is now fixed at thelevel set in the MANUAL LEVEL screen. Switch back to Automatic mode using theAUTO/MANUAL key.

Stopping: During the Stop Time, the EZ-TRAC is still in Automatic mode, but the output is momentarilychanged by Stop Multiplier. At the end of Stop Time, the EZ-TRAC switches to HOLD mode.

Hold Mode: In Hold mode the output is fixed at the Hold Level.

E-Stop: During Emergency Stop, the output goes to full on for unwind systems and to zero output for allother systems.

Off: The output is zero when tension is turned off either by the TENSION ON/OFF key or by aremote connection.

2

4.1 Operator Screens

The operator screens (shown in the figure) are those normally usedduring machine operation and are accessed using � and � from theHOME screen. A complete flow chart is shown in the back of this manual.

The SETPOINT TENSION screen sets the desired tension forAUTOMATIC mode. The CORE TENSION screen sets the desiredtension at CORE DIAMETER for a TAPER REWIND system.

The WEB WIDTH screen sets the width of the web, and only appearswhen TENSION/WIDTH units are selected.

The TAPER PERCENT screen is used on rewinds to decrease theweb tension as the diameter increases. This screen is displayed onlyfor a TAPER REWIND system.

The TAPER MUST BE SETUP screen appears if the taper setupparameters have not been set and the present diameter has notbeen calibrated. See Section 4.5, TAPER SETUP.

The MANUAL LEVEL screen sets the desired output when in Manualmode.

The OUTPUT LEVEL screen shows the present output when inAutomatic or Manual mode.

Enter Operator Screen values here:

SetpointTension

Web Width Taper Percent Manual Level

4.2 System Setup

Basic setup cannot be performed if E-Stop input is open, or ifRUN/STOP input is open.

Press PROGRAM and use � and � to enter theCONFIGURATION menu. Use � to access the SYSTEMscreen. Use � or � to select unwind, rewind, taper rewind,or one of the point-to-point types NORMAL, or REVERSE.See Figure 1 for a description of system types.

Then continue through the flow chart at right entering thedesired data in each screen.

See 6.15 for description of screens.

Enter System Setup values here:

System StartTime

StopTime

StopMultiplier

HoldLevel

OutputRange

3

4.3 Tension Sensor Calibration

NOTE: Continuing past the � for SENSOR CALIBRATE screen will erase anyprevious sensor calibration.

Press PROGRAM and use � or � to display CAL SENSORS. Press �. Followthe steps at the right to calibrate the tension sensors.

Maximum tension should be set to a value greater than the highest tension expected inthe application. This value is also the 100% level of the analog bar graph.

Applied tension is the known forced used in the diagram below.

If any error screens are displayed during calibration see Section 7.0,TROUBLESHOOTING.

Sensor calibration will require loading the sensor roll with a known force. The knownforce will be applied using a weight and a temporary web as shown below. Thetemporary web should be threaded as the web would normally be threaded in themachine to ensure the same wrap angles. In wide web applications, the known forceshould be applied near the center of the sensing roll using a narrow web such as arope.

Enter Tension Sensor Calibration here:

MaximumTension

AppliedTension

4.4 Tuning

Enter the desired SETPOINT TENSION. Press PROGRAM and � or � toaccess the TUNING screen. Press � to access the first tuning screen.

The procedure for optimizing tuning in any of the screens shown at the right islisted below:

1. Press and hold the – key until the tension becomes unstable.2. Press and hold the + key until the tension is again stable. System stability

can be observed on the bar graph.

Run the machine at a moderate speed, with the control in AUTOMATIC mode andperform dynamic calibration using the above procedure in the indicated sequence.

STABility is normally optimized at full roll. COMPensation is normally optimized at core. If the tension becomes unstable at some other roll diameter see “TensionOscillates” in Section 7, TROUBLESHOOTING.

4

4.5 Taper Setup

Taper tension is used on rewinds to make better rolls by reducing full rolltension compared to core tension. Taper tension is selected by setting theSYSTEM type to TAPER REWIND. Press PROGRAM and � or � toaccess the TAPER SETUP screen. Press � and enter the CORE and FULLROLL diameters.

Next, the present diameter must be calibrated, since the EZ-TRAC estimatesdiameter from the running torque and tension.

The diameter must be calibrated with TAPER PERCENT set to zero.

Press � to access the ENTER PRESENT DIA screen, and enter the presentdiameter with the machine running.

Press HOME and use � to access the TAPER PERCENT screen. Enter thedesired taper percent.

Enter Taper Setup values here:

Core Diameter Full RollDiameter

Enter PresentDiameter

5.0 INSTALLATION OF POWER AMPLIFIERS (IF USED)

5.1 PA-90

Install the PA-90 before applying power to the control.Remove the EZ cover or open the EZE door.Set JP6 on the EZ-TRAC p.c. board to “0-10v”.Set JP1 on the power amplifier for the desired output current range.On model EZ, unplug TB6 and remove the knockout from the rear of the enclosure.Mount Power Amplifier per Figure 2 using the standoffs provided with the PA-90.Resecure cover or door.

When using the PA-90, the 0 to 10 vdc control output is still active but no longer isolated, and is referenced tothe AC line.

5.2 PA-2

Install the PA-2 before applying power to the control.Remove the EZ cover or open the EZE door.Set JP6 on the EZ-TRAC p.c. board to “0-10v”.Set JP1 and JP2 on the power amplifier for the desired output voltage and current range.On model EZ unplug TB6 and remove the knock-out from the rear of the enclosure.Mount Power Amplifier per Figure 2 using the standoffs provided with the PA-2Resecure cover or door.

When using the PA-2, the 0 to 10 vdc control output is still active but no longer isolated, and is referenced to theAC line.

5

6.0 OPTIONAL CONNECTIONS, FUNCTIONS AND OTHER TECHNICAL INFORMATION

TABLE OF CONTENTS

ALTERNATE TENSION INPUTS .................................................................... 6.1RUN/STOP .................................................................................................. 6.2E-STOP .................................................................................................. 6.3REMOTE TENSION ON/OFF.......................................................................... 6.4SELECTING OUTPUT VOLTAGE/CURRENT................................................ 6.5OPERATOR SCREENS.................................................................................. 6.6UNITS OF MEASURE ..................................................................................... 6.7LANGUAGE .................................................................................................. 6.8MANUAL MODE.............................................................................................. 6.9TAPER TENSION.......................................................................................... 6.10STOP MULTIPLIER....................................................................................... 6.11HOLD LEVEL CONTROL.............................................................................. 6.12SECURITY ................................................................................................ 6.13RECALIBRATIE OUTPUT............................................................................. 6.14SCREEN DESCRIPTIONS............................................................................ 6.15

6.1 Alternate Tension Inputs

100 mv/v TENSION SENSORS

On the main PCB cut jumpers JP11 and JP12.Connect wires to TB2 and TB3 as shown using shielded wiring.Only one full bridge can be used.

10vdc TENSION SIGNAL

On the main PCB cut jumpers JP10, JP11, JP12 and JP13.Connect signal between terminals TB2.1(+) and TB2.2(-) usingshielded wiring. Connect TB2.2 to TB3.1 (GND).

6.2 RUN/STOP

Connect TB3.4 to TB3.3 to initiate the stopping function. During STOP TIME the EZ-TRAC continues to controltension as a closed loop system and STOP MULTIPLIER is also activated.

When using the internal 5 vdc supply (set JP8-7)OPTO SUPPLY) to INT (internal)), 2 madc flows in the switch.See Section 6.4 to use isolated logic inputs (5 to 24 vdc).

6.3 E-STOP (E-STOP is an auxiliary function not intended to provide category 1 safety protection)

Open the connection between TB3.2 and TB3.1 to initiate E-STOP. On unwinds the output goes full on. On allother systems the output goes to zero. When using the internal 5 vdc supply (set JP8-7)OPTO SUPPLY) to INT(internal)), 2 madc flows in the switch. See Section 6.5 to use isolated logic inputs (5 to 24 vdc).

6.4 REMOTE TENSION ON/OFF

TENSION OFF sets the output to zero for all types of systems. For type REVERSE system OUTPUT LEVEL willdisplay 100% since these systems are reverse acting (i.e. tension decreases with increasing output).

REMOTE TENSION ON/OFF duplicates TENSION ON/OFF on the keypad. A momentary connection madebetween TB3.5 and TB3.3 will toggle between TENSION ON and OFF. The TENSION ON/OFF key remainsfunctional.

When using the internal 5 vdc supply (set JP8-7)OPTO SUPPLY) to INT (internal)), 2 madc flows in the switch.See Section 6.5 to use isolated logic inputs (5 to 24 vdc).

6

6.5 ISOLATED LOGIC INPUTS

If it is desired to isolate the logic inputs on TB4 to interface with other equipment or for increased noise immunity,an external power supply can be used as shown in the diagram below. On the main PCB set JP8-7 (OPTOSUPPLY) to EXT (external).

6.6 SELECTING OUTPUT VOLTAGE/CURRENT

Then output voltage/current at TB4.1(+) and TB4.2(-) is set by positioning jumpers on JP6 as shown below. JP6must be set for 0 to 10vdc when the PA-2 or PA-90 Power Amplifier is used.

The –10vdc to +10vdc output is normally used with regenerative drives in torque mode. If the drive is wired so that+10vdc creates torque in the first quadrant, use SYSTEM TYPE normal. Otherwise use SYSTEM TYPEREVERSE. In either case tension can now increase or decrease from T1 to T2. See Figure 1.

If the PA-2 or PA-90 Power Amplifier is used, select current and voltage per Figure 2.

6.7 OPERATOR SCREENS

The operator screens are those normally used during machine operation and are accessed using � or � from theHOME screen. These are the only screens which are accessible when security is set per Section 6.14. Theoperator screens are “TENSION”, “SETPOINT TENSION”, “MANUAL LEVEL”, “OUTPUT LEVEL”, “TAPERPERCENT”, (if TAPER REWIND is selected), and “WEB WIDTH” (if TENSION/WIDTH UNITS are selected).

6.8 UNITS OF MEASURE

PREFERENCES can be used to select units of measure from:

LB Kg N/cmOZ N G/mmPLI G(grams)OZ/IN Kg/cm

7

6.9 LANGUAGE

PREFERENCES can be used to select different languages. The available languages are:

ENGLISH (factory default)FRANCAISDEUTSCHESPANOLITALIANO

6.10 MANUAL / AUTOMATIC MODE

Use the key to toggle between AUTOMATIC and MANUAL mode. In MANUAL MODE the output levelis fixed at the level set in the MANUAL LEVEL screen.

6.11 TAPER TENSION

Taper tension is used on rewinds to make better rolls by reducing full roll tension compared to core tension.Percent taper is defined as the percent decrease in tension from core to full roll.

The EZ-TRAC estimates diameter from the running torque and tension. Diameter must be calibrated while runningbefore taper tension can be used. When calibrating diameter, TAPER PERCENT must be set to zero.

6.12 STOP MULTIPLIER

Extra torque is often needed to help stop large unwind rolls. STOP MULTIPLIER is available to increase the outputas a multiple of the present running torque.

6.13 HOLD LEVEL CONTROL

During normal automatic operation the output changes to correct for changes in SETPOINT TENSION, rolldiameter, etc. During the STOP TIME the EZ-TRAC is still in automatic mode, but the output is momentarilychanged by STOP MULTIPLIER to help stop the unwind roll. At the end of STOP TIME the EZ-TRAC switches toHOLD mode. In HOLD mode the output is fixed at the HOLD LEVEL.

6.14 SECURITY

The “UNLOCKED � LOCK” screen can be used to prevent changes to all the programming parameters. Whensecured, only values in the operator screens can be changed. Enter code number, record here ___ ___ ___ ___press �.

6.15 RECALIBRATE OUTPUT

The output is calibrated at the factory and adjustment is not normally required. The RECALibrate OUTPUT screenallows fine adjustment of the output voltage/current at 0% and 100%. Use the + or – keys to adjust the actualoutput with a meter on TB4.2 and TB4.1.

8

6.16 SCREEN DESCRIPTIONS

OPERATOR SCREENS

TENSION Displays current measured tension and operating mode.SETPOINT TENSION The tension set point for AUTOMATIC mode and STOPPING mode. (Does not appear

when taper tension is used).CORE TENSION This is the SETPOINT TENSION at CORE DIAMETER when taper tension is used.MANUAL LEVEL The output percent when in MANUAL MODE.OUTPUT LEVEL Current output as a percent of maximum.TAPER PERCENT Appears only when taper tension is used. The core tension is reduced by this

percentage as the rewind roll increases to FULL ROLL DIAMETER.WEB WIDTH Appears only when TENSION/WIDTH UNITS are used. Enter the width of the present

web to enable TENSION/WIDTH calculations.

PARAMETER SCREENS

ERROR LIMIT This value limits the percent of error that is acted upon.HOLD LEVEL The output will stay at this percent level while in HOLD mode.INTEGRATOR TIME This time adjusts the response to errors. Larger values slow down the response to

rapidly changing error.PROPORTIONAL GAIN Generates an output adjustment proportional to the error.START TIME Provides a soft-start when starting with a slack web. The output is limited to the HOLD

LEVEL at start, but the limit level is increased with time. This is the time taken toincrease the limit to full output. A longer start time will provide a softer start.

STOP MULTIPLIER Upon receipt of a stop signal, the output is increased by this multiplier (1 creates noincrease). Since the output is proportional to roll diameter, this is a simple adjustmentfor roll inertia.

STOP TIME This is the time that EZ-TRAC stays in STOPPING (automatic) mode after the stopsignal is received. At the end of this time the control goes to HOLD mode. Stop timeshould be slightly longer than actual machine stopping time.

CONFIGURE SCREENS

OUTPUT RANGE Normal, -10 vdc to +10 vdcSYSTEM UNWIND, REWIND, TAPER REWIND, NORMAL, REVERSE. Select TAPER REWIND

to enable taper tension. NORMAL and REVERSE are for point-to-point applications.See Figure 1 for description of each type.

SCREEN CONTRAST Adjusts the readability of the screen.

PREFERENCES SCREENS

LANGUAGE Selects display language. ENGLISH, FRANCAIS, DEUTSCH, ESPANOL or ITALIANOUNITS Selects display units. LB, OZ, PLI, OZ/IN, KG, N, G, KG/CM, N/CM, G/MM.

TAPER SETUP SCREENSCORE DIAMETER CORE TENSION is commanded at this diameter.FULL ROLL DIA At this diameter the tension will be reduced by the taper percent.ENTER PRESENT DIA This screen is used to calibrate the estimated diameter. Enter the present diameter

while running to calibrate diameter.

9

7.0 TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE SOLUTION OR DIAGNOSTICScreen blank or hard to read Contrast misadjusted

Power select switchimproperly set.

Press PROGRAM, �, and then use + or – keys toadjust.

Set 115/230 vac power select switch to theappropriate voltage.

Output always low TENSION ON/OFF set toOFF

E-STOP is active (exceptunwind).

E-STOP is wired incorrectly.

Press TENSION ON/OFF on the keypad once.

If the internal logic is being used (the factorydefault) TB3.2 must be connected to TB3.1 todisable E-STOP. Also verify JP8-7 set to “INT”.

Output always high E-STOP is active (unwindsonly).

E-STOP is wired incorrectly.

See above.

Cannot enterPROGRAMMING orCALIBRATION screens.

Not in HOLD mode.

RUN/STOP not wiredcorrectly.

If the internal logic supply is being used (the factorydefault) TB3.4 must be connected to TB3.3 to be inHOLD mode. Also verify JP8-7 set to “INT”.

“EXCESSIVE ROLLWEIGHT”

Sensor(s) misapplied. The total weight of the sensor idler roll and shaftmust be less than ½ of sensor rating. When twosensors are used this is the combined rating of both(i.e. 100 lbs for two 50 lb sensors).

“MAXIMUM TENSION TOOHIGH”

Selected maximum tensionis out of sensor range.

Calibration can be completed by using a smallmaximum tension. See “Maximum tension is out ofrange” below.

“SENSOR SIGNAL TOOLOW”

Maximum tension is out ofsensor range.

1. This problem is often caused by loading thesensor in the wrong direction. It can be correctedby reversing +SIG and –SIG (TB2-1 and TB2-2).

2. If signal direction is correct, calibration canoften be completed by using a larger maximumtension. See “Maximum tension is out of range”below.

3. Maximum tension is out ofsensor range.

When maximum tension is applied the load on thesensors must be less than the total sensor ratingand greater than 1/8 of total sensor rating. Whentwo sensors are used this is the combined rating ofboth (i.e. 100 lbs for two 50 lb sensors). Calculatethis load from:

LOAD = 2*MAX*SIN(WRAP/2)Where:MAX=maximum tension entered during sensorcalibration.WRAP=wrap angle.

Tension oscillates

ERROR LIM needsadjustment

COMP needs adjustment

STAB needs adjustment

STAB is max

DIAGNOSTIC:1. From the HOME screen use � or � to go toOUTPUT LEVEL.2. While the machine is running record theapproximate output level.3. Enter this value in the MANUAL LEVEL.4. Switch to MANUAL mode.5. If the tension continues to oscillate there is anout of round roll or other machine generated tensionvariation.6. If the oscillation stops the control may bemistuned. See “ERROR LIM needs adjustment”.

1. Go to OPTIMIZE ERROR LIM.2. Press and hold � until the oscillation stops.3. If ERROR LIM is max go to “COMP needsadjustment”.

1. Go to OPTIMIZE COMP (ignore reference tocore)2. Press and hold � until oscillation stops.3. If oscillations cease, optimize ERROR LIMIT.4. If COMP is max go to “STAB needs adjustment”.

1. Go to OPTIMIZE STAB (ignore reference to fullroll).2. Press and hold � until the oscillation stops.3. If oscillations cease, optimize COMP and thenoptimize ERROR LIM.4. If STAB is max go to “STAB is max”.

This is extremely rare. You have a system thatneeds more than 150 sec integrator to be stable.Verify this result by performing the diagnostic under“Tension Oscillates”. If verified this system mayneed to use PID for the OPTIMIZE METHOD.Consult the factory.

Front panel TENSIONON/OFF does not work

E-STOP is active

E-STOP is wired incorrectly

If the internal logic is being used (the factorydefault) TB3.2 must be connected to TB3.1 todisable E-STOP.

8. RESET PROCEDURES

If it is desired to reset parameters to factory default values perform the following reset procedure:

1. Simultaneously press � and � and hold for 2 seconds. “RESETTING PARAMETERS” will appear on thescreen for 1 second.

2. Program reset is complete. The basic (tension sensor) calibration has not been erased, and all otherprogramming has been reset to factory default values. Begin at Section 4.0 to reprogram.

11

EZ-TRAC SPECIFICATIONS

Supply Voltage: 115 or 230 volts rms, ± 10%Supply Frequency: 50 or 60 cycles per second, sinusoidal

Fuses: F1, F2 1.6 amp, Littelfuse Part No. 21606.6, orWickmann Part No. 19194-053-FS

EnclosureEZ Front Panel IP65 (IEC529)

IP20 (IEC529)EZE Enclosure IP65 (IEC529)

Climate Class: 3K3 (EN60721)Temperature Range:

Operating 0°C to 40°CStorage -30° to +80°C

Relative Humidity 5% to 85%Pollution Degree 2 (IEC664-1)Altitude: 0-2000 meters

Compatible Residual Current Device Types: A or B (IEC755)Worst Case Fault Current: 1.6 amperers

Inputs:Tension Sensor 2.1 millivolts/volt using +5 and –5 volts (10 volts) across one

350 ohm sensor or two 350 ohm sensors in parallel, or100 millivolts/volt, using 5 volts across one 100 ohm full bridge, or0 to +10 volts analog

E-Stop switch closure or 5 volt or 24 volt logicRun/Stop switch closure or 5 volt or 24 volt logicTension Off switch closure or 5 volt or 24 volt logic

Outputs:Torque 0 to +10 vdc, 1 milliamp maximum

4 to 20 madc., 500 ohms maximum-10 to +10 vdc, 1 milliamp maximum

12

17