MAXTRAC Web Tension Control

A Unified Tension Control Platform Built for Scalability

The MAXTRAC builds on a legacy of MAGPOWR engineering, incorporating proven functionality from previous controllers alongside new capabilities designed to reduce total system cost. Every configuration (wall mount, panel mount, or DIN rail mount) ships with the full feature set regardless of mounting style, so you can choose the form factor that fits your machine without sacrificing capability.

The MAXTRAC supports direct control of AC/DC and servo drives, air brakes and clutches, differential shafts, and magnetic particle brakes and clutches through standard control outputs. Optional external transducers or amplifiers expand compatibility further.

Key Benefits

• Five Selectable Control Modes: Choose from follower arm or diameter-based open loop control, load cell or dancer-based closed-loop control, and free loop control to match your process.
• Scalable Architecture: Expand from a single-zone setup to a complex multi-zone, PLC-integrated system without replacing your controller.
• Ease-of-Use Design: Intuitive touchscreen interface with Auto Tune and direct PID parameter access reduces commissioning time.
• Advanced Compensation Algorithms: Out-of-round roll compensation, gain scheduling, and inertia compensation maintain tension accuracy across changing roll conditions.
• Flexible Integration: Optional fieldbus communication, including Modbus TCP, Ethernet/IP, PROFINET, EtherCAT, and CC-Link, enables seamless integration with PLCs, HMIs and industrial networks.
• Reduced Total System Cost: Modular, plug-in design eliminates the need for separate controllers across zones or configurations.

Five Control Modes, One Controller

The MAXTRAC’s selectable tension control modes give operators the flexibility to optimize performance for their specific web handling process:

• Load-cell closed-loop control
• Dancer closed-loop control
• Diameter-based open-loop control
• Follower arm open-loop control
• Free loop control

Each mode is accessible directly from the controller’s interface, with programmable alarms for diameter limits, tension levels, and other machine conditions.

MAXTRAC Configurations

The MAXTRAC is available in three mounting configurations to accommodate different installation environments and machine architectures. All three share the same core feature set and control capabilities.

MAXTRAC Wall Mount (MAXTRAC-WM)

The MAXTRAC-WM is a standalone wall-mounted controller featuring a 5” high-resolution color touchscreen for direct operator interaction. Designed for environments where panel space is limited or a dedicated machine-side enclosure is preferred, the wall mount unit provides full MAXTRAC functionality in an IP-65-rated housing.

Wall Mount Highlights

• 5” high-resolution color touchscreen
• IP-65 enclosure rating
• Standalone operation–no separate operator interface required
• Optional communication cards for PLC, HMI, and industrial network integration
• Supports Modbus TCP, Ethernet/IP, PROFINET, EtherCAT, and CC-Link via optional fieldbus module
• HTML browser-based graphical interface for remote monitoring
• Automatic backup of setup and calibration data

MAXTRAC Panel Mount (MAXTRAC-PM)

The MAXTRAC-PM integrates directly into a machine control panel, offering the same 5” touchscreen interface and full MAXTRAC feature set in a panel-flush form factor. The front panel carries an IP-65 rating, with IP-54 protection for the enclosure body.

Panel Mount Highlights

• 5” high-resolution color touchscreen
• IP-65 front panel / IP-54 enclosure rating
• Designed for flush panel-mount installation
• Standalone operation with optional communication card expansion
• Supports advanced turret and splicing functions
• Weightless load cell calibration

MAXTRAC DIN Rail Mount (MAXTRAC-DRM)

The MAXTRAC-DRM is built for panel-efficient installations and multi-zone machine architectures. Its slim DIN rail form factor minimizes panel footprint, while its modular, stackable design allows multiple tension zones to share a single operator interface and communication module.

The DRM operates with simple analog I/O control out of the box. Adding the optional DRM-COM communication module enables Modbus TCP, Ethernet/IP, PROFINET, EtherCAT, or CC-Link connectivity across the stacked system.

DIN Rail Mount Highlights

• Slim DIN rail design minimizes panel space
• IP-20 enclosure rating
• Stackable, multi-zone architecture with shared operator interface options (handheld, panel, or wall-mounted remote OI)
• Add-on DRM-COMM module for full fieldbus connectivity
• Optional MAXTRAC-OI remote operator interface
• Compatible with US-3 Ultrasonic Sensor and LS-1 Laser Sensor accessories

Compatible Accessories

The MAXTRAC DIN Rail system supports a range of add-on accessories powered directly from the controller:

• MAXTRAC-OI: Remote Operator Interface (IP-65)
• DRM-COMM: DIN Rail Mount Communication Module (Modbus TCP, Ethernet/IP, PROFINET, EtherCAT, CC-Link)
• LS-1: Laser Sensor (IP-65, 24 VDC supplied from controller)
• US-3: Ultrasonic Sensor (IP-65, 24 VDC supplied from controller)

MAXTRAC Tension Control Applications

The MAXTRAC is engineered for web tension control across unwinds, rewinds, and point-to-point applications in industries including:

• Paper and board converting
• Flexible packaging
• Tag and label
• Foil and film processing
• Textile and nonwoven manufacturing
• Printing and coating lines
• Battery
• Specialty converting