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1395-RTP-5 1.book

1. 3 2 Start Up Checklist 3 3 Control 0 3 7 Cross Reference _ 4 3 9 Speed Match da Drs Bungee dece Bidens ete Meet 3 16 Dancer Calibration 3 16 Chapter 4 Troubleshooting Introduction 4 1 Adapter ih Sa xe e 4 2 Digital Reference Fault Messages 4 4 Multi Comm Fault Messages 4 5 5d uus bate ab teint 4 5 DH Only Faults Sess a yr 4 5 Press Speed Magnetic Pickup 4 6 Index Publication 1395 RTP 5 1 September 1997 Table of Contents This page intentionally left blank Publication 1395 RTP 5 1 September 1997 Who Should Use This Manual Purpose of This Manual Preface Preface Read this preface to familiarize yourself with the rest of the manual This preface covers the following topics who should use this manual the purpose of this manual safety precautions contents of this manual related documentation conventions used in this manual productreceiving Allen Bradley support Use this manual if you are responsible for installing an Allen Bradley 1395 Reel Tension Paster RTP Drive If you do not have a basic understanding of the 1395 Drive the RTP adapter or the digital reference adapter for RTP app
2. Ty Allen Bradley Reel Tension Paster Adapter Bulletin 1395 User Manual Important User Information 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 Allen Bradley does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Allen Bradley publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Allen Bradley 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 part without written permission of Allen Bradley Company Inc is prohibited Throughout this manual we use notes to make yo
3. command The main contactor will remain energized until the Drive senses zero speed ATTENTION If the Drive Permit signal is high the Drive will start as soon as dancer is pulled down below web out position Description of Operation 2 5 Mode 11 REGENERATIVE STOP This mode is entered if Drive Permit drops out during any of the Modes 1 to 5 This mode is also entered when exiting Mode 8 Auto Slack Web Loose Mode 9 Reverse Run Dancer High and Mode 14 Reverse Run Dancer Center This stops the roll by sending the controller into a regenerative stop Configuration Parameter 572 Bit 2 will determine if Drive will go into a full regen stop or a ramped regen stop Refer to Logic State Diagrams Mode 12 INTERNAL DRIVE FAULT If the Drive detects an internal fault the main contactor will open and set the belt emergency brake The Drive will latch in a faulted state and must be stopped reset and restarted once the fault has been corrected For detailed troubleshooting information refer to the Bulletin 1395 Installation and Maintenance Manual Mode 13 DRIVE NOT READY Any time the Drive ready bit Bit 7 in the logic status word Parameter 100 goes low the Drive will go to Mode 13 Refer to the Bulletin 1395 Installation and Maintenance Manual for more information on logic status The Drive will not exit Mode 13 until Bit 7 goes high and inputs 2 7 and 8 are all low Mode 14 RUN REVERSE DANCER CENTER
4. or for adjustable Emulate Speed Reference Control Europe Either of these customer inputs will enter the Drive at analog input number 2 of the Digital Reference Adapter DRA board of the Bulletin 1395 Drive Parameter 572 is a configuration Parameter that is to be used to determine if analog input number 2 will be used for either adjustable Emulate Speed Reference ESR or adjustable Auto Slack Reference defined as Auto Slack Tight Variable Reference ASTVR Digital input number 9 of the DRA board must also be held high to access mode 30 ESR Parameter 572 The Parameter 572 configuration truth table follows Refer to the Logic State Diagrams in Chapter 6 of this manual Bit2 Bitl 0 0 0 USA 0 0 1 Europe ESR Mode 30 0 1 0 Asia Pacific ASTVR Mode 31 Note Parameter 572 Bit 2 is set to a value of one for CTSOP design Without making any link changes to the Drive these two new modes of operation can be accessed by the proper configuration of Parameter 572 and the customer supplied inputs to analog input number 2 of the Digital Reference Adapter board Following are the descriptions of the two additional reference control modes Publication 1395 RTP 5 1 September 1997 2 8 Description of Operation Publication 1395 RTP 5 1 September 1997 Mode 30 EMULATE SPEED REFERENCE ESR Europe The speed reference to the Drive will be one of the following The press line speed which enters th
5. 10000 777 78 327 25 222 29 333 33 12000 933 33 392 70 266 75 400 00 14000 1088 89 458 15 311 20 466 67 16000 1244 44 523 60 355 66 533 33 18000 1400 00 589 05 400 12 600 00 Start Up Instructions 3 15 Table 6 Cross Reference Printing Diameter 15 Gear Teeth 140 Continued IMP RTP PRESS WEB BELT PRESS HOUR SPD SENSOR VELOCITY MOTOR DRIVE FREQ HZ FT MIN RPM SHAFT RPM 20000 555 56 654 50 444 58 666 67 22000 1711 11 719 94 489 04 733 33 24000 1866 67 785 39 533 49 800 00 26000 2022 22 850 84 571 95 866 67 28000 2177 78 916 29 622 41 933 33 30000 2333 33 981 74 666 87 1000 00 32000 2488 89 1047 19 711 32 1066 67 34000 2644 44 1112 64 755 78 1133 33 36000 2800 00 1178 09 800 24 1200 00 38000 2955 56 1243 54 844 70 1266 67 40000 3111 11 1308 99 889 16 1333 33 42000 3266 67 1374 44 933 61 1400 00 44000 3422 22 1439 89 978 07 1466 67 46000 3577 78 1505 34 1022 53 1533 33 48000 3733 33 1570 79 1066 99 1600 00 50000 3888 89 1636 24 1111 44 1666 67 52000 4044 44 1701 69 1155 90 1733 33 54000 4200 00 1767 14 1200 36 1800 00 56000 4355 56 1832 59 1244 82 1866 66 58000 4511 11 1898 04 1289 28 1933 33 60000 4666 67 1963 49 1333 73 2000 00 62000 4822 22 2028 93 1378 19 2066 66 64000 4977 78 2094 38 1422 65 2133 33 66000 5133 33 2159 83 1467 11 2200 00 68000 5288 89 2225 28 1511 56 2266 66 70000 5444 44 2290 7
6. In other words if the max Press Speed is 75 KIPH and this corresponded to 1667 RPM which is the value you would have set into Parameter 608 then adjust the tracking Parameter P562 until the Drive is running at 1667 RPM This will be as accurate as can be achieved until paper has been readied or in extraordinary circumstances a special roll has been prepared such that the belts are engaged and the press is running but no paper is webbed into the machine In this instance the magnetic pickup would be active if the system were not in the Emulate mode Running With Paper Important Preliminary Steps A Remove the blocks from the dancer that held it in the center position Enable the process trim system by setting Parameter 628 to one ATTENTION Parameter 628 must be set to 1 prior to pulling paper Assure that the integral channel of the P I Regulator setting of Parameter 567 is zero Start Up Instructions 3 19 Final Speed Match The dancer should now be free to move and ready for contact with the web and the dancer position system has been enabled Important A full diameter roll of paper should be used for this procedure 1 The preset 1 speed of 20 RPM is the default assuming that the press speed during auto slack is less than this value If not enough slack is inserted during Mode 7 fast enough adjust Parameter 633 to a greater value 2 The Max Press Ref RPM Parameter 562 will again be used to make the
7. completed and then returned to the value of 50 5 The integral gain of the Regulator will remove all of the dancer movement downward as the roll of paper builds down During normal operation with a roll that does not have a large amount of eccentricity the dancer should stay at the level position for the entire run The process trim output during a normal run will build in value especially close to core diameter which is where the belt errors predominate 6 Toadjust the dancer position during normal run Parameter 553 should be changed accordingly However this should not normally be necessary Publication 1395 RTP 5 1 September 1997 3 20 Start Up Instructions This page intentionally left blank Publication 1395 RTP 5 1 September 1997 Introduction Chapter 4 Troubleshooting This chapter describes the Digital Reference Adapter Board fault diagnostics and how they are processed by the 1395 Drive Proper sequencing of the logic and control modes may be verified by monitoring Parameters 596 597 and 598 with the DHT or ITS It should be noted that improper operation of the Belt Drive System may often be caused by problems external to the 1395 Drive System Always check that the proper logic commands are being received from the Paster Panel per the Logic State Diagram Also check that press and belt speed frequency signals are being received from the Paster Panel Table 1 is provided as a quick reference of the Para
8. detector is de energized when the dancer reaches full position and the web becomes fully slack This sets the torque reference to zero which will allow the motor to free wheel no armature current or torque but keeps the Drive energized The normal exit from Mode 8 is back to Mode 7 via the Dancer reaching mid position unless both inputs DI2 and DI7 are low in which case Mode 8 exits to Mode 11 Mode 9 REVERSE RUN DANCER HIGH The Reverse Run Mode is designed so the belts will slowly run in reverse to pull the dancer to the center position In the Reverse Run Mode a Slack Removal signal is received by the Drive This sets the Drive logic command to start the Drive and follow the internal preset 2 speed reference This signal is adjustable with Drive Parameter 634 and requires a negative number for reverse operation When the web out detector senses the web out of position on the slack side of center the belts will reverse slowly The Drive logic command ensures that the Drive will run from the preset 2 speed reference with no dancer trim Mode 10 WEB OUT If the web breaks when the Drive is in any Normal Run Mode Modes 1 through 5 the Drive goes into a regenerative stop Configuration Parameter 572 Bit 2 will determine if Drive will go into a full regen stop or a ramped regen stop Refer to Logic State Diagrams When the Drive senses that the dancer has gone fully slack dancer full up the Drive loses its
9. paper from the reel to the press during emulate mode or the belts are up and not contacting the paper place the dancer in the center position for this portion of the testing using the block method discussed above 1 Determine the proper gear pulse per revolution from the printing diameter cross reference chart Tables 3 through 6 Set the Press Ref PPR Parameter 561 to the proper value 2 Determine the maximum belt motor RPM versus maximum press speed IMP HOUR from this same chart and enter the proper value in Parameter 608 Forward Speed Limit 3 Determine the maximum drive shaft speed of the press usually 2566 RPM versus maximum press speed in KIPH from this same chart and enter this value in Parameter 562 Press Ref RPM the major tracking adjustment for the RTP Drive Publication 1395 RTP 5 1 September 1997 3 18 Start Up Instructions Publication 1395 RTP 5 1 September 1997 Monitor the Drive speed on the DHT or use the ITS via a computer and monitor Parameter 106 Velocity Feedback With the GSD console in Emulate start the Drive with the Emulate reference at a comfortable minimum value Run the reel to maximum press speed and adjust the Drive reference for proper maximum speed This is accomplished using Parameter P562 Max Press Ref RPM Adjust this Parameter until the velocity feedback via Parameter 106 is equal to the value as set in Parameter 608 for the maximum Press Speed
10. the 15 LEDs for the digital I O The 10 input LEDs are mounted left to right 1 through 10 followed by the 5 output LEDs mounted left to right 1 through 5 Publication 1395 RTP 5 1 September 1997 4 4 Troubleshooting Digital Reference Fault Messages Publication 1395 RTP 5 1 September 1997 The fault messages available on the Digital Reference Adapter Board are as follows DR 01 DIG REF OK Indicates no faults are present in the Adapter DR 60 Illegal Mode Soft Fault Indicates an internal adapter error Power down and reapply power If not solved reinitalize drive reload parameters and repower drive If still not solved replace Digital Reference Adapter Reapply power if not solved reinstall original adapter replace Main Control Board reapply power DR 70 DP HANDSHAKE Soft Fault The 1395 Main Computer Board is no longer maintaining communications with the adapter through Dual Ported RAM Ensure proper connection to Microbus interface Power down and reapply power If not solved replace Digital Reference Adapter Reapply power if not solved reinstall original adapter replace Main Control Board reapply power DR 71 Mbus RAM Test Soft Fault The 1395 Main Computer commanded an illegal mode for this adapter Clear fault power down and reapply power If not solved replace Digital Reference Adapter Reapply power if not solved reinstall original adapter replace Main Control Board reapply po
11. 06 40 Rockwell Automation Asia Pacific Headquarters 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 1395 RTP 5 1 September 1997 p n 159431 Supersedes Publication 1395 RTP September 1997 1997 Rockwell International All Rights Reserved Printed in USA
12. 1 122 45 83 20 133 33 6000 436 67 183 67 124 80 200 00 8000 582 22 244 89 166 40 266 67 10000 727 78 306 11 208 00 333 33 12000 873 33 367 34 249 60 400 00 14000 1018 89 428 56 291 20 466 67 16000 1164 44 489 78 322 80 533 33 18000 1310 00 551 00 374 40 600 00 20000 1455 55 612 23 416 00 666 67 22000 1601 11 673 45 457 60 733 33 24000 1746 66 734 67 499 20 800 00 26000 1892 22 795 89 540 80 866 67 28000 2037 78 857 12 582 40 933 33 30000 2183 33 918 34 624 00 1000 00 32000 2328 89 979 56 665 60 1066 67 34000 2474 44 1040 78 707 20 1133 33 36000 2620 00 1102 01 748 80 1200 00 38000 2765 55 1163 23 790 39 1266 67 Publication 1395 RTP 5 1 September 1997 3 10 Start Up Instructions Publication 1395 RTP 5 1 September 1997 Table 3 Cross Reference Printing Diameter 14 1 32 Gear Teeth 131 Continued IMP RTP PRESS WEB BELT PRESS HOUR SPD SENSOR VELOCITY MOTOR DRIVE FREQ HZ FT MIN RPM SHAFT RPM 40000 2911 11 1224 45 831 99 1333 33 42000 3056 66 1285 67 873 59 1400 00 44000 3202 22 1346 90 915 19 1466 67 46000 3347 77 1408 12 956 79 1533 33 48000 3493 33 1469 34 998 39 1600 00 50000 3638 89 1530 56 1039 99 1666 67 52000 3784 44 1591 79 1081 59 1733 33 54000 3930 00 1653 01 1123 19 1800 00 56000 4075 55 1714 23 1164 79 1866 66 58000 4221 11 1775 45 1206 39 1933 33 60000 4366 66 1836 68 1247 99 2000 00 62000 4512 22 1897 90 128
13. 1133 33 38000 2850 00 1202 09 814 53 1266 67 40000 3000 00 1265 36 857 40 1333 33 42000 3150 00 1328 62 900 27 1400 00 44000 3300 00 1391 89 943 14 1466 67 46000 3450 00 1455 16 986 01 1533 33 48000 3600 00 1518 43 1028 88 1600 00 Publication 1395 RTP 5 1 September 1997 3 12 Start Up Instructions Publication 1395 RTP 5 1 September 1997 Table 4 Cross Reference Printing Diameter 14 1 2 Gear Teeth 135 Continued IMP RTP PRESS WEB BELT PRESS HOUR SPD SENSOR VELOCITY MOTOR DRIVE FREQ HZ FT MIN RPM SHAFT RPM 50000 3750 00 1581 70 1071 75 1666 67 52000 3900 00 1644 96 1114 62 1733 33 54000 4050 00 1708 23 1157 49 1800 00 56000 4200 00 1771 50 1200 36 1866 66 58000 4350 00 1834 77 1243 23 1933 33 60000 4500 00 1898 04 1286 10 2000 00 62000 4650 00 1961 30 1328 97 2066 66 64000 4800 00 2024 57 1371 84 2133 33 66000 4950 00 2087 84 1414 71 2200 00 68000 5100 00 2151 11 1457 58 2266 66 70000 5250 00 2214 37 1500 45 2333 33 72000 5400 00 2277 64 1543 32 2400 00 74000 5550 00 2340 91 1586 19 2466 66 75000 5625 00 2372 54 1607 62 2500 00 76000 5700 00 2404 18 1629 06 2533 33 78000 5850 00 2467 45 1671 93 2600 00 80000 6000 00 2530 71 1714 80 2666 66 Table 5 Cross Reference Printing Diameter 13 11 16 Gear Teeth 128 IMP RTP PRESS WEB BELT PRESS HOUR SPD SENSOR VELOCITY MOTOR DRIVE FREQ
14. 3 1556 02 2333 33 72000 5600 00 2356 18 1600 48 2400 00 74000 5755 55 2421 63 1644 94 2466 66 75000 5833 33 2454 36 1667 17 2500 00 76000 5911 11 2487 08 1689 40 2533 33 78000 6066 67 2552 53 1733 85 2600 00 80000 6222 22 2617 98 1778 31 2666 66 Publication 1395 RTP 5 1 September 1997 3 16 Start Up Instructions Speed Match Dancer Calibration Publication 1395 RTP 5 1 September 1997 The Drive is set up at the factory to ensure an accurate speed match between the new roll coming up to speed and the existing web This is accomplished by using the at set speed algorithm in the Drive The up to speed tolerance Parameter 709 sets the hysteresis in motor RPM around the at speed point When the new roll is speed matched with the press speed reference and the motor is not at zero speed the Drive will go into Mode 5 which is speed match This turns on digital output 1 to produce an external indication to the paster panel Drive Not Started Dancer Voltage The dancer potentiometer voltage should always be plus when the dancer is in the up or WEB OUT position Determine whether the specific application is right hand or left hand as observed from the GSD console looking at the reel Check to assure that the Drive wiring conforms to applicable configuration Dancer at Center Position The dancer at center position or at a horizontal level position is a mechanical benchmark which will continue to be used thr
15. 4V Power Supply Fault Warning Fault 4 4 DR 81 Logic State Fault Soft Fault 4 4 DR 82 Auxiliary Logic Soft Fault 4 4 DR 83 Dancer Parameters Soft Fault 4 5 Drive Not Started Calibration 3 16 Drive Started Calibration 3 17 Drive System 1 1 2 1 Drive System Modes 2 1 E Emulate Mode 3 17 F Index Final Speed Match 3 19 H Hard Faults 4 2 ITS 3 2 L Linking 3 2 M Main Control Board A8 3 7 Mode 0 2 1 Mode 1 2 1 Mode 2 2 2 Mode 3 2 2 Mode 4 2 2 Mode 5 2 3 Mode 6 2 3 Mode 7 2 3 Mode 8 2 4 Mode 9 2 4 Mode 10 2 4 Mode 11 2 5 Mode 12 2 5 Mode 13 2 5 Mode 14 2 5 Mode 20 2 5 Mode 21 2 6 Mode 22 2 6 Publication 1395 RTP 5 1 September 1997 Index Mode 23 2 6 Mode 24 2 6 Mode 25 2 6 Mode 26 2 6 Mode 27 2 7 Mode 30 2 8 Mode 31 2 8 Parameter 3 1 Pre Power Drive Checks 3 1 Press Speed Magnetic Pickup 4 6 R Read Only Parameter 3 1 Running With Paper 3 18 Set Up Parameter 3 1 Sink 3 2 Soft Faults 4 2 Source 3 2 Speed Match 3 16 Start Up Checklist 3 3 Start Up Instructions 3 1 T Terminology 3 1 Troubleshooting 4 1 Troubleshooting Parameter Reference 4 1 Warning Faults 4 2 Publication 1395 RTP 5 1 September 1997 N Rockwell Automation Rockwell Automation helps its customers receive a superior return on their investment by bringing n 06 leading brands in industrial automation creating a broad spect
16. 612 51 1097 47 1800 00 56000 3982 22 1672 23 1138 12 1866 66 58000 4124 44 1731 96 1178 77 1933 33 Publication 1395 RTP 5 1 September 1997 3 14 Start Up Instructions Publication 1395 RTP 5 1 September 1997 Table 5 Cross Reference Printing Diameter 13 11 16 Gear Teeth 128 Continued IMP RTP PRESS WEB BELT PRESS HOUR SPD SENSOR VELOCITY MOTOR DRIVE FREQ HZ FT MIN RPM SHAFT RPM 60000 4266 66 1791 68 1219 41 2000 00 62000 4408 88 1851 40 1260 06 2066 66 64000 4551 11 1911 13 1300 71 2133 33 66000 4693 33 1970 85 1341 35 2200 00 68000 4835 55 2030 57 1382 00 2266 66 70000 4977 77 2090 29 1422 65 2333 33 72000 5119 99 2150 02 1463 29 2400 00 74000 5262 22 2209 74 1503 94 2466 66 75000 5333 33 2239 60 1524 27 2500 00 76000 5404 44 2269 46 1544 59 2533 33 78000 5546 66 2329 18 1585 24 2600 00 80000 5688 88 2388 91 1625 88 2666 66 Table 6 Cross Reference Printing Diameter 15 Gear Teeth 140 IMP RTP PRESS WEB BELT PRESS HOUR SPD SENSOR VELOCITY MOTOR DRIVE FREQ HZ FT MIN RPM SHAFT RPM 100 7 78 3 27 2 22 3 33 400 31 11 13 09 8 89 13 33 600 46 67 19 63 13 34 20 00 800 62 22 26 18 17 78 26 67 1000 77 78 32 72 22 23 33 33 1200 93 33 39 27 26 67 40 00 2000 155 56 65 45 44 46 66 67 4000 311 11 130 90 88 92 133 33 6000 466 67 196 35 133 37 200 00 8000 622 22 261 80 177 83 266 67
17. 9 59 2066 66 64000 4657 77 1959 12 1331 19 2133 33 66000 4803 33 2020 34 1372 79 2200 00 68000 4948 88 2081 57 1414 39 2266 66 70000 5094 44 2142 79 1455 99 2333 33 72000 5239 99 2204 01 1497 59 2400 00 74000 5385 55 2265 23 1539 19 2466 66 75000 5458 33 2295 85 1559 99 2500 00 776000 5531 11 2326 46 1580 79 2533 33 78000 5676 66 2387 68 1622 39 2600 00 80000 5822 22 2448 90 1663 99 2666 66 Start Up Instructions 3 11 Table 4 Cross Reference Printing Diameter 14 1 2 Gear Teeth 135 IMP RTP PRESS WEB BELT PRESS HOUR SPD SENSOR VELOCITY MOTOR DRIVE FREQ HZ FT MIN RPM SHAFT RPM 100 7 50 3 16 2 14 3 33 400 30 00 12 65 8 57 13 33 600 45 00 18 98 12 86 20 00 800 60 00 25 31 17 15 26 67 1000 75 00 31 63 21 43 33 33 1200 90 00 37 96 25 72 40 00 2000 150 00 63 27 42 87 66 67 4000 300 00 126 54 85 74 133 33 6000 450 00 189 80 128 61 200 00 8000 600 00 253 07 171 48 266 67 10000 750 00 316 34 214 35 333 33 12000 900 00 379 61 257 22 400 00 14000 1050 00 442 87 300 09 466 67 16000 1200 00 506 14 342 96 533 33 18000 1350 00 569 41 385 83 600 00 20000 1500 00 632 68 428 70 666 67 22000 1650 00 695 95 471 57 733 33 24000 1800 00 759 21 514 44 800 00 26000 1950 00 822 48 557 31 866 67 28000 2100 00 885 75 600 18 933 33 30000 2250 00 949 02 643 05 1000 00 32000 2400 00 1012 29 685 92 1066 67 34000 2550 00 1075 55 728 79
18. HZ FT MIN RPM SHAFT RPM 100 7 11 2 99 2 03 3 33 400 28 44 11 94 8 13 13 33 600 42 67 17 92 12 19 20 00 800 56 89 23 89 16 26 26 67 1000 71 11 29 86 20 32 33 33 1200 85 33 35 83 24 39 40 00 2000 142 22 59 72 40 65 66 67 4000 284 44 119 45 81 29 133 33 Start Up Instructions 3 13 Table 5 Cross Reference Printing Diameter 13 11 16 Gear Teeth 128 Continued RTP PRESS WEB BELT PRESS HOUR PD SENSOR VELOCITY MOTOR DRIVE FREQ HZ FT MIN RPM SHAFT RPM 6000 426 67 179 17 121 94 200 00 8000 568 89 238 89 162 59 266 67 10000 711 11 298 61 203 24 333 33 12000 853 33 358 34 243 88 400 00 14000 995 55 418 06 284 53 466 67 16000 1137 78 471 18 325 18 533 33 18000 1280 00 537 50 365 82 600 00 20000 1422 22 597 23 406 47 666 67 22000 1564 44 656 95 447 12 733 33 24000 1706 66 716 67 487 76 800 00 26000 1848 89 716 39 528 41 866 67 28000 1991 11 836 12 569 06 933 33 30000 2133 33 895 84 609 71 1000 00 32000 2215 55 955 56 650 35 1066 67 34000 2417 78 1015 29 691 00 1133 33 36000 2560 00 1075 01 731 65 1200 00 38000 2702 22 1134 73 772 29 1266 67 40000 2844 44 1194 45 812 94 1333 33 42000 2986 66 1254 18 853 59 1400 00 44000 3128 89 1313 90 894 24 1466 67 46000 3271 11 1373 62 934 88 1533 33 48000 3413 33 1433 34 975 53 1600 00 50000 3555 55 1493 07 1016 18 1666 67 52000 3697 77 1552 79 1056 82 1733 33 54000 3840 00 1
19. Initial Settings Parameter Value Description x 551 0 0 ANALOG OFFSET 1 553 0 0 DIGITAL OFFSET 1 558 1500 DANCER FULL POSITION 559 750 DANCER MID POSITON 561 131 PRESS REF PPR m 562 2566 MAX PRESS REF RPM 563 400 VELOCITY KI LOW 564 1700 VELOCITY KI HIGH 565 150 VELOCITY KP LOW 566 425 VELOCITY KP HIGH 567 50 PROCESS REG KI 569 30 VP KI KP SWITCH RPM m 570 20 LOW SUM RRDH 571 0 LOW SUM NORMAL 600 625 VEL INDIRECT 1 P 163 601 721 VEL INDIRECT 2 P 164 602 659 VEL INDIRECT 3 P 165 603 660 VEL INDIRECT 4 P 166 606 1750 BASE MOTOR SPEED m 607 20 REVERSE SPEED LIMIT a 608 1560 FORWARD SPEED LIMIT BELT MOTOR RPM PER CHART 609 210 ENCODER PPR 610 500 RATED MOTOR VOLTAGE 611 20 6 MOTOR ARMATURE FLA 612 1 2 RATED FIELD MOTOR CURRENT 613 6 MOTOR INERTIA 614 5 78 ARMATURE RESISTANCE 615 40 RATED ARMATURE BRIDGE CURRENT 616 2 1 RATED FIELD BRIDGE CURRENT 617 460 RATED AC LINE VOLTAGE 621 0 FEEDBACK DEVICE TYPE 628 1 PROCESS TRIM SELECT 633 20 PRESET SPEED 1 634 20 PRESET SPEED 2 635 0 PRESET SPEED 3 Publication 1395 RTP 5 1 September 1997 3 6 Start Up Instructions Publication 1395 RTP 5 1 September 1997 Table 2 Parameter List Factory Initial Settings Continued Paramete
20. P 5 1 September 1997 3 8 Start Up Instructions Connection to Power Stage Interface Microbus Port A Publication 1395 RTP 5 1 September 1997 Figure 3 1 Main Control Board Overview Connection to Programming Terminal 4 75 Connection to Power Stage Interface TP19 21 20 nS TP33 O O 4 Tp27 7 DeC EU TP48 Q TP49 TPS3 58 54 Oso 5V 12 IGND 150 TP52 PSG TPSS 57 5V 242 1270 AGND Microbus Port B Start Up Instructions 3 9 Cross Reference The printing diameter Tables 3 through 6 provide the proper tracking information such as the number of gear teeth for the magnetic pickup gear the maximum belt motor speed and the press shaft speed at maximum press impressions per hour The main tracking Parameter Parameter 562 should be set at the maximum press shaft speed that corresponds to the maximum press impressions per hour The value used for default is 2566 Table 3 Cross Reference Printing Diameter 14 1 32 Gear Teeth 131 IMP RTP PRESS WEB BELT PRESS HOUR SPD SENSOR VELOCITY MOTOR DRIVE FREQ HZ FT MIN RPM SHAFT RPM 100 7 28 3 06 2 08 3 33 400 29 11 12 24 8 32 13 33 600 43 67 18 37 12 48 20 00 800 58 22 24 49 16 64 26 67 1000 72 78 30 61 20 80 33 33 1200 87 33 36 73 24 96 40 00 2000 145 56 61 22 41 60 66 67 4000 291 1
21. States plus representatives in every major country in the world Local Product Support Contact your local Allen Bradley representative for sales and order support product technical training warranty support support service agreements Technical Product Assistance If you need to contact Allen Bradley for technical assistance please review the product and troubleshooting information in this manual first Then call your local Allen Bradley representative For the quickest possible response we recommend that you have the catalog numbers of your products available when you call Publication 1395 RTP 5 1 September 1997 P 6 Preface Publication 1395 RTP 5 1 September 1997 This page intentionally left blank Drive System Controller Chapter 1 Drive Description The Drive System is designed to utilize tension feedback from an Unwind Dancer to regulate paper roll tension allowing for continuous non stop pasting of the new roll to the existing web The Drive System utilizes a Bulletin 1395 microprocessor based Drive to control the speed and torque of the associated motor The Drive employs line overcurrent devices to reduce the potential for damage to power semiconductor devices caused by short circuit currents The Drive also utilizes three microprocessors on the main control board to control the regulator control logic functions and control SCR firing and system communication functions In addition
22. T be at Zero Speed Mode 6 NORMAL STOP When the Decel input is received in Modes 4 or 5 the belt Drive system is stopped by ramping to zero speed and opens the main contactor At zero speed the operator initiated Tension Reset signal is received returning the Drive to Mode zero Drive ready Mode 7 AUTO SLACK WEB TIGHT The Auto Slack Mode is designed so that the belts will slowly pay off web whenever the dancer is tensioned In the Auto Slack Mode as in the Normal Run Mode the web out detector compares the dancer position with an acceptable dancer range The Drive is allowed to enter Mode 7 when the dancer is below the dancer mid position level which is halfway between the dancer center and dancer full positions When the Auto Slack signal is received the Drive automatically starts in Mode 7 and runs at a preset speed adjustable with Drive Parameter 633 which is set above the press thread inch speed Thus during Mode 7 the reel is paying out paper The belts will run from this internal speed reference with no dancer trim The normal exit from Mode 7 is to Mode 8 when the Dancer reaches full position If the Drive receives a Drive Permit signal DI2 the Drive reverts to Mode 1 Normal Run Publication 1395 RTP 5 1 September 1997 2 4 Description of Operation Publication 1395 RTP 5 1 September 1997 Mode 8 AUTO SLACK WEB LOOSE With the Auto Slack signal present the web out
23. TP 5 1 September 1997 3 2 Start Up Instructions Preliminary Steps Publication 1395 RTP 5 1 September 1997 Configuration Parameter Parameter whose value may be changed during normal operation of the Drive The Configuration Parameters are used to input reference and feedback information to the Drive and to provide monitoring points for control signals The Configuration Parameters are one of two types termed Source or Sink Parameters Refer to the Bulletin 1395 Installation and Maintenance manual for detailed description of Source and Sink Parameters Source Parameter which may be used as a source of data for output to a sink Sink Parameter which acts as an input of data from a source Linking The process of connecting a Sink Parameter to a Source Parameter These steps should already have been accomplished in a Custom Drive Manufactured and Shipped as an RTP Unwind Drive 1 Ifa Drive that has already been installed is receiving a Digital Adapter Board as an added feature then all of the necessary configuration links etc will have to be made 2 Ifa given Drive for any reason loses the EE memory information it will also be necessary to go through the necessary software steps in order to perform the links and set defaults of the setup Parameters These steps will vary from one installation to the next dependent upon the capability of the support equipment available 3 Should there be a need to check or download Pa
24. This mode is entered from Mode 9 Run Reverse Dancer High when slack is removed pulling dancer to center position If dancer moves above center position Drive enters Mode 9 and returns to Mode 14 when dancer reaches center position The normal exit out of Mode 14 is back to Mode 9 which occurs when the dancer moves above center position but if a Drive permit DI2 is received the Drive goes directly into Mode 1 Normal Run Mode 20 SPEED REFERENCE RESET The Drive does not have a speed reference in this mode It has not gone into a normal run auto slack or slack remove mode Publication 1395 RTP 5 1 September 1997 2 6 Description of Operation Publication 1395 RTP 5 1 September 1997 Mode 21 LINE SPEED REFERENCE When the Drive is in a normal run Mode 1 or accel cycle Mode 4 the Drive will follow the press speed reference Mode 22 PRESET 1 SPEED REFERENCE When the Drive is in auto slack with the web tight Mode 7 the Drive will follow the Preset 1 speed reference This is a low forward speed reference which is adjustable in Drive Parameter 633 Mode 23 PRESET 2 SPEED REFERENCE When the Drive is in run reverse dancer high Mode 9 the Drive will follow the Preset 2 speed reference This is a low reverse speed reference which is adjustable in Drive Parameter 634 Mode 24 TORQUE SELECT The torque select Parameter in the Drive Parameter 625 is normally set so the Drive is a velocity regulator Whe
25. ation concerning related Allen Bradley products and related standards To obtain a copy of Allen Bradley publications contact your local Allen Bradley office or distributor For Read This Document Document Number Detailed description of the enhanced programming Enhanced Programming Terminal Manual 1300 5 4 terminal Detailed description of the programming terminal Programming Terminal Manual 1300 5 5 Information on the 1395 digital DC Drive 1395 User manual 1395 5 40 Information on troubleshooting the 1395 digital DC 1395 Troubleshooting Manual 1395 5 45 Drive Information on the digital reference adapter for RTP Digital Reference Adapter for RTP 1395 RTP 5 2 applications Applications User Manual A description of Drive Tools software Drive Tools Software Brochure 9303 1 0 Information on the Intelligent Terminal System Bulletin 1300 Intelligent Terminal System D1300 L00 ITS Documentation Set An article on wire sizes and types for grounding National Electrical Code ANSI NFPA 70 electrical equipment Published by the National Fire Protection Association of Boston MA An article on safety procedures Standard for Electrical Safety ANSI NFPA 70E Requirements for Employee Workplaces A complete listing of current Allen Bradley Allen Bradley Publication Index SD499 documentation including ordering instructions Also indicates whether the documents are available on CD ROM or in multi languages 7 1 A glos
26. c control precautions are required when installing testing or repairing this assembly Component damage can result if ESD control procedures are not followed If you are not familiar with static control procedures refer to Allen Bradley publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook ATTENTION Potentially fatal voltages may result from improper usage of an oscilloscope and other test equipment The oscilloscope chassis may be at potentially fatal voltage if not properly grounded If an oscilloscope is used to measure high voltage waveforms use only a dual channel oscilloscope in the differential mode with X100 probes It is recommended that the oscilloscope be used in the A minus B Quasi differential mode with the oscilloscope chassis correctly grounded to an earth ground Refer to equipment safety instructions for all test equipment before using with the Drive Publication 1395 RTP 5 1 September 1997 P 4 Preface Contents of This Manual Chapter Title Contents Preface Purpose background and scope of this manual 1 Drive Description Description of equipment and specifications 2 Description of Operation Drive system modes and the global RTP 3 Start Up Instructions Terminology parameter set up and configurations 4 Troubleshooting Digital reference adapter fault messages Related Documentation The following documents contain additional inform
27. cer performance will continue to degrade until the system will cause web out with the dancer either too high or too low The problem can be observed in its early stages or at lower press speed by the sudden movement of the dancer usually downward followed by dancer recovery The Drive control variable which can be used to observe this phenomenon is process trim output The process trim output will vary but the variance due to the magnetic pickup device will be exhibited in erratic behavior which will begin occurring at some high press speed The dancer may also move downward without recovery While press is running at a thread speed monitor Parameter 154 Velocity Reference Whole If the value remains at zero stop the press and calibrate the magnetic pickup This should be accomplished with the use of an oscilloscope to observe a 50 50 duty cycle Once the problem has been identified try not to run the press above this threshold of speed until the pickup can be properly aligned and verified for proper operation A Adapter 4 2 Configuration Parameter 3 2 Control Board Main 3 7 Controller 1 1 Cross Reference Gear Teeth 3 9 D Dancer at Center Position 3 16 Dancer Calibration 3 16 Dancer Voltage 3 16 Description of Operation 2 1 DHT 3 3 Digital Reference Fault Messages 4 4 DR 01 DIG REF OK 4 4 DR 60 Illegal Mode Soft Fault 4 4 DR 70 DP HANDSHAKE Soft Fault 4 4 DR 71 Mbus RAM Test Soft Fault 4 4 DR 80 Low 2
28. d as follows Refer to Logic State Diagrams in the System Binder as required Mode Description 0 to 14 Drive logic 20 to 31 Drive reference control The status of each input and output signal to the Drive Digital Reference Adapter Board is tabulated at the end of this section This table may be used to diagnose the status of the system if a fault is suspected LED indicators are employed on the Adapter Board to assist in identifying which inputs and outputs are ON at any given time Mode 0 DRIVE READY When the Drive is at standstill with the contactor open in a ready condition it will be in Mode zero In this Mode the Drive is waiting for any type of run command Mode 1 NORMAL RUN Motor controller follows press speed trimmed by dancer position A Drive Permit signal is received which starts the Drive A pulsed Emulate signal is also received approximately 2 seconds in length which allows the Drive to pull the dancer into position without detecting a web out Publication 1395 RTP 5 1 September 1997 2 2 Description of Operation Publication 1395 RTP 5 1 September 1997 The press speed is measured with a magnetic pickup and fed into the Digital Reference Adapter Board on the Drive This signal serves as the basic speed reference for the unwind belts The press speed signal is linked to the Drive Velocity Reference Parameters 153 and 154 and sent through the Drive Ramp Control The dancer input is fed int
29. e Drive at the Digital Reference input of the DRA board A preset speed for Auto Slack and Run Reverse Dancer High RRDH Slack Remove Refer to the State Logic Diagram in the system binder An Emulated line speed from a potentiometer Drive reference control mode 30 can be observed in Parameter 597 which is a read only Parameter if the proper input conditions are met Refer to the Drive Reference Control State Diagram in the system binder The combination of digital input number 9 of the DRA board and bit 0 of Parameter 572 set high will determine which speed reference will be used by the Drive to enter either mode 21 or mode 30 Mode 30 is used for testing and calibrating purposes to simulate a running press Mode 21 is the normal speed reference mode for the Drive to follow the line speed of the press during normal running conditions Mode 31 AUTO SLACK TIGHT VARIABLE REFERENCE ASTVR Asia Pacific With the proper input conditions present as shown on the Drive Reference Control State Diagram in the system binder Mode 31 will be entered and allow the Auto Slack speed to be adjustable by an external means such as a potentiometer connected to analog input number 2 The combination of Bit 1 of Parameter 572 set high and the Auto Slack digital input number 7 set high will access this mode which can be observed in the read only Parameter ROP 597 Introduction Terminology Chapter 3 Start Up Instructi
30. e ramp rate is set by Drive Parameter 652 At this point the turret indexes and a new roll of paper is positioned under the raised belts When the new roll is in position the belts may be lowered Mode 4 ACCEL CYCLE The belts accelerate a new roll of paper to speed match with the press When the Accel signal is received the press speed reference is once again used as the velocity reference for the Drive The belts ramp up to the press speed The accel rate is set by Drive Parameter 651 Description of Operation 2 3 When the belts have accelerated to line speed the up to speed algorithm in the Drive energizes the Speed Match output The belts should be fully down on the new roll before the accelerate mode is initiated When the Speed Match signal is present the new roll is ready to splice Mode 5 SPEED MATCH The new roll is spliced in and the belt Drive system returns to Mode 1 When the new roll has been accelerated to speed match with the press and the new web has been pasted onto the web from the old roll the knife will fire to cut off the old roll At the same time the knife fires the Tension Reset signal is sent momentarily This resets the tension remove timer and resets the Drive to Mode 1 When the Tension Reset signal is received dancer control will return to the belts and the Goss core brake will be disabled To enter Mode 5 the At Speed signal must be ON and the motor CANNO
31. final speed matching adjustment for maximum speed tracking for the Drive when following the press line speed reference signal This adjustment must be made with the integral gain of the P I Regulator P 567 set to zero so as not to try to compensate for tracking error As the press speed is gradually increased the dancer trim circuit process trim may continue to correct for tracking tension error Monitor Parameter 119 process trim output to observe this error Every 5000 impressions per hour increase would be a good idea to evaluate whether the dancer voltage has moved significantly TP14 amp 12 and if the process trim output P 119 has increased Adjust Parameter 562 until the process trim output P 119 is as close as possible to zero The default value for Parameter 562 is 2566 based ona 14 1 32 print diameter Normal position for the dancer during this part of the start up is slightly above center corresponding to less than 1 volt at TP14 to TP12 3 The RTP Drive should be tracked at maximum speed with a roll of paper at least 75 of full roll 4 Ifthe press is to remain at a given maximum speed for a period of time and a significant amount of paper is to be run the integral gain Parameter should be set to its final value of 50 P 567 HOWEVER anytime the system is taken to a higher speed the remainder of the tracking should be accomplished and again Parameter 567 should be set to zero until the tracking adjustments are
32. ions Publication 1395 RTP 5 1 September 1997 Connect hand held programming terminal to Drive at DHT Connector located to the left of TB3 at the bottom of the Drive Upon power up communications are initialized as indicated by the letter I in Drive graphically displaying a moving pendulum Check LEDs on Digital Reference Adapter Board for 12V 12V 5V and 24V Status See Troubleshooting section for further explanation Verify links and parameters match the tables provided using the Programmable Terminal To access links enter Drive Set Up mode select Read Edit and view the next link each time the ENTER key is depressed If necessary parameters and links can be entered with the DHT or the Intelligent Terminal System ITS if available or Drive Tools software Table 1 Link List Parameter Links Sink Source 450 TO 100 151 TO 400 152 TO 200 153 TO 404 154 TO 403 161 TO 407 163 TO 405 164 TO 408 165 TO 410 166 TO 411 250 TO 100 The following Parameter list is a quick reference table showing the set up parameters and values associated with an RTP start up The motor data is for and Baldor Motors refer to proper 18 drawings for other motors Refer to Bulletin 1395 Drive Installation amp Maintenance Manual or associated schematics for complete Parameter list and descriptions Start Up Instructions 3 5 Table 2 Parameter List Factory
33. lications contact your local Allen Bradley representative for information before using this product This manual describes the digital reference adapter board functionality for firmware version 4 xx The xx designator may vary but it does not affect information in this manual Use this manual if you are responsible for installing wiring starting up or troubleshooting RTP control systems This manual is intended for qualified service personnel responsible for setting up and servicing the 1395 digital DC Drive and RTP accessories You must have previous experience with and a basic understanding of electrical terminology programming procedures required equipment and safety precautions before attempting to service the 1395 Drive for RTP applications Publication 1395 RTP 5 1 September 1997 P 2 Preface Safety Precautions Publication 1395 RTP 5 1 September 1997 The following general precautions apply to Bulletin 1395 Drives and to RTP applications ATTENTION Only those familiar with the RTP system the products used in the system and the associated machinery should plan or implement the installation startup and future maintenance of the system Failure to comply can result in personal injury and or equipment damage ATTENTION Verify that all sources of AC and DC power are deenergized and locked out or tagged out in accordance with the requirements of ANSI NFPA 70E Part II ATTENTION Servicing energized ind
34. meters that may be used to check incoming logic commands speed signals and dancer operation Table 1 Troubleshooting Parameter Reference Logic Status P596 Logic Mode Parameters P597 Speed Reference Mode P598 Process Trim Mode P100 P450 Logic Status P151 P400 Logic Control Speed amp Feedback P154 P403 Speed Reference Whole Parameters P153 P404 Speed Reference Fractional P106 Digital Velocity Feedback Process Trim P628 Process Trim Select Parameters P161 Process Trim Reference P104 Final Ref Velocity w Trim P567 Dancer Integral Gain P568 Dancer Proportional Gain Dancer Position P595 Raw Dancer In Digital Parameters P551 Analog Dancer Offset P558 Dancer Webout Position 1500 default P559 Dancer Mid Position 750 default P560 Dancer Center Position TP14 TP12 Buffered Analog Dancer Trim Input 10V DC to 10V DC Speed Match amp P561 Press Speed Gear Tooth Count Set up Related P608 Max Belt Motor RPM at 75KIPH Parameters P606 Base Motor Speed 1750 RPM P562 Max Line Shaft Speed at Max Belt Motor RPM All adapters provide initial fault handling based on conditions within their environment and then signal the 1395 which provides further disposition based on system requirements Faults are divided into three categories as described below Publication 1395 RTP 5 1 September 1997 4 2 Troubleshooting Adapter Publication 1395 RTP 5 1 September 1997 Hard Faults Ha
35. n running in auto slack with the dancer in the full up position the torque select Parameter is set to zero which is zero torque command This prevents any motor armature current and torque while keeping the Drive energized with the main contactor picked up This will prolong contactor life by eliminating the cycling ON and OFF of the contactor during web up Mode 25 TORQUE SELECT TORQUE REFERENCE REVERSE This mode is used for reverse run only When in logic Mode 9 the Drive will run slowly in reverse at preset 2 speed reference until dancer is centered then reference will change to torque mode with zero torque command This prevents motor armature current and torque while keeping the Drive energized with the main contactor picked up Mode 26 PROCESS TRIM DISABLE Any time the Drive is in the paste cycle the dancer trim is disabled This allows the Drive to run from the velocity reference only The velocity reference could be zero or press speed reference Global RTP Drive USA Europe Asia Pacific Description of Operation 2 7 Mode 27 PROCESS TRIM ENABLE This enables the process trim in the Drive to allow proper tensioning of the web Movement of the dancer will either add or subtract from the press speed reference in order to hold the dancer close to the center position at all times during normal run Two new drive reference control modes have been added to allow for adjustable Auto Slack Speed Control Asia Pacific
36. o the analog input channel on the Drive and linked to the Process Trim Reference Parameter 161 and sent through the Process Trim Control The output of the ramp control is summed with the output of the process trim to obtain the final velocity reference The position of the dancer is continuously monitored in all Normal Run Modes so that if a web break occurs the motor controller will regenerate to zero speed under current limit control The Drive Permit input will remain present for 15 seconds after zero speed is reached keeping the Main Contactor closed At the end of 15 seconds the Drive Permit input drops out causing the Main Contactor to open and the Drive will turn off See Mode 10 Mode 2 PASTE CYCLE Motor controller follows press speed with no dancer trim When the Tension Remove input is received the belts are removed from the expiring roll and the dancer trim is turned OFF hence the motor controller follows press speed only At this point the Goss core brake has control of the expiring roll Mode 3 DECEL CYCLE Decelerate under ramp control 2 seconds after initiating a paste After 2 seconds determined by Parameter 580 after receiving the Tension Remove signal the press speed reference is removed and the Drive velocity reference is set to zero preset speed 3 with a value of zero RPM This will ramp the Drive down to zero speed with the main contactor remaining energized and the Drive active Th
37. ons The following start up instructions should be used to fine tune the operation of the RTP Drive The complete start up procedure for the associated Drive can be found in the Bulletin 1395 Installation and Maintenance Manual Read and understand the complete procedure prior to attempting start up of the RTP Drive Important Before attempting to operate the Drive ensure that the mechanics of the associated press system have been checked and properly set up Check the e gearbox fluid level type of lubricant used belt tension associated wiring mag pick up gap per Goss specifications Pre Power Drive Checks 1 Power Terminations within the Drive are tight All control wiring is secure 2 3 wiring and cabinets are properly grounded 4 control boards are secure 5 All terminal blocks are secure Parameter Memory location used to store Drive set up data or to monitor real time input or output information Each parameter is assigned a name and number which does not change Set Up Parameter Parameter whose values do not change during normal operation of the Drive The Set Up Parameters are used for scaling and calibration of specific Drive functions which are application and or hardware dependent Read Only Parameter Parameter whose value cannot be changed by any external device Special Parameter used only for the purpose of monitoring several internal strategic variables Publication 1395 R
38. oughout the life of the press One way of quickly and reputably setting the dancer at center position is to establish a mechanical data point for the placement of a machined block that acts as a setup block to restrict the dancer of downward movement only during setup and troubleshooting with no paper webbed from the reel Two of these machined blocks are recommended one for each side of the dancer Once the dancer potentiometer has been set up for 0 0 volts DC 0 2 volts with the dancer in the horizontal level position the following normal adjustments to the setup parameters can be made prior to starting the Drive Preliminary Steps A Disable the process trim system by setting Parameter 628 to zero B Disable the integral channel of the P I Regulator by setting Parameter 567 to zero 1 Using a digital voltmeter monitor test point TP14 to TP12 on the Digital Reference Adapter Board The voltage should be 0 0 volts DC with the dancer in the horizontal or dancer center position If there is a need to trim the voltage to a value closer to zero use Parameter 551 eg V TP14 0 5 volts using the DHT find Parameter 551 arrow down to the value use the DEC key to change from the default value of 0 0 volts to a negative number Continue to enter DEC until the value at TP14 is as close as possible to 0 0 volts Start Up Instructions 3 17 2 Once step 1 is complete the dancer should be allowed to move freely Move the dance
39. r Value Description 651 20 ACCEL TIME 652 10 DECEL TIME 659 400 KI VELOCITY LOOP 660 150 KP VELOCITY LOOP 661 65535 KF VELOCITY LOOP 663 150 FORWARD BRIDGE CURRENT LIMIT 664 150 REVERSE BRIDGE CURRENT LIMIT 713 0 PROCESS TRIM FILTER 714 0 INTEGRAL PRELOAD 715 0 KI INTEGRAL GAIN 716 4096 KP PROPORTIONAL GAIN 717 165 PROCESS TRIM LOW LIMIT 718 165 PROCESS TRIM HIGH LIMIT 719 1 P I REGULATOR OUTPUT GAIN 720 150 OVERLOAD PENDING LEVEL 721 0 PROCESS TRIM LOW SUM 722 1750 PROCESS TRIM HIGH SUM 724 75 ABSOLUTE OVERSPEED 725 10 EXTERNAL OVERTEMP DELAY 726 10 SCR OVERTEMP DELAY 727 2 STALL DELAY 728 1 AC LINE TOLERANCE DELAY 730 1 FIELD FAILURE DELAY 731 15 TACH LOSS CEMF 732 0 5 TACH LOSS VELOCITY 733 1 ARM BRIDGE TYPE 734 155 K DISCONTINOUS 735 1659 KP ARMATURE LOOP 736 136 KI ARMATURE LOOP 737 16384 KP FIELD LOOP 738 512 KI FIELD LOOP m 739 12350 K ARM VOLTS z 740 7200 K AC VOLTS DEFAULTS may be adjusted per installation as required Start Up Instructions 3 7 Control Boards Main Control Board A8 Figure 3 1 illustrates the major hardware points on the board The board performs all control functions of the Bulletin 1395 Drive Hardware located on the board is used to support operation of the microprocessor program The primary functions performed include Microbus Interface Control Firmware Analog Signal Interface Develop gate control signals sent to the Power Stage Interface Publication 1395 RT
40. r up and down to make sure there is no mechanical binding Then move the dancer to the approximate position of WEB OUT Monitor the value of Parameter 595 the analog 1 raw output The value should normally be greater than 1500 The default value that has been arrived at for the setup of the production units for the web out setting is 1500 Parameter 558 Dancer Full Position This sets the internal logic to recognize a web out at the position of 1500 which should be approximately 5 8 inch to 3 4 inch below full up at auto slack tension 5 to 5 1 2 PSI The Goss preferred method for establishing web out is to position dancer so that the flag or hammer is just touching shock absorber no compression observe Parameter 595 note value and subtract 100 drive units then enter that value into Parameter 558 Dancer Full Position Note Parameter 559 Dancer Mid Position must be set to half the value of Parameter 558 Dancer Full Position This is all that is required prior to starting the Drive The following suggested adjustments should be made during initial checkout Permanently store the parameters in EEPROM before proceeding Important The magnetic pickup signal is summed with the pulse generator for the Emulate signal in the GSD Console Panel Thus when the Drive is in the emulate mode the magnetic pickup and associated circuitry are not part of the system Drive Started Emulate Mode Since there is no
41. rameters to the Drive use of the ITS device will prove to be one of the most efficient methods ITS Monitor To monitor Parameters From Main Menu Select Diagnostics ENTER key Select Monitor ENTER key Select Table ENTER key Start Up Checklist Start Up Instructions 3 3 ITS Download To download from ITS to Drive From Main Menu Select Drive Data Select Edit ENTER key Select Parameter cursor through Parameters make changes ESC Select EEPROM ENTER key Select Save ENTER key DHT Hand Held Programming Terminal From Main Menu Select Parameters Type Parameter number ENTER key Arrow down cursor to value and type new value ENTER key When changes are completed depress MENU key The DHT will prompt SAVE CHANGES Select Yes ENTER key Verify J6 and J7 jumpers on the Digital Reference Adapter Board are in Position 1 2 Verify J1 jumper on Feedback section of the PSI Switcher Board of the 1395 Drive is in Position 3 Verify J8 J9 and J10 jumpers on the Main Control Board of the 1395 Drive to be in Position 1 2 Figure 3 1 Verify burden resistors on Feedback Board to be 25 2 Ohms on TB1 and 80 Ohms on TB3 for a 1395 B68 or 13 8 Ohms on TB1 and 45 9 Ohms on TB3 for a 1395 B70 Verify incoming AC line to Drive L1 L2 and L3 to 380 or 460 VAC 10 Publication 1395 RTP 5 1 September 1997 3 4 Start Up Instruct
42. rd Faults are nonrecoverable That is the 1395 Drive must either be RESET or POWER CYCLED in order to clear the faulted condition An adapter board transmits a fault to the 1395 Main Computer Board through the Dual Port Ram as explained in the 1395 Instruction Manual A Hard Fault in an adapter is designed to create an ECOAST stop Soft Faults Soft Faults occur when an adapter detects a condition which may result in undesirable operation The adapter takes appropriate action within its domain to guard against further operation and signals the condition to the 1395 Drive In addition the fault may be cleared and normal operation resumed at the point the fault occurred Warning Faults Conditions detected within the system that may produce Soft Faults if the condition is allowed to persist Each processor or adapter provides its own set of sophisticated diagnostics which the user can examine to help determine the nature of problems that may arise Maintenance is done at the board level Examining the diagnostic fault messages available determines whether a board should be replaced The malfunctioning board may be returned to Allen Bradley for further disposition The board mounted LEDs can be of assistance in easily narrowing down a problem to a specific area Figure 4 1 depicts the Adapter decal located on inside door of the Drive This reference decal should be used to aid in the location and identification of LED indicators and other boa
43. rd components The LEDs DS1 DS2 mounted near the top of the board indicate the status of the Drive s main 12V DC power supply Also test points for the supplies are mounted in close proximity along with analog common so that the actual voltage can be measured The 5 volt supply is combined with the processor OK logic both indicated as being OK with the next LED down from the top Again if the 5 volt supply is suspect it can be measured with respect to digital common with test points mounted close to the top of the board If any of the power supply voltages are out of tolerance further troubleshooting is required such as interconnection wiring checks as well as actual power supply voltage measurements at the power supply Troubleshooting 4 3 Figure 4 1 Digital Reference Adapter Board LED Location amp Identification LJ J1 DS1 DS2 Cu 12V DC OK 12V DC OK 5V DC amp Computer OK DS4 24V DC OK TENSION REMOVE 003 BELT EMERGENCY BRAKE D 04 DIGITAL OUTPUT 4 pos DIGITAL OUTPUT 5 DECEL DIGITAL INPUT 10 Di6 TENSION RESET QC AuTOSLACK SLACK REMOVE DIGITALINPUTS D01 SPEED MATCH DRIVE PERMIT O READY EMULATE N OQ The 24V DC power supply has its LED mounted close to the input fuse for the input power Mounted at the bottom of the board are
44. rum of easy to integrate products These are supported by local technical resources available worldwide a global network of system solutions providers and the advanced technology resources of Rockwell Worldwide representation Argentina Australia Austria Bahrain Belgium Bolivia Brazil Bulgaria Canada Chile China People s Republic of e Colombia Costa Rica Croatia Cyprus Czech Republic Denmark Dominican Republic Ecuador Egypt El Salvador Finland France Germany Ghana Greece Guatemala Honduras Hong Kong Hungary Iceland India Indonesia Iran Ireland Israel Italy Jamaica Japan Jordan Korea Kuwait Lebanon Macau Malaysia Malta Mexico Morocco The Netherlands New Zealand Nigeria e Norway Oman Pakistan Panama Peru Philippines Poland Portugal Puerto Rico Qatar e Romania Russia Saudi Arabia Singapore Slovakia Slovenia South Africa Republic of Spain Sweden Switzerland Taiwan Thailand Trinidad Tunisia Turkey United Arab Emirates United Kingdom United States Uruguay Venezuela Rockwell Automation Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Rockwell Automation European Headquarters SA NV avenue Herrmann Debrouxlaan 46 1160 Brussels Belgium Tel 32 2 663 06 00 Fax 32 2 663
45. sary of industrial automation terms and abbreviations Allen Bradley Industrial Automation Glossary Publication 1395 RTP 5 1 September 1997 Common Techniques Used in This Manual Product Receiving Allen Bradley Support Preface P 5 The following conventions are used throughout this manual Bulleted lists such as this one provide information not procedural steps e Numbered lists provide sequential steps or hierarchical information When we refer you to another location the section name appears in italics e The exclamation point inside of a triangle followed by the word ATTENTION indicate circumstances that can lead to personal injury death property damage or economic loss You the customer are responsible for thoroughly inspecting the equipment before accepting the shipment from the freight company Check the item s that you receive against your purchase order If any items are obviously damaged it is your responsibility to refuse delivery until the freight agent has noted the damage on the freight bill Should you discover any concealed damage during unpacking you are responsible for notifying the freight agent Leave the shipping container intact and request that the freight agent make a visual inspection of the equipment Allen Bradley offers support services worldwide with Sales Support Offices authorized distributors and authorized Systems Integrators located throughout the United
46. st be greater than dancer center P558 Internal Drive logic of the Digital Reference Adapter Board has reached an invalid state Clear fault power down and reapply power If not solved INITIALIZE EEPROM re download links and Parameters SAVE to EEPROM then CLEAR FAULTS If not solved replace Digital Reference Adapter Message Fault Type Cause Action Message Fault Type Cause Action Message Fault Type Cause Action Message Fault Type Cause Action CA 64 ADAPTER PROCESSOR FAULT CA 65 ADAPTER PROCESSOR FAULT CA 66 ADAPTER PROCESSOR FAULT CA 67 ADAPTER PROCESSOR FAULT Hard Adapter internal diagnostic malfunction Check dip switch settings and reset drive if condition persists replace adapter board CA 70 RESET PROGRAM TEST CHA CA 85 RESET PROGRAM TEST CHB Soft Warning PLC was switched from run mode to another mode Check PLC mode switch and I O control reset if condition persists replace adapter board CA 71 RIO COMM LOSS CHA CA 86 RIO COMM LOSS CHB Soft Warning Loss of communication between adapter and PLC Check wiring and connections verify adapter is being scanned if condition persists replace adapter board 75 NODE ADDR CHA CA 90 DUP NODE ADDR CHB Soft Warning One or more nodes with the same address exist on the DH network Check that each node has a different address if condition persists replace adap
47. ter board Publication 1395 RTP 5 1 September 1997 4 6 Troubleshooting Press Speed Magnetic Pickup Publication 1395 RTP 5 1 September 1997 Message CA 76 GLOBAL DATA NODE LOSS CHA CA 91 GLOBAL DATA NODE LOSS CHB Fault Type Soft Warning Cause Global data was being received from node address and has ceased Action Check configuration Parameter for correct global data node address verify node address is on the network If condition persists replace adapter board Message 77 LOSS NETWORK DEAD CHA CA 92 COMM LOSS NETWORK DEAD CHB Fault Type Soft Action Check wiring and connections replace MCA board if condition persists Important The magnetic pickup signal is summed with the pulse generator for the emulate signal in the GSD console panel As a result when the Drive is in the emulate mode the magnetic pickup and associated circuitry are not part of the system One of the possible areas of concern is the press speed magnetic pickup The device is normally located directly overhead of the respective RTP Drive of interest The magnetic pickup has an adjustment procedure which will allow the mechanical movement of the position of the sensor which also adjusts the device output voltage magnitude at a given press speed The problem will exhibit itself in poor performance of the dancer relative to position tracking at a given maximum press speed Once this speed is reached the dan
48. the digital reference adapter utilizes another microprocessor to provide for a digital to digital line speed reference as well as special Dancer potentiometer circuitry and on board drive state machines for outer loop control of the Drive Extensive diagnostics are built into the Drive to aid in troubleshooting thus correcting many Drive and related system problems The Drive resolves all internal faults to guard against needless Drive trips during normal operation To better understand the associated Drive refer to the appropriate Bulletin 1395 Instruction Manual to obtain in depth knowledge of the Drive functions Publication 1395 RTP 5 1 September 1997 2 Drive Description This page intentionally left blank Publication 1395 RTP 5 1 September 1997 Drive System Drive System Modes Chapter 2 Description of Operation The RTP Drive utilizes a three phase armature regeneration digital DC Bulletin 1395 Drive to control the DC motor in a surface driven unwind The speed demand for the Unwind Drive is generated from press speed via a zero speed magnetic pickup In normal operation the press speed reference is trimmed by dancer position error to maintain constant dancer position The Drive allows for speed matching automatic slack take up paying off to full dancer storage regenerative stopping under current limit control and regenerative stopping with controlled deceleration The Drive operation modes are groupe
49. u aware of safety considerations ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attention statements help you to identify a hazard avoid a hazard recognize the consequences Important Identifies information that is critical for successful application and understanding of the product DriveTools is a trademark of Rockwell International or its subsidiaries Table of Contents Preface Who Should Use This Manual 1 Purpose of This P 1 Safety P 2 Contents of This Manaul P 4 Related Documentation P 4 Common Techniques Used in This Manual P 5 Product Receiving P 5 Allen Bradley P 5 Chapter 1 Drive Description Drive System 1 1 Controller 1 1 Chapter 2 Description of Operation Drive System 2 1 Drive System Modes 2 1 Global RTP Drive USA Europe Asia Pacific 2 7 Chapter 3 Start Up Instructions Introduction Su Do ere PA RC a 3 1 Terminology sn Cos ci eb eg e tane 3 1 Preliminary
50. ustrial control equipment can be hazardous Severe injury or death can result from electrical shock burn or unintended actuation of controlled equipment Hazardous voltages may exist in the cabinet even with the circuit breaker in the off position Recommended practice is to disconnect and lock out control equipment from power sources and discharge stored energy in capacitors if present If itis necessary to work in the vicinity of energized equipment the Safety Related Practices of NFPA 70 E ELECTRICAL SAFETY FOR EMPLOYEE WORKPLACES must be followed DO NOT work alone on energized equipment ATTENTION The system may contain stored energy devices To avoid the hazard of electrical shock verify thatall voltage on capacitors has been discharged before attempting to service repair or remove a Drive system or its components You should only attempt the procedures in this manual if you are qualified to do so and are familiar with solid state control equipment and the safety procedures in publication NFPA 70E ATTENTION An incorrectly applied or installed Drive canresult in component damage and or a reduction in product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply and excessive ambient temperatures can result in the malfunction of the Drive equipment Preface P 3 ATTENTION This Drive system contains ESD electrostatic discharge sensitive parts and assemblies Stati
51. wer DR 80 Low 24V Power Supply Warning Fault The fault indicates that the remote 24V DC power supply has failed This can occur because of incorrect wiring of one of the digital inputs from the paster or GSD console panel Check fuse on board check voltage at terminal strip etc Correct external problem clear fault If not solved replace Digital Reference Adapter DR 81 Logic State Fault Soft Fault The internal Drive logic of the Digital Reference Adapter Board has reached an invalid state Clear fault power down and reapply power If not solved replace Digital Reference Adapter DR 82 Auxiliary Logic Soft Fault The auxiliary input logic via digital inputs 9 and 10 cannot be set to the same bit i e Parameter 578 amp 579 must not be set equal to each other if they are set to anything other than 16 The auxiliary inputs are a way to run and stop the Drive without using the internal logic state diagram based logic system Correct Parameters clear fault If not solved replace Digital Reference Adapter Multi Comm Fault Messages RIO Faults DH only Faults Troubleshooting 4 5 DR 83 Dancer Parameters Soft Fault The dancer parameters corresponding to dancer center dancer mid midpoint between center and full and dancer full Parameters 560 559 and 558 respectively must be given values in the proper numeric sequence Dancer full Parameter 558 must be greater than dancer mid P559 Dancer mid mu

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