Diameter Calculator Reference Manual

Drive
Application
Software
Function Module
Diameter Calculation
Imperial Units
Reference Manual
FM – Inertia Compensation
Important User Information
Users of this Reference Manual must be familiar with the application this Function Module is
intended to support and its usage. Function Modules intended usage are as a building blocks for
a created application. The user must be familiar with the programming tools used to implement
this module, the program platform to be used in the application, and the Rockwell Automation
drive products to be controlled in the application.
Because of the variety of uses for the products described in this publication, those responsible for
the application and use of this control equipment must satisfy themselves that all necessary steps
have been taken to assure that each application and use meets all performance and safety
requirements, including any applicable laws, regulations, codes and standards.
The illustrations, charts, sample programs and layout examples shown in this guide are intended
solely for purposes of example. Since there are many variables and requirements associated with
any particular installation, Rockwell Automation does not assume responsibility or liability (to
include intellectual property liability) for actual use based upon the examples shown in this
publication.
Rockwell Automation publication SGI-1.1, Safety Guidelines for the Application, Installation, and
Maintenance of Solid-State Control (available from your local Rockwell Automation office),
describes some important differences between solid-state equipment and electromechanical
devices that should be taken into consideration when applying products such as those described
in this publication.
Reproduction of the contents of this copyrighted publication, in whole or in part, without written
permission of Rockwell Automation, is prohibited.
Trademarks
RSLogix5000 is a trademark of Rockwell Automation
PowerFlex is a trademark of Rockwell Automation
Application Software – page 2 of 30
FM – Diameter Calculation
Table of Contents
1.0
Precautions ............................................................................................................5
2.0
Definitions ..............................................................................................................6
2.1
Conventions ..........................................................................................................6
2.2
Normalized Quantities...........................................................................................6
2.3
Terminology ..........................................................................................................7
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
3.0
Web .................................................................................................................................... 7
Strip .................................................................................................................................... 7
Drive ................................................................................................................................... 7
Motor Torque....................................................................................................................... 7
Section................................................................................................................................ 7
Overview .................................................................................................................8
3.1
Diameter effects on surface speed .......................................................................8
3.2
Diameter effects on surface tension......................................................................9
4.0
Functional Description ........................................................................................10
4.1
Overview .............................................................................................................10
4.1.1
4.1.2
4.1.3
Main routine .......................................................................................................................10
DiamPreset routine.............................................................................................................10
DiamCalc routine................................................................................................................10
4.2
Main routine ........................................................................................................10
4.3
DiamPreset routine .............................................................................................11
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
4.3.8
4.3.9
4.3.10
4.3.11
4.4
Preset1Cmmd ....................................................................................................................11
Preset2Cmmd ....................................................................................................................11
Preset3Cmmd ....................................................................................................................11
Preset1Val_in.....................................................................................................................12
Preset2Val_in.....................................................................................................................12
Preset3Val_in.....................................................................................................................12
PresetIncCmmd..................................................................................................................12
PresetDecCmmd................................................................................................................12
PresetIncDecRate_inSec....................................................................................................12
DiamPresetCmmd ..............................................................................................................12
DiamPresetVal_in...............................................................................................................13
DiamCalc routine ................................................................................................13
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.4.6
4.4.7
4.4.8
4.4.9
4.4.10
4.4.11
4.4.12
4.4.13
4.4.14
CalcEnbl.............................................................................................................................14
CalcEnblThresh_FPM.........................................................................................................15
CalcUpdate_Rev ................................................................................................................15
SpeedLine_FPM.................................................................................................................15
SpeedMotor_Rpm ..............................................................................................................15
GearRatio...........................................................................................................................15
DiamMinEC_in ...................................................................................................................15
DiamFR_in .........................................................................................................................15
DiamMeasEnbl ...................................................................................................................16
DiamMeasInput ..................................................................................................................16
DiamMeasMin_DC .............................................................................................................16
DiamMeasMax_DC ............................................................................................................16
DiamMeasMin_in................................................................................................................16
DiamMeasMax_in...............................................................................................................16
Drive Application Software – page 3 of 30
FM – Inertia Compensation
4.4.15
4.4.16
4.4.17
4.4.18
4.4.19
4.4.20
4.4.21
4.4.22
4.4.23
4.4.24
4.4.25
4.4.26
5.0
DiamPresetCmmd..............................................................................................................16
DiamPresetVal_in ..............................................................................................................16
DiamRate_inRev ................................................................................................................17
DiamIncEnbl.......................................................................................................................17
DiamDecEnbl .....................................................................................................................17
DiamCalc_in.......................................................................................................................17
RadiusCalc_ft.....................................................................................................................17
BuildUpRatio......................................................................................................................18
BuildUpRatioRec................................................................................................................18
DiamMeas_in.....................................................................................................................18
Constant_RPMperFPM ......................................................................................................18
Constant_RPMperFPM ......................................................................................................18
Setup / Configuration ..........................................................................................19
5.1
Overview.............................................................................................................19
5.2
DiamPreset JSR Instruction................................................................................19
5.2.1
5.2.2
5.2.3
5.3
DiamCalc JSR Instruction...................................................................................20
5.3.1
5.3.2
5.3.3
6.0
Input Parameters................................................................................................................19
Return Parameters.............................................................................................................19
Default Tags used in Drive Application Software.................................................................20
Input Parameters................................................................................................................20
Return Parameters.............................................................................................................21
Default Tags used in Drive Application Software.................................................................22
Tuning / Startup ...................................................................................................23
6.1
Installing the Application Module ........................................................................23
6.2
Drive Tuning & Configuration..............................................................................23
6.3
Offline Tuning / Startup.......................................................................................24
6.4
Online Tuning / Startup.......................................................................................24
6.4.1
6.4.2
Measured Diameter Enable True........................................................................................24
Measured Diameter Enable False (typical configuration).....................................................24
Appendix A -
Process Line Command & Status Words..........................................26
Appendix B - Block Diagram .....................................................................................28
Appendix C - Parameter (Tag) Table ........................................................................29
Drive Application Software – page 4 of 30
FM – Diameter Calculation
1.0 Precautions
Class 1 LED Product
ATTENTION: Hazard of permanent eye damage exists when using optical transmission
equipment. This product emits intense light and invisible radiation. Do not look into
module ports or fiber optic cable connectors.
General Precautions
ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and
assemblies. Static control precautions are required when installing, testing, servicing or
repairing this assembly. Component damage may result if ESD control procedures are
not followed. If you are not familiar with static control procedures, reference Allen Bradley
publication 8000-4.5.2, “Guarding Against Electrostatic Damage” or any other applicable
ESD protection handbook.
ATTENTION: An incorrectly applied or installed drive can result in component damage or
a reduction in product life. Wiring or application errors such as under sizing the motor,
incorrect or inadequate AC supply, or excessive surrounding air temperatures may result
in malfunction of the system.
ATTENTION: Only qualified personnel familiar with the PowerFlex 700S AC Drive and
associated machinery the products control should plan, program, configure, or implement
the installation, start-up and subsequent maintenance of the system / product. Failure to
comply may result in personal injury and/or equipment damage.
ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus
capacitors has discharged before performing any work on the drive. Measure the DC bus
voltage at the +DC & –DC terminals of the Power Terminal Block (refer to Chapter 1 in the
PowerFlex 700S User Manual for location). The voltage must be zero.
ATTENTION: Risk of injury or equipment damage exists. DPI or SCANport host products
must not be directly connected together via 1202 cables. Unpredictable behavior can
result if two or more devices are connected in this manner.
ATTENTION: Risk of injury or equipment damage exists. Parameters 365 [Encdr0 Loss
Cnfg] - 394 [VoltFdbkLossCnfg] let you determine the action of the drive in response to
operating anomalies. Precautions should be taken to ensure that the settings of these
parameters do not create hazards of injury or equipment damage.
ATTENTION: Risk of injury or equipment damage exists. Parameters 383 [SL CommLoss
Data] - 392 [NetLoss DPI Cnfg] let you determine the action of the drive if communications
are disrupted. You can set these parameters so the drive continues to run. Precautions
should be taken to ensure the settings of these parameters do not create hazards of injury
or equipment damage.
Drive Application Software – page 5 of 30
FM – Inertia Compensation
2.0 Definitions
A Function Module [FM] is a base program designed to perform a specific function (operation) in
an application. Function Modules are not complete applications and will require additional
programming to control a machine section. The additional programming required for the
application and configuration of the overall application is the responsibility of the user.
An Application Module [AM] is a complete program designed to perform a specific machine
sections application (task). Application Modules are complete programs and only require
configuration setup in order to perform the designated tasks.
2.1 Conventions
The conventions described below are used in programming and documentation of Function
Modules and Application Modules.
1. All FM tags are program scoped.
2. All user connections to the FM are through the Jump to Sub-Routine (JSR)
instruction input and return parameters.
3. Users cannot edit Function Modules.
4. Data format
Data Type
RSLogix Type
Format
B = Boolean
BOOL
x
I = Integer
INT
x
D = Double INT
DINT
x
R = Real (Float)
REAL
x.x
* = Applies to single precision accuracy.
Range
0 to 1
+/- 32767
+/- 2097151
+/-16777215*
Example
0 or 1
8947
74364
3.4 / 13.0
2.2 Normalized Quantities
Often a physical quantity is normalized by dividing the physical quantity by a base quantity
with the same engineering units as the physical quantity. As a result, the normalized quantity
does not have units, but is ‘expressed per-unit’. The normalized quantity has a value of 1.0
[per-unit] when the physical quantity has a value equal to the base quantity.
A good example of this is the physical quantity of motor current. The information that the
motor is drawing 40 amps has little significance. The motor nameplate states that the rated
motor current is 30 amps. The motor is drawing 133% current is significant information. In
the previous illustration the quantity of motor amps was normalized to 133%. In per unit, the
quantity is normalized to 1.33.
Drive Application Software – page 6 of 30
FM – Diameter Calculation
2.3 Terminology
2.3.1 Web
A web is defined as the material that is being transported through the machine. A
web is sometimes referred to as “sheet” or “strip”.
2.3.2 Strip
The strip is defined as the material that is being transported through the machine. A
web is sometimes referred to as “sheet” or “web”. The term “strip tension” is
referencing the tension of the material in the machine.
2.3.3 Drive
The drive is the power device that is transmitting power to the motor. The motor is
connected to a mechanical device that is propelling the material. This manual is
specific to the PowerFlex 700S drive.
2.3.4 Motor Torque
A D.C. Motor has two currents flowing through it. The first current is the flux, also
known as the field current. This is the magnetizing current that allows the motor to
produce torque. The second current is the armature current. This is the actual
torque producing current of the motor.
An A.C. motor has only one current physically flowing through the machine.
However, this current is a combination of both magnetizing and torque producing
current. Motor Torque on an AC motor is the torque producing portion of the total
current flowing through the motor.
2.3.5 Section
A Web Handling Machine is broken up into sections. A section consists of one or
more drives used to propel the material through the line.
An Unwind Section could consist of one drive, one motor, and one spindle
A lead Section could consist of more than one drive and one motor combination.
This could consist of line pacer and then several helper drives. The helper drives
“help” in transporting the strip through the machine.
Typically when more than one drive is in a section, one drive is the leader and the
other drive is the follower. The follower typically follows the leader’s torque
reference.
Drive Application Software – page 7 of 30
FM – Inertia Compensation
3.0 Overview
Diameter calculation is the process by which a dynamically changing roll diameter is
mathematically calculated during machine operation. In center driven winding and unwinding
applications, the actual diameter of the driven section changes as product is wound about the axis
or unwound from the axis. As the diameter of the driven section changes it is necessary to
change the axial speed and torque in order to maintain constant surface speed and tension on the
product. Diameter calculation can also be used to calculate the change in total reflected inertia.
This is typically used to profile the speed loop gain and in inertia compensation.
3.1 Diameter effects on surface speed
Speed
If the rotational speed of the driven section is kept constant, the surface speed will increase
as the diameter of the section increases. To maintain constant surface speed, the rotational
speed must decrease proportional to the increase in roll diameter. If the roll diameter
doubles, the rotational speed must be reduced by half to maintain constant surface speed.
2000
1800
1600
1400
1200
1000
800
600
400
200
0
Motor Speed (Rpm)
Surface Spd (Fpm)
4
8
12 16
20 24
28
32 36
40 44
48 52
Roll Diameter (in)
RollDiameter(ft) =
RollDiameter(in)
12
MotorSpeed(Rpm) =
Drive Application Software – page 8 of 30
LineSpeed(Fpm)
*GearRatio
RollDiameter(ft)*p
FM – Diameter Calculation
3.2 Diameter effects on surface tension
If the torque applied to a driven section is kept constant, the tension applied to the product at
the surface of the roll will decrease as the diameter of the driven section increases. To
maintain constant tension on the product, the torque must be increased proportional to the
change in diameter. If the roll diameter doubles the torque applied must double to maintain
constant product tension at the surface of the roll.
120
Torque / Tension
100
80
Surface Tension (lbs)
60
Motor Torque (lbft)
40
20
0
4
8
12
16
20
24
28
32
36
40
44
48
52
Roll Diameter
RollDiameter(ft) =
RollRadius(ft) =
RollDiameter(in)
12
RollDiameter(ft)
2
MotorTorque(lbft) =
RollRadius(ft)*Tension(lbs)
GearRatio
Drive Application Software – page 9 of 30
FM – Inertia Compensation
4.0 Functional Description
4.1 Overview
The Diameter Calculation Function Module consists of a program with three routines in
RSLogix 5000. The three routines are the Main, DiamPreset, & DiamCalc. These routines
are dependent on one another and may not be separated. The user may edit the Main
routine to connect signals (tags) and configure the FM. The user cannot edit the DiamPreset
or DiamCalc routines.
4.1.1 Main routine
The Main routine is where the user connects user created controller tags to the input
and output program tags of the FM. These links are created in the Jump to SubRoutine (JSR) instructions. One JSR is used to call the DiamPreset routine and
another JSR is used to call the DiamCalc routine.
4.1.2 DiamPreset routine
The DiamPreset routine is used to select and command a preset value to the
diameter calculator. Diameter preset is used to “reset” the roll diameter to a preset
value such as core diameter as used in winder applications or to the starting roll
diameter as used in unwind applications. If the diameter calculator is not preset to
the correct starting roll diameter, the machine control may not function correctly.
4.1.3 DiamCalc routine
The DiamCalc routine is where the diameter is actually calculated. The diameter is
calculated by measuring the distance of web wound onto the roll for a given number
of roll revolutions. Setting the number of roll revolutions to a whole number, helps
avoid variations in diameter calculation with eccentric rolls.
4.2 Main routine
The Main routine consists of two rungs of ladder logic programming. A rung description
briefly describes the Input and Return (output) parameters of the JSR instructions for each
routine called. Temporary tags have been entered for each input parameter and each return
parameter. The tag names entered in the JSR’s are not declared. The user must replace
these tag names with existing project tags or create new tags. The routine will show an error
until all input and return parameters are satisfied. The input parameters may also be entered
as actual values. If an input parameter is set to a value and not a tag, the value cannot be
edited in run mode. Values entered directly in the JSR should be constants that do not
change during machine operation. Specific formatting is required for values entered directly
in the JSR.
NOTE: For Application Module users, the tags in the JSR’s are predefined and configured for
operation. No additional integration is necessary.
Data Type
B = Boolean
I = Integer
R = Real (Float)
Format
x
x
x.x
Example
0 or 1
123
3.4 / 13.0
If any signal scaling is required to interface the FM into the user application, the user may use
the main routine for this programming. Note; any scaling for inputs to the routines should be
done before the JSR and any scaling applied to the return values from the routines should be
done after the JSR.
Below are descriptions of each parameter required for use of the Diameter Calculation FM.
Drive Application Software – page 10 of 30
FM – Diameter Calculation
4.3 DiamPreset routine
The diameter preset routine is designed for applications where the diameter calculator will be
preset to one of several preset diameters or where a preset increase/decrease function is
required. If only a single diameter preset is required, this routine and the JSR instruction can
be deleted. If the DiamPreset routine is deleted, the (DiamCalc – In15 & In16) inputs
[yDiamPresetCmmd] & [yDiamPresetVal_in] must be controlled by the user’s custom
programming. If the diameter is not properly preset, the machine section may not be able to
regulate product tension in the process.
Input Parameters
Name
1 Preset1Cmmd
2 Preset2Cmmd
3 Preset3Cmmd
4 Preset1Val_in
5 Preset2Val_in
6 Preset3Val_in
7 PresetIncCmmd
8 PresetDecCmmd
9
PresetIncDecRate_inSec
Return Parameters
Name
Type
BOOL
Range
0 to 1
0 to 1
0 to 1
0 to 500
0 to 500
0 to 500
0 to 1
0 to 1
REAL
0 to 10
Type
Range
BOOL
BOOL
BOOL
REAL
REAL
REAL
BOOL
1
DiamPresetCmmd
BOOL
0 to 1
2
DiamPresetVal_in
REAL
0 to 500
Description
Preset diameter to Preset1Val_in
Preset diameter to Preset2Val_in
Preset diameter to Preset3Val_in
Value of Preset 1
Value of Preset 2
Value of Preset 3
Manual Diameter Increase
Manual Diameter Decrease
Manual Diameter Increase/Decrease
Rate adjustment
Description
Diameter Preset Command to
DiamCalc routine
Diameter Preset Value to DiamCalc
routine
4.3.1 Preset1Cmmd
This input is the command to the routine to select the Preset1Val_in as the output
DiamPresetVal_in. When this input is high and EnablePresets is high the
DiamPresetCmmd will be set high and the DiamPresetVal_in will be set equal to
Preset1Val_in.
Usage – Use this input to activate the value of Preset1Val_in as the preset input to
the DiamCalc routine.
4.3.2 Preset2Cmmd
This input is the command to the routine to select the Preset2Val_in as the output
DiamPresetVal_in. When this input is high and EnablePresets is high the
DiamPresetCmmd will be set high and the DiamPresetVal_in will be set equal to
Preset2Val_in.
Usage – Use this input to activate the Preset2Val_in as the preset value of the
DiamCalc routine.
4.3.3 Preset3Cmmd
This input is the command to the routine to select the Preset3Val_in as the output
DiamPresetVal_in. When this input is high and EnablePresets is high the
DiamPresetCmmd will be set high and the DiamPresetVal_in will be set equal to
Preset3Val_in.
Usage – Use this input to activate the Preset3Val_in as the preset value of the
DiamCalc routine.
Drive Application Software – page 11 of 30
FM – Inertia Compensation
4.3.4 Preset1Val_in
The value of Preset1 entered in inches of roll diameter. This value will be sent to the
diameter calculator when Preset1Cmmd is set high.
Usage – Set this vale for the smallest roll diameter used when presetting the
diameter calculator in Winder applications. For Unwind applications, set to the
largest diameter used when presetting the diameter calculator.
4.3.5 Preset2Val_in
The value of Preset2 entered in inches of roll diameter. This value will be sent to the
diameter calculator when Preset2Cmmd is set high.
Usage – Set this value to the diameter in inches to be used for Preset2Cmmd.
4.3.6 Preset3Val_in
The value of Preset3 entered in inches of roll diameter. This value will be sent to the
diameter calculator when Preset3Cmmd is set high.
Usage – Set this value to the diameter in inches to be used for Preset3Cmmd.
4.3.7 PresetIncCmmd
The diameter preset increase input is used to increase the calculated diameter. The
function of this input is inhibited when the EnablePresets input is low. The rate of
change for this increase in diameter is set by the DiamIncDecRate_inSec input.
Usage – This input should be connected to a dynamic command that can be set high
when the operator wishes to increase the diameter calculator, using an increase
pushbutton.
4.3.8 PresetDecCmmd
The diameter preset decrease input is used to decrease the calculated diameter.
The function of this input is inhibited when the EnablePresets input is low. The rate
of change for this decrease in diameter is set by the DiamIncDecRate_inSec input.
Usage – This input should be connected to a dynamic command that can be set high
when the operator wishes to decrease the diameter calculator, using a decrease
pushbutton.
4.3.9 PresetIncDecRate_inSec
The diameter increase/decrease rate input is set in inches of diameter change per
second. This parameter sets the rate of change for the DiamInc and DiamDec
inputs. To aid in manual adjustment of the calculated diameter, the rate of change
will be increased by 3x when the DiamInc or DiamDec inputs are high for more than 3
seconds. If the inputs are set low and then high again, the 3 second delay will
repeat. This configuration allows for precise adjustment of the diameter preset value
and quick changes if the amount of change to be made is significant.
Usage – Adjust this input for a value that allows the operator to accurately adjust the
diameter preset as desired. Recommend initial setting of 0.5 to 1 in/Sec.
4.3.10 DiamPresetCmmd
This return parameter is used to activate the preset function of the DiamCalc routine.
This output will be set high when the EnablePresets is high and one of the preset
inputs are high. This output will command the DiamCalc routine to read the value in
DiamPresetVal_in as the actual diameter.
Usage – The tag entered in the DiamPreset JSR instruction for this return parameter
should be entered as an input parameter to the DiamCalc JSR instruction.
Drive Application Software – page 12 of 30
FM – Diameter Calculation
4.3.11 DiamPresetVal_in
This return parameter is used as the value to preset the diameter calculation when
the DiamPresetCmmd is high.
Usage - The tag entered in the DiamPreset JSR instruction for this return parameter
should be entered as an input parameter to the DiamCalc JSR instruction.
4.4 DiamCalc routine
The diameter calculation routine is the heart of this function module. The routine includes
programming for the diameter calculator, programming to scale an external measurement of
diameter, and scaled outputs for referencing to the drive and to other function modules. The
module has been configured for operation in Imperial units. All data must be entered in the
units specified by the tags. If the line speed is not directly available in FPM, the user must
scale the line speed reference to FPM. The programming for this may be entered in the main
routine and should be executed before the JSR instruction for the DiamCalc routine.
Example equations for converting the line speed reference to FPM are below.
Note: The change in diameter or actual roll diameter should not be used in the calculation of
Line Speed. The Line Speed input parameter (DiamCalc routine – In4) must be an
independent source of line speed, not the spindle rotational speed converted to line speed
(using the calculated diameter).
LineSpeed(Fpm) =
LineSpeedMtr(Rpm) MinCoreDiam(in)*p
*
GearRatio
12
LineSpeed(Fpm) = 0.083333*LineSpeed(in/min)
LineSpeed(Fpm) = 3*LineSpeed(Ypm)
LineSpeed(Fpm) = 0.05*LineSpeed(Yph)
LineSpeed(Fpm) = 3.2804*LineSpeed(Mpm)
Typically, line speed reference is used for the diameter calculator line speed input. If the line
speed reference is not available, a line speed feedback signal from an adjacent fixed
diameter drive or a surface tachometer can also be used.
The externally measured diameter may be used for the calculated diameter output. It is
recommended to utilize the Diameter Calculation FM when measuring the actual diameter
with an external device. Using the FM will provide rate of change limits to prevent step
changes in the diameter or errors in the external measurement device from instantaneously
changing the output diameter value used in the speed reference to the machine section. If
the measured diameter output, scaled in inches, is programmed as one of the three preset
inputs, the measured diameter can be used as a preset.
Drive Application Software – page 13 of 30
FM – Inertia Compensation
Input Parameters
Name
1 CalcEnbl
2 CalcEnblThresh_FPM
3 CalcUpdate_Rev
4 SpeedLine_FPM
5 SpeedMotor_RPM
6 GearRatio
7 DiamMinEC_in
Type
Range
0 to 1
0 to 50
1 to 200
+/- 5000
+/- 7200
1 to 100
0 to FR
MinEC to
500
0 to 1
NA
NA
NA
0 to 500
0 to 500
0 to 1
0 to 500
0.00 to 1
0 to 1
0 to 1
Description
Enable the Diameter Calculation
Diameter Calc low speed thresh hold
Number of revolutions per length count
Line Speed
Actual motor speed
Motor RPM / Roll RPM
Minimum diameter Empty Core
REAL
Range
0 to 500
0 to 21
1 to 20
0.05 to 1
0 to 500
REAL
NA
Description
Actual calculated diameter
Actual calculated radius
Ratio of actual diameter to min core
(1 / BuildUpRatio)
Scaled value of measured diameter
Scaling constant FPM to minimum
empty core RPM
BOOL
REAL
REAL
REAL
REAL
REAL
REAL
8
DiamFR_in
REAL
9
10
11
12
13
14
15
16
17
18
19
DiamMeasEnbl
DiamMeasInput
DiamMeasMin_DC
DiamMeasMax_DC
DiamMeasMin_in
DiamMeasMax_in
yDiamPresetCmmd
yDiamPresetVal_in
DiamRate_inRev
DiamIncEnbl
DiamDecEnbl
BOOL
Return Parameters
Name
1 DiamCalc_in
2 RadiusCalc_ft
3 BuildUpRatio
4 BuildUpRatioRec
5 DiamMeas_in
6
Constant_RPMperFPM
REAL
REAL
REAL
REAL
REAL
BOOL
REAL
REAL
BOOL
BOOL
Type
REAL
REAL
REAL
REAL
Full Roll diameter
Use DiamMeas value for actual Diam
Measured diameter input (Raw data)
Raw data minimum
Raw data maximum
Actual diameter at DiamMeasMin_DC
Actual diameter at DiamMeasMax_DC
Preset command from DiamPreset
Preset value form DiamPreset
Max allowed diameter rate of change
Allow diameter calc to increment
Allow diameter calc to decrement
4.4.1 CalcEnbl
The CalcEnbl input enables the diameter calculator. When the input is low, the
DiamCalc_in output will maintain its last value, unless the Measured Diameter Enable
input parameter (DiamCalc – In9) is true. If a preset is commanded, the DiamCalc_in
output will be updated to the preset value. When the input is high, the DiamCalc_in
output will be calculated based on line speed and the number of roll rotations. If the
line speed input is below CalcEnblThresh_FPM, the DiamCalc_in output will be held
at last value, regardless of the CalcEnbl state.
Usage – This input should be set high when the section is in run and the line speed
input represents roll surface speed (e.g. web tension control is on (Dancer / Tension /
Torque). The diameter calculator is typically disabled if some form of tension control
is not active.
Drive Application Software – page 14 of 30
FM – Diameter Calculation
4.4.2 CalcEnblThresh_FPM
This input adjusts the minimum line speed in FPM that the diameter calculation will
be active. The diameter calculation will be disabled if the line speed is below the
CalcEnbleThresh_FPM. The diameter calculation should be disabled at low line
speed to prevent errors in the calculation.
Usage – Typically a setting of 1% to 5% of line speed will work well.
4.4.3 CalcUpdate_Rev
This input adjusts the number of roll revolutions per diameter calculation. The
calculator will measure the length of web accumulated at the set number of
revolutions. A greater number of revolutions will naturally average the roll diameter.
A lower number of revolutions will generate faster updates to the diameter calculator.
Usage – Typically set for 1 to 8 revolutions of the roll. Thicker webs ( > 62mils)
should be set lower, and thinner webs ( < 62mils) should be set higher. Using a
whole number of revolutions will help reduce diameter calculation variations due to
roll eccentricity.
4.4.4 SpeedLine_FPM
This is the line speed, translation speed, or surface speed of the roll in FPM.
Usage – Connect to the tag that represents line speed scaled in FPM. If the signal is
not available in FPM, see section 4.4 for calculating FPM.
4.4.5 SpeedMotor_Rpm
Actual speed of the driven sections motor (RPM).
Usage – Connect to the tag that is the actual motor speed (RPM) of the drive section.
4.4.6 GearRatio
The gear ratio of the machine section.
GearRatio =
MotorRevolutions
RollRevolutions
Usage – Connect to the gear ratio tag or set the value of gear ratio in the JSR
instruction.
4.4.7 DiamMinEC_in
The minimum Empty Core diameter in inches. This value is used to limit the
calculated diameter and calculate BuildUpRatio and the FPM to RPM conversion
constant. Enter the smallest diameter of roll cores to be used in the machine. If this
is a coreless machine, enter the starting diameter for the Winder.
Usage – Set for the minimum core value.
4.4.8 DiamFR_in
The Full Roll diameter in inches. This value is used to limit the calculated diameter.
If the FR diameter is a changing value and can be set, connect the tag for the value
to this input. If the FR diameter is constant or can not predicted, set the input for the
maximum used in the machine.
Usage - Connect to the Full Roll tag or set the constant value in the JSR.
Drive Application Software – page 15 of 30
FM – Inertia Compensation
4.4.9 DiamMeasEnbl
This input activates the measured diameter as the actual diameter output
DiamCalc_in. This is set high when the actual diameter is to be measured and the
controller should not calculate the diameter based on roll revolutions and length
wound. Setting this input low does not inhibit usage of measured diameter for a
preset. When set high, the measured diameter rate of change will be limited by
DiamRate_inRev input, the measured diameter will be limited by
DiamMinEC_in/DiamFR_in and the DiamCalc_in output will be held at last state
when the diameter calculator is disabled.
Usage – Set high when using measured diameter for actual diameter. Set low when
using measured diameter only for preset and calculated diameter for actual (running)
diameter.
4.4.10 DiamMeasInput
This is the input from the external diameter measurement device.
Usage – Connect to the tag for the external measurement device. This should be the
“raw” data from the device.
4.4.11 DiamMeasMin_DC
This is the minimum value of the measurement device raw data.
Usage – Set for the minimum value the measurement device will output.
4.4.12 DiamMeasMax_DC
This is the maximum value of the measurement device raw data.
Usage – Set for the maximum value the measurement device will output.
4.4.13 DiamMeasMin_in
This input scales the measured diameter (DiamMeasMin_DC) to inches.
Usage – Enter the actual diameter of the measured roll for the DiamMeasMin_DC
value.
4.4.14 DiamMeasMax_in
This input scales the measured diameter (DiamMeasMax_DC) to inches.
Usage – Enter the actual diameter of the measured roll for the DiamMeasMax_DC
value.
4.4.15 DiamPresetCmmd
This is the command bit from the DiamPreset routine. When the input is high, the
diameter calculator will be set to the DiamPresetVal_in. Do not set this bit when the
machine section is running.
Usage – Connect the yDiamPresetCmmd tag (default) to this input.
4.4.16 DiamPresetVal_in
This is the preset value from the DiamPreset routine. When the DiamPresetCmmd is
high, the DiamPresetVal_in is loaded into the diameter calculator.
Usage – Connect the yDiamPresetVal_in tag (default) to this input.
Drive Application Software – page 16 of 30
FM – Diameter Calculation
4.4.17 DiamRate_inRev
This input controls the max rate of change for the diameter calculator. The value is
entered in inches per revolution of the spindle (roll). The maximum rate of change
required for the process should entered in the tag. The change in diameter per
revolution is the product thickness * 2. This input is used only for limitation of the
diameter calculator. The formula below calculates the minimum value that should be
used for DiamRate_inRev. Actual values should be at increased at least 5% to avoid
unwanted limitation of the diameter calculator.
Usage – Set the input for the maximum rate of change for the application.
DiamRate_inRev =
MaxWebThickness_mils*2
1000
4.4.18 DiamIncEnbl
This input sets the function of the diameter calculator. If the input is low, the diameter
calculator cannot increase. If the input is set high, the diameter calculator can
increase. The setting of this input has not effect on the diameter preset functions.
Usage – Set this bit high for winder applications. This bit is typically set low for
unwind applications.
4.4.19 DiamDecEnbl
This input sets the function of the diameter calculator. If the input is low, the diameter
calculator cannot decrease. If the input is set high, the diameter calculator can
decrease. The setting of this input has not effect on the diameter preset functions.
Usage – Set this bit high for unwind applications. This bit is typically set low for
Winder applications.
4.4.20 DiamCalc_in
This output is the actual calculated diameter in inches. If DiamMeasEnbl is high, this
is the limited measured diameter value.
Usage – This output is typically be used for scaling and calculation in the winder
application and for display of the running diameter.
4.4.21 RadiusCalc_ft
This output is the calculated roll radius in feet.
DiamCalc_in
RadiusCalc_ft =
=
24
DiamCalc_in
12in
2
Usage – Typically used for calculating required motor torque or converting from FPM
to RPM
Torque _ lbft = Tension _ lb * Radius _ ft
Drive Application Software – page 17 of 30
FM – Inertia Compensation
4.4.22 BuildUpRatio
This output is a ratio of the actual diameter to the minimum empty core diameter.
BuildUpRatio =
DiamCalc_in
DiamMinEC_in
Usage – Typically used to scale the spindle rotational speed reference.
SpindleSpeed_RPM =
CoreLineSpeedRef_RPM
BuildUpRatio
4.4.23 BuildUpRatioRec
This output is the reciprocal ratio of the actual diameter to the minimum empty core
diameter.
BuildUpRatioRec =
1
=
DiamCalc_in
DiamMinEC_in
DiamMinEC_in
DiamCalc_in
Usage – Typically used to scale the spindle rotational speed reference.
SpindleSpeed_RPM = CoreLineSpeedRef_RPM*BuildUpRatioRec
4.4.24 DiamMeas_in
This output is the scaled measured diameter from an external source.
Usage – (default) This output is connected to the DiamPreset routine, for use as a
preset to the diameter calculator.
4.4.25 Constant_RPMperFPM
This output is created for use as a pre-calculated scaling constant. The constant is
used in conversions from FPM linear speed ref to RPM motor speed. The change in
roll diameter is not included in the constant and must be applied separately.
MotorSpeed_RPM =
LineSpeed_FPM*Constant_RPMperFPM
BuildUpRatio
Constant_RPMperFPM =
GearRatio
DiamMinEC _ in * π
12
Usage – Use to convert speed in FPM to motor speed in RPM.
4.4.26 Constant_RPMperFPM
This output is created to convert line speed values in FPM to the corresponding
motor speed at minimum empty core diameter in RPM.
Drive Application Software – page 18 of 30
FM – Diameter Calculation
5.0 Setup / Configuration
5.1 Overview
All setup and configuration is done in the Main routine. The Diameter Calculation Function
Module is connected to the balance of the application software by placing application tag
names in the Jump to Sub-Routine (JSR) instructions. One JSR is used to call the
DiamPreset routine and a second JSR is used to call the DiamCalc routine.
When JSR instruction input parameters are configured with tags, which are intended to be
tuned by the user at commissioning, it is recommended that the (z prefix) naming convention
be used for tags of this type.
5.2 DiamPreset JSR Instruction
Note: If only a single diameter preset is required, the DiamPreset routine and JSR instruction
can be deleted. If the DiamPreset routine is deleted, the (DiamCalc – In15 & In16) inputs
[yDiamPresetCmmd] & [yDiamPresetVal_in] must be controlled by the user’s custom
programming. If the diameter is not properly preset, the machine section may not be able to
regulate product tension in the process.
5.2.1 Input Parameters
5.2.1.1
Preset1Cmmd – In 1, Preset2Cmmd – In 2, Preset3Cmmd – In 3
Enter application tags for the Preset Command input parameters (DiamPreset In1, In2, and In3). Enter '0' for unused Preset Command input parameters.
5.2.1.2
DiamPreset1Val_in – In 4, DiamPreset2Val_in – In 5,
DiamPreset3Val_in – In 6
Enter application tags for the Preset Value input parameters (DiamPreset - In4,
In5, and In6). If the application tag values are not in units of inches, add a rung to
the Main routine that will scale the tag values to inches. Enter '0.0' for unused
Preset Value input parameters.
Measured diameter can be used as a preset by configuring the tag used for the
DiamCalc JSR instruction Measured Diameter return parameter (DiamCalc –
Ret5) for one of the preset values.
5.2.1.3
PresetIncCmmd – In 7, PresetDecCmmd – In 8
Enter application tags for the Preset Increase/Decrease input parameters
(DiamPreset - In7, In8). Enter '0' if Diameter Increase/Decrease function is not
used.
5.2.1.4
PresetIncDecRate_inSec – In 9
Enter an application tag for the Preset Increase/Decrease Rate input parameter
(DiamPreset - In9). If the application tag value is not in units of inches per
second, add a rung to the Main routine that will scale the tag value to inches per
second. If the preset increase/decrease function is not used, enter '0.0' for the
Preset Increase/Decrease Rate input parameter.
5.2.2 Return Parameters
5.2.2.1
DiamPresetCmmd – Ret 1
Enter an application tag, for the Diameter Preset Command return parameter
(DiamPreset - Ret1. This tag should be used in the DiamCalc JSR instruction
input parameter (DiamCalc – In15).
5.2.2.2
DiamPresetVal_in – Ret 2
Enter an application tag, for Diameter Preset Value return parameter (DiamPreset
– Ret2). This tag should be used in the DiamCalc JSR instruction input parameter
(DiamCalc – In16).
Drive Application Software – page 19 of 30
FM – Inertia Compensation
5.2.3 Default Tags used in Drive Application Software
5.3 DiamCalc JSR Instruction
5.3.1 Input Parameters
5.3.1.1
CalcEnbl – In 1
Enter an application tag for the Diameter Calculator Enable input parameter
(DiamCalc - In1). (See section 4 for guidelines on programming this tag.) If the
Measured Diameter Input is always used, enter '0' for the Diameter Calculator
Enable input parameter.
5.3.1.2
CalcEnblThresh_FPM – In 2, CalcUpdate_Rev – In 3
Enter an application tag for the Diameter Calculator Enable Threshold and the
Diameter Calculator Update Interval input parameters (DiamCalc – In2, In3). If
the Measured Diameter Input is always used, enter ‘0.0 for both the Diameter
Calculator Threshold and the Diameter Calculator Update Interval. The Diameter
Calculator Threshold and the Diameter Calculator Update Interval are typically
configured with tags that can be tuned on-line.
5.3.1.3
LineSpeed _FPM – In 4
Enter an application tag for the Line Speed input parameter (DiamCalc - In4). If
the application tag values are not in units of FPM and RPM, add a rung to the
Main routine that will scale the tag values to FPM and RPM. (See section 4 for
guidelines on programming these tags.)
Drive Application Software – page 20 of 30
FM – Diameter Calculation
5.3.1.4
SpeedMotor_RPM – In 5, GearRatio – In 6
Enter application tags for the Motor Speed and Gear Ratio input parameters
(DiamCalc – In5, In6). The Gear Ratio is typically configured with a tag that can
be tuned on-line. Since diameter rate is a function of Motor Speed and Gear
Ratio, Motor Speed and Gear Ratio should always be configured.
5.3.1.5
DiamMinEC_in – In 7, DiamFR_in – In 8
Enter application tags for the Minimum Empty Core Diameter and Full Roll
Diameter input parameters (DiamCalc – In7, In8). The Minimum Empty Core
Diameter and Full Roll Diameter are typically configured with tags that can be
tuned on-line. The Minimum Empty Core Diameter and Full Roll Diameter limit
the magnitude of the Diameter Calculator return parameters. Build-Up Ratio is a
function of Minimum Empty Core Diameter.
5.3.1.6
DiamMeasEnbl – In 9, DiamMeasInput – In 10, DiamMeasMin_DC –
In 11, DiamMeasMax_DC – In 12, DiamMeasMin_in – In 13,
DiamMeasMax_in – In 14
Enter application tags for Measured Diameter Enable, Measured Diameter Input
[Data Counts], Minimum Measured Diameter [Data Counts], Maximum Measured
Diameter [Data Counts], Minimum Measured Diameter [Inches], Maximum
Measured Diameter [Inches] input parameters (DiamCalc – In9, In10, In11, In12,
In13, In14). If a Measured Diameter signal is not used, enter ‘0’ for Measured
Diameter Enable, ‘0.0’ for Measured Diameter Input, ‘1.0’ for both Minimum
Measured Diameters, and ‘2.0’ for both Maximum Measured Diameters. When a
Measured Diameter signal is used, Minimum and Maximum Diameter tags are
typically configured with tags that can be tuned on-line.
5.3.1.7
DiamPresetCmmd In 15, DiamPreset Val_in – In 16
Enter application tags for Diameter Preset Command and Diameter Preset Value
input parameters (DiamCalc – In15, In16). If the DiamPreset routine is used,
enter the tags used as return parameters in the DiamPreset JSR instruction. If
the DiamPreset routine is not used, enter the appropriate application tags.
Measured diameter can be used as a preset by configuring the tag used for the
Measured Diameter input parameter (DiamCalc – Ret5).
5.3.1.8
DiamRate_inRev – In 17, DiamIncEnbl – In 18, DiamDecEnbl – In 19
Enter application tags for Diameter Rate Limit, Diameter Calculator Increase
Enable and Diameter Calculator Decrease Enable input parameters. These
parameters are typically configured with tags that can be tuned on-line.
5.3.2 Return Parameters
5.3.2.1
DiamCalc_in – Ret 1, RadiusCalc_ft – Ret 2
Enter application tags, for the Calculated Diameter and Calculated Radius return
parameters.
5.3.2.2
BuildUpRatio – Ret 3, BuildUpRatioRec – Ret 4
Enter application tags, for the Normalized Diameter and Reciprocal of Normalized
Diameter return parameters (DiamCalc – Ret3, Ret4).
5.3.2.3
DiamMeas_in – Ret 5
Enter an application tag, for the Measured Diameter return parameter (DiamCalc
– Ret5). If the Measured Diameter is used to preset the Diameter Calculator and
the Diameter Preset routine is used, enter this tag name for the one of the Preset
Value input parameters. If the Measured Diameter is used to preset the Diameter
Calculator and the Diameter Preset routine is not used, enter this tag name for the
Diameter Preset Value input parameter (DiamCalc – In16).
5.3.2.4
Constant_RPMperFPM – Ret 6
Enter an application tag, for the Calibration Constant return parameter.
Drive Application Software – page 21 of 30
FM – Inertia Compensation
5.3.3 Default Tags used in Drive Application Software
Drive Application Software – page 22 of 30
FM – Diameter Calculation
6.0 Tuning / Startup
6.1 Installing the Application Module
Perform the following operations in the order listed to ensure proper signal connections between
the DriveLogix controller and the PowerFlex 700S firmware.
1. Download the RSLogix 5000 [.acd] file to the DriveLogix controller
2. Download the DriveExecutive [.dno] file to the PowerFlex 700S
Note, order of these events are critical as the DriveLogix controller must send the Peer
Communication format to the PowerFlex 700S firmware before the PowerFlex 700S will
accept all the configuration settings provided in the DriveExecutive file. Manually setting the
Peer Communication format in the drive will not be effective until configured in DriveLogix. If
this sequence of operation is not followed, the DriveLogix controller may not communicate
with the PowerFlex 700S.
6.2 Drive Tuning & Configuration
For basic commissioning of the application, the drive must first be tuned to regulate the
motor. The following steps will guide you through the basic requirements of drive tuning
when using an application module.
1. Set param 153 bit 8 high. This will set the start/stop control to 3 wire for
operation via the HIM. When the start up is complete this must be set to low for
2 wire operation from DriveLogix.
2. From the HIM, select the “Start-Up” function and follow the directions. In this
section you will perform the following steps.
a. Motor Control
i. FOC – for Induction Motor
ii. PMag – for Permanent Magnet Motor
b. Motor Data – Enter all motor data for the attached motor, check # poles
c. Feedback Config – Select feedback type
d. Pwr Circuit Diag
e. Direction Test – (NOTE, the motor will run) recommend always changing
wires and not software, this is for maintenance purposes, if the program
is restored it will default to the standard direction setting.
f. Motor Tests – (NOTE, the motor will run)
g. Inertia Measure – (NOTE, the motor will run)
h. Speed Limits
i. Select “+/- Speed Ref”
ii. Fwd Speed Limit
iii. Rev Speed Limit
iv. Abs Overspd Lim – Max over speed past the Fwd and Rev
Speed Limit. This is where the drive will fault
i. Do not complete the remainder of the Start-Up procedure in the drive
j. Scroll down to “Done/Exit”
3. Tune the speed regulator. Depending on the inertia of the machine and other
factors, the speed regulator bandwidth (param 90) should be set for 15 to 50
radians.
4. Set param 153 bit 8 Low. This will set the start/stop control to 2 wire for
operation via DriveLogix
Drive Application Software – page 23 of 30
FM – Inertia Compensation
6.3 Offline Tuning / Startup
Verify that the number and order of JSR input parameters and JSR return parameters agree
with the JSR rung comment and section 4 of this user manual.
Verify that the data type of all JSR instruction input and return parameters agree with the data
type described in the JSR instruction rung comment and section 4 of this user manual. If
immediate values are used for input parameters, the immediate value data type can be
controlled by using or excluding a decimal point. For example, if the JSR instruction input
parameter is designated as type REAL, and the desired value is zero, use “0.0” in the JSR
instruction input parameter. An Input entered a “0” is used as an INTEGER value.
Check the value of all JSR instruction input parameter tags. If the tag is calculated by other
Logix instructions, verify that the tag will be calculated in the correct engineering units. If the
tag is not calculated by other Logix instruction, preset the tag per section 4 of this user
manual.
6.4 Online Tuning / Startup
6.4.1 Measured Diameter Enable True
With the Logix controller in run, verify that the Measured Diameter return parameter
(DiamCalc – Ret5) agrees with the actual diameter.
If the Measured Diameter return parameter (DiamCalc – Ret5) is not accurate:
1. Check that the value of the following input parameters:
• Measured Diameter Input (DiamCalc - In10)
• Minimum Measured Diameter (DiamCalc - In11)
• Maximum Measured Diameter (DiamCalc - In12)
• Minimum Measured Diameter (DiamCalc - In13)
• Maximum Measured Diameter (DiamCalc - In14)
Preset the Diameter Calculator to the actual diameter drive (The diameter can only
be preset with the Diameter Calculator Enable input parameter (DiamCalc – In1)
false.) and run the drive (The diameter rate limit is zero when the motor speed is
zero.) Verify that Calculated Diameter return parameter (DiamCalc - Ret1) tracks the
actual diameter.
If the Calculated Diameter return parameter (DiamCalc - Ret1) does not change with
actual diameter:
1. Verify that the value of the Diameter Increase Enable, Diameter Decrease
Enable and the Diameter Rate Limit (DiamCalc – In17, In18, and In19) will allow
the diameter to ramp to the measured value.
2. Verify that the Motor Speed and Gear Ratio input parameters (DiamCalc – In5,
In6) are entered correctly.
6.4.2 Measured Diameter Enable False (typical configuration)
Preset the Diameter Calculator to the actual diameter (the diameter can only be
preset with the Diameter Calculator Enable input parameter (DiamCalc – In1) false).
After diameter preset is complete, set the Diameter Calculator Enable input true.
Run the drive at a line speed greater than the Diameter Calculator Enable Threshold
(DiamCalc – In2). Verify that the Calculated Diameter return parameter (DiamCalc Ret1) tracks the actual diameter.
If the Calculated Diameter return parameter (DiamCalc - Ret1) does not change with
actual diameter:
1. Verify that the Diameter Calculator Enable input parameter (DiamCalc – In1) is
true.
2. Verify that the value of the Diameter Increase Enable, Diameter Decrease Enable
and the Diameter Rate Limit (DiamCalc – In17, In18, and In19) will allow the
diameter to ramp to the measured value.
3. Verify that the Motor Speed and Gear Ratio input parameters (DiamCalc – In5,
In6) are entered correctly.
Drive Application Software – page 24 of 30
FM – Diameter Calculation
If the Calculated Diameter return parameter (DiamCalc - Ret1) is not accurate:
1. Hand tach the roll surface and verify that the correct value of Line Speed
(DiamCalc - In4). Finally, monitor motor speed and verify the correct value of
Motor Speed (DiamCalc – In5).
Note: The diameter calculator is only as accurate as the Line Speed and Motor
Speed input parameters (DiamCalc – In4, In5). For example, if a line speed
reference signal is used for the Line Speed input parameter, lead section speed
errors, lead section calibration errors, dancer loop velocity, and/or material stretch will
contribute to differences between the actual surface speed of the roll and the Line
Speed input parameter value.
If the Calculated Diameter return parameter (DiamCalc - Ret1) is accurate but is
fluctuating:
1. Increase the Diameter Calculator Update Interval (DiamCalc – In3) and use a
whole number of revolutions. Using a whole number of revolutions for the
Diameter Calculator Update Interval will help reduce fluctuations due to roll
eccentricity.
Drive Application Software – page 25 of 30
FM – Inertia Compensation
Appendix A - Process Line Command & Status Words
The following table is a functional list of the Process Line command word
[wDLx_DrvCmmdProcLn]
Bit
00
01
02
03
04
05
06
07
Input Signal
Clear Fault
Run (2 Wire)
Reserved
Coast Stop
Jog Forward
Jog Reverse
08
Stall Tension
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Tension Control
Torque Control
Dancer Control
Torque Trim
Speed Trim
Draw Trim Off
Torque Follower Control
Diam Preset 1
Diam Preset 2
Diam Preset 3
Diam Preset Increase
Diam Preset Decrease
Diam Calc Increase Enable
Diam Calc Decrease Enable
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Torque Mem Enable
30
Torque Mem Boost Enable
31
Torque Mem Knife Cut
Reverse Rotation (Under Wind)
Tension Control Enable
Drive Application Software – page 26 of 30
Description
Clear all Faults
1 = Start, transition to 0 = Stop
not supported in rev 110101
Jog in Forward direction
Jog in Reverse direction
Under wind selection
Activates selected mode of Tension Control
User determines how and when to activate
Stall Tension
Selects Tension Control Mode - Tension
Selects Tension Control Mode - Torque
Selects Tension Control Mode - Dancer
Selects Trim type – Torque is trimmed
Selects Trim type – Speed is trimmed
Zeros the Draw trim signal
Special Control mode for torque follower
Commands preset 1 for Diam Calc
Commands preset 2 for Diam Calc
Commands preset 3 for Diam Calc
Manual increase for Diameter Calc
Manual decrease for Diameter Calc
Releases Diameter Clac for Increase
Releases Diameter Calc for Decrease
Memorizes running torque
Boosts the memorized torque by user set
percentage.
Boosts the memorized torque by user set
percentage.
FM – Diameter Calculation
The following table is a functional list of the Process Line status word
[DLx_DrvStatProcLn]
Bit
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Output Signal
Fault
Running
Reserved
Motor Ctrl On
Reserved
Jogging
30
Operate Permissive
31
On Permissive
Rotational Reverse
Tension Control On
Zero Speed
Diameter Calculation Active
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Enable Loss Fault
Fail to Run fault
Communication fault
Message fault
Motor Overload Fault
Motor Overtemperature Flt
Motor Blower Loss Fault
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Description
Drive Fault or a System Fault
Drive is Running / not stopping
Motor is being control (Motor POWER)
section Jogging
Under Wind
Selected mode of Tension control is enabled
Below Zero Line speed set point
Future
Drive Enable lost
Drive failed to start
NA – not support
NA – not support
Overload alarm from drive
Over temperature alarm from drive
Motor blower has stopped or tripped off
Use in line control logic to command a
coordinated line ramp stop.
Loss of permissive resets start command.
The drive will coast stop or ramp stop
depending on configuration
Drive Application Software – page 27 of 30
12
Drive Application Software – page 28 of 30
DiamRate_inRev
RollSpeed_FPM
CalcEnableThresh_FPM
LineSpeedRef_FPM
Calculator Enable
RollSpeed_RPM
LineSpeedRef_FPM
>
X
+*/
3.14
/
&
/
1
0
DiamPresetVal_in
DiamDecEnable
DiamIncEnable
DiamCalcAvtive
DiamMeasured_in
DIV_03.Dest
DiamMeasEnbl
&
&
DiamPresetCmmd
0
0
1
0
1
0
1
0
Ramp
DiamCalc_in
FM – Inertia Compensation
Appendix B - Block Diagram
FM – Diameter Calculation
Appendix C - Parameter (Tag) Table
Input Tags for Diameter Calculation Function Module
Name
Type Source Tag
from Routine
Default
User
Value
DiamPreset – Routine
Preset1Cmmd
Bx
wDLx_DrvCmmdProcLn.16
NA
0
Preset2Cmmd
Bx
wDLx_DrvCmmdProcLn.17
NA
0
Preset3Cmmd
Bx
wDLx_DrvCmmdProcLn.18
NA
0
Preset1Val_in
R x.x
zDLx_DiamPreset1Val_in
NA
4.0
Preset2Val_in
R x.x
zDLx_DiamPreset2Val_in
NA
6.0
Preset3Val_in
R x.x
zDLx_DiamPreset2Val_in
NA
9.0
PresetIncCmmd
Bx
wDLx_DrvCmmdProcLn.19
NA
0
PresetDecCmmd
Bx
wDLx_DrvCmmdProcLn.19
NA
0
zDLx_DiamPresetIncDecRate_
inSec
NA
0.0
DLx_DrvStatProcLn.7
NA
0
PresetIncDecRate_inSec
R x.x
DiamCalc – Routine
CalcEnbl
Bx
CalcEnblThresh_FPM
R x.x
zDLx_CalcEnblThresh_FPM
NA
5.0
CalcUpdate_Rev
R x.x
zDLx_CalcUpdate_Rev
NA
2.0
SpeedLine_FPM
R x.x
DLx_LineSpdRf_FPM
RunJogSpdRf
NA
SpeedMotor_RPM
R x.x
SpeedMotor_RPM
Main – scaled to (RPM)
NA
GearRatio
R x.x
zDLx_GearRatio
NA
5.0
DiamMinEC_in
R x.x
zDLx_DiamMinEC_in
NA
4.0
DiamFR_in
R x.x
zDLx_DiamFR_in
NA
30.0
DiamMeasEnbl
Bx
None
NA
0
DiamMeasInput
R x.x
None
NA
0.0
DiamMeasMin_DC
R x.x
None
NA
1.0
DiamMeasMax_DC
R x.x
None
NA
2.0
DiamMeasMin_in
R x.x
None
NA
1.0
DiamMeasMax_in
R x.x
None
NA
2.0
yDiamPresetCmmd
Bx
DiamPresetCmmd
DiamPreset
NA
yDiamPresetVal_in
R x.x
DiamPresetVal_in
DiamPreset
NA
DiamRate_inRev
R x.x
zDLx_DiamRate_inRev
NA
0.25
DiamIncEnbl
Bx
wDLx_DrvCmmdProcLn.21
NA
0
DiamDecEnbl
Bx
wDLx_DrvCmmdProcLn.22
NA
0
Drive Application Software – page 29 of 30
www.rockwellautomation.com
for Drive Application Software www.ab.com/drives/drvappsw
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Americas: Rockwell Automation, 6040 Ponders Court, Greenville, SC 29615-4617 USA, Tel: (1) 864.297.4800, Fax: (1) 864.281.2433
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U.S. Allen-Bradley Drives Technical Support
Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: [email protected], Online: www.ab.com/support/abdrives
Publication: 9329-RM001B-EN-E March 2003
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