Diameter Calculator Reference Manual
Contents
1. ES TOS NWW e9uUed ul enesa1 gue paLugiesaig ueid Ia 5 U Peq Wda peedsiou E INdW usen jergeuzpie Wd4 jeupeedseuri epeua QPM X eV Drive Application Software page 28 of 30 Appendix C Parameter Tag Table Input Tags for Diameter Calculation Function Module FM Diameter Calculation Name Type Source Tag from Routine Default ys dn 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 Rxx zDLx DiamPreset1Val in NA 4 0 Preset2Val in Rxx zDLx DiamPreset2Val in NA 6 0 Preset3Val in Rxx zDLx DiamPreset2Val in NA 9 0 PresetIncCmmd Bx wDLx_DrvCmmdProcLn 19 NA 0 PresetDecCmmd Bx wDLx DrvCmmdProcLn 19 NA 0 PresetIncDecRate_inSec R xx oc al ac NA 0 0 DiamCalc Routine CalcEnbl Bx DLx_DrvStatProcLn 7 NA 0 CalcEnblThresh FPM Rxx zDLx CalcEnblThresh FPM NA 5 0 CalcUpdate Rev Rxx zDLx CalcUpdate Rev NA 2 0 SpeedLine FPM Rxx DLx LineSpdRf FPM RunJogSpdRf NA SpeedMotor RPM Rxx SpeedMotor RPM Main scaled to RPM NA GearRatio Rxx zDLx GearRatio NA 5 0 DiamMinEC in Rxx zDLx DiamMinEC in NA 4 0 DiamFR in Rxx zDLx DiamFR in NA 30 0 DiamMeasEnbl Bx None NA 0 DiamMeasInput Rxx None NA 0 0 DiamMeasMin_DC Rxx None NA 1 0 DiamMeasMax_DC Rxx None NA 2 0 DiamMeasMin_in Rxx None NA 1 0 DiamMeasMax_2. esssssssee enne 9 4 0 Functional Description eeeeeeseieeseseeeeseeee seen nennen nennen nant nant annua 10 Aol SONGIVIOW S edu a ls eon A ea eoo te 10 4 1 1 MEL ee ee ee ee ce eee eee caede ceu ee dee ee ae decet esee ee cue caen 10 4 1 2 Diarrea cna derat 10 4 1 3 DiamGalc routine eee dd cede uet a AAA Dee dre aa 10 42 A cerae cec cere Les resolves cet cree 10 o E LLL c 11 4 3 1 Preset CMMd Li nan dise isst risen rien 11 4 3 2 Preset2Gmimd en ae 11 4 3 3 Preset3Cmmd ccccccccccceccceeccceeescuececuecscueeseueeseueeeeuuceeauceaaueeeuueseueueeuaeeauaeeeuaeeeuuseueeseneeees 11 4 3 4 A sec to AR EE 12 4 3 5 IA IIAE A 12 4 3 6 PresetoVallIN tito oa aaa ceden one 12 4 3 7 PresetlmncGOmrid ente llei efe Poit PO LT 12 4 3 8 PresetDecGOmimd 5 ib vet isa e Po dto 12 4 3 9 PresetlncD cRalte inS86 0 etel oreet etate tede t edet ana tu Uude t aee edet udo tudo ade n e De Ene eC NE UG 12 4 3 10 DiamPresetGCmlimnd e E OE D Pob POI 12 4 3 11 DiamPresetVall in rca di 13 41 DIAM Gale TOUS aree stet aeree arse AE il alot Rl win eld Are np AT Heu arr 13 4 4 1 Gal cal PD 14 4 4 2 GalcEnblThreslhi F PM eee oe t e e ve a er e e e a d e ea e e 15 443 GalcUpdate Rev ee eee oda ds 15 444 Speedbine S o i eoe eroe tee ae eerte E Re EU A darte ue ue gue 15 44 5 SpeedMolor Riad ds 15 4 4 6 Gear ali tc cte Term ae lc nc et eee an eU Le UE e hl Ge 15 4 4 7 DIaMMINEC oe In ER c Oe E 15 4 4 8 IB
3. Jog in Forward direction 05 Jog Reverse Jog in Reverse direction 06 Reverse Rotation Under Wind Under wind selection 07 Tension Control Enable Activates selected mode of Tension Control User determines how and when to activate 08 Stall Tension i Stall Tension 09 Tension Control Selects Tension Control Mode Tension 10 Torque Control Selects Tension Control Mode Torque 11 Dancer Control Selects Tension Control Mode Dancer 12 Torque Trim Selects Trim type Torque is trimmed 13 Speed Trim Selects Trim type Speed is trimmed 14 Draw Trim Off Zeros the Draw trim signal 15 Torque Follower Control Special Control mode for torque follower 16 Diam Preset 1 Commands preset 1 for Diam Calc 17 Diam Preset 2 Commands preset 2 for Diam Calc 18 Diam Preset 3 Commands preset 3 for Diam Calc 19 Diam Preset Increase Manual increase for Diameter Calc 20 Diam Preset Decrease Manual decrease for Diameter Calc 21 Diam Calc Increase Enable Releases Diameter Clac for Increase 22 Diam Calc Decrease Enable Releases Diameter Calc for Decrease 23 Reserved 24 Reserved 25 Reserved 26 Reserved 27 Reserved 28 Reserved 29 Torque Mem Enable Memorizes running torque 30 Torque Mem Boost Enable Boosts the memorized torque by user set percentage 31 Torque Mem Knife Cut Boosts the memorized torque by user set percentage Drive Application Software page 26 of 30 FM Diameter Calculation The following table is a fun
4. 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 EncdrO 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 configurati
5. 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 uan 5 Os nire T SEU ee e 6 21 Conventions socor eon Ui DNI XII LXI DIRMI ED RIAM XL 6 2 2 Normalized Quianlill8S oce clouds kde cece eel ecadsedceead be ec ed ee ene ee Cesare eee e dene 6 2 30 Terminology A mutua rer recur C Ra Fun ea tu re oa t tn ua reve ea ta a Rau a e e do EE ea qe eua 7 2 3 1 Web ida 7 2 3 2 Qo S 7 2 3 3 A RT 7 2 3 4 Motor Tor qUe cc nia 7 2 3 5 0 110 e A no E RM 7 O OVER VIC Wasi 8 3 1 Diameter effects on surface speed o ooooooooocccnccccconocononnnnnnnnnncnnnnonnnnnnnnnnnnnnnnnnnnnnnns 8 3 2 Diameter effects on surface tension
6. 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 diam
7. 0 The three routines are the Main DiamPreset amp 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 Sub Routine 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 descr
8. 3 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 8 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 7008 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 consi
9. D 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 amp 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
10. 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
11. I gp RN 15 4 4 9 DiamMeasEnbl z or reor eee eee esto iio 16 44 10 Di mbMesaslnput orent eerte ita 16 4 4 11 DiamMeasMin DC 0 ccc cece cece cece nennen eene nnn nnn nnn nnn n nnns nnns EEE EE EEA EEE EELS 16 4 4 12 DiamMeasMax_DC coccccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nono nnn nnn nn nnns nn ERENER nnne EEE esses EE EE EEE EE EEE EES 16 2 413 ed 16 44 14 DiamMeasMax in erroreren E EEEa LE E E AO EEE e A EA A AE EEE EEA 16 Drive Application Software page 3 of 30 FM Inertia Compensation 4 4 15 DiamPresetCmirnda oet eo oes eee rises ee eset etate viet pne o ease eva et noohd 16 2 416 DiamPresetiVal Muntaner 16 4 amp 4 T7 DiamRate INReOV scarico aio 17 LN PNLLSSMNEIT oe iot 17 aS S S MENDITINIBIe ijo er H 17 44 207 Diet ale anise ict ose at 17 4 44 21 RadiusGalc Tui 17 44 22 Bull PRA 23 4 A An AAS ie eS eee eS e vk 18 44 23 vBulldUplsauoRec ea e et aoe ei I DEIN I ee 18 24 24 DidIMMCAS IM ora 18 44 25 Constant RREMperR Ma 18 4 4 26 Constant RPMperFPM ssssseseeeeee eene nnn 18 5 0 Setup Configuration an 19 ST A S In A 19 5 2 DiamPreset JSR Instruct On ioc Det eoo pu peii 19 5 2 1 Input Parameters i scs cient nteneetentete edo 19 5 2 2 Iset rm Parameters uigiiesiehiitbhbebi mibi iiis 19 5 2 3 Default Tags used in Drive Application Software sssse 20 5 9 DiamCalc JSRInSIrU6ll
12. JE 746 144 TE DR 29 934 step Conveyor or Step C int Stat UP Check MM SM Drive OM Application Sli See NAAA Software Function Module Diameter Calculation Imperial Units Reference Manual Allen Bradley RELIANCE ELECTRIC Automation FM Inertia Compensation APPLICATION SOFTWARE 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
13. Newton Road 11 01 02 Revenue House Singapore 307987 Tel 65 351 6723 Fax 65 355 1733 U S Allen Bradley Drives Technical Support Tel 1 262 512 8176 Fax 1 262 512 2222 Email support drives ra rockwell com Online www ab com support abdrives Publication 9329 RM001B EN E March 2003 Copyright 2003 Rockwell Automation All rights reserved Printed in USA
14. Ql1 uu ooc o qoe zi rero A Eoo Po Feo Pee Free teo de 20 5 3 1 NAAA 20 5 3 2 Return A eoe eae A aede ERES 21 5 3 3 Default Tags used in Drive Application Software sssss 22 6 0 Tuning T SEartu aie receptor cease a aa 23 6 1 Installing the Application Module cccccconnnnnnnccconcccccccccnonnncnnnnconononnnnnnnnnnnos 23 6 2 Drive Tuning GS OMG URAL OMe ss sospes ae xao Deco D RR o i PR c a a E E RR 23 6 3 Offline Tuning 7 Startups o e o ov atas ee eae 24 6 4 Online Tuning Startups ane eee me Rp epe NI pe Nor epe RS ee Re A needa 24 6 4 1 Measured Diameter Enable TrU8 cccccocccnccconnnnnonononnconononnnnnnnnnnnnnonononannnnnnnnnnnnnnnnennnenanos 24 6 4 2 Measured Diameter Enable False typical configuration sssseees 24 Appendix A Process Line Command amp Status Words 26 Appendix B Block DiaQrant asco te roca ee eee eee 28 Appendix C Parameter Tag Table ccccccceeeeeeeeeeeeeeeeeeeeeeeeneeeeeeeeeeeeeeeeeaeeeees 29 Drive Application Software page 4 of 30 FM Diameter Calculation 1 0 Precautions Class 1 LED Product gt 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 gt PB BBR gt ATTENTION This drive contains ES
15. 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 DiamCalc in DiamMinEC in BuildUpRatio Usage Typically used to scale the spindle rotational speed reference CoreLineSpeedRef RPM SpindleSpeed RPM a BuildUpRatio 4 4 23 BuildUpRatioRec This output is the reciprocal ratio of the actual diameter to the minimum empty core diameter 1 DiamMinEC in DiamCalc in i DiamCalc_in DiamMinEC in BuildUpRatioRec 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 LineSpeed_FPM Constant_RPMperFPM BuildUpRatio MotorSpeed_RPM GearRatio DiamMinEC _in T 12 Constant_RPMperFPM 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 co
16. 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 Subroutine Inputs Inl Bx PresetlCmmd Preset 1 Command In2 Bx PresetlCmmd Preset Z Command In3 Bx PresetlCmmd Preset 3 Command In4 Rx x PresetlVal in Preset 1 Value Inches In5 Rx x PresetlVal in Preset 2 Value Inches In Rx x PresetlVal in Preset 3 Value Inches In Bx PresetIncCmmd Preset Increase Command Ins Bx PresetDecCmmd Preset Decrease Command In9 Rx x PresetIncDecRate inSec Preset Increase Decrease Rate Inches Second Subroutine Outputs Retl Rx x DiamPresetCmmd Diameter Preset Command Ret2 Rx x DiamPresetVal_in Diameter Preset Value Inches Diameter Preset JSE Jump To Subroutine Routine Name DiamPreset Input Par wDLx DrvCmmdProcLn l Input Par wDLx DrvCmmdProcLn 17 Input Par wDLx DrvCmmdProcLn 18 Input Par zbLx DiamPresetlVal in Input Par zbLx DiamPreset2Val in Input Par zbLx DiamPreset3Val in Input Par wDLx_DrvCmmdProcLn 19 Input Par wDLx_DrvCmmdProcLn 20 Input Par zDLx DiamPresetIncDecRate inSec Return Par DiamPresetCmmd Return Par DiamPresetVal in 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 inpu
17. ant 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 Subroutine Inputs Inl Bx CalcEnbl Diameter Calculator Enable In2 Rx x CalcEnblThresh FPM Diameter Calculator Enable Threshold FPM In3 Rx x CalcUpdate Rev Diameter Calculator Update Interval Roll Revolutions In4 Rx x SpeedLine FPM Line Speed or Translational Speed FPM In5 Rx x SpeedMotor RPM Motor Speed RPM In6 Rx x GearRatio Gear Ratio Motor Revolutions Roll Revolutions In Rx x DiamMinEC in Minimum Empty Core Diameter Inches Ing Rx x DiamFR in Full Roll Diameter Inches In9 Bx DiamMeasEnbl Measured Diameter Enable InlO Rx x DiamMeasInput Measured Diameter Input Inll Rx x DiamMeasMin DC Minimum Measured Diameter Data Counts Inl2 Rx x DiamMeasMax DC Maximum Measured Diameter Data Counts Inl3 Rx x DiamMeasMin in Minimum Measured Diameter Inches Inl4 Rx x DiamMeasMax in Maximum Measured Diameter Inches Inl5 Bx yDiamPresetCmmd Diameter Preset Command from DiamPreset routine Inl6 Rx x yDiamPresetVal in Diameter Preset Value from DiamPreset routine Inl7 Rx x DiamRate inRev Diameter Rate Limit Inches Roll Revolution Inl8 Bx DiamIncEnbl Diameter Calculator Increase Enable Inl9 Bx DiamDecEnbl Diameter Calculator Decrease Enable S
18. ase 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 surfa
19. ce 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 amp Status Words The following table is a functional list of the Process Line command word WDLx DrvCmmdProcL n Bit Input Signal Description 00 Clear Fault Clear all Faults 01 Run 2 Wire 1 Start transition to O Stop 02 Reserved 03 Coast Stop not supported in rev 110101 04 Jog Forward
20. ctional list of the Process Line status word DLx DrvStatProcL n Bit Output Signal Description 00 Fault Drive Fault or a System Fault 01 Running Drive is Running not stopping 02 Reserved 03 Motor Ctrl On Motor is being control Motor POWER 04 Reserved 05 Jogging section Jogging 06 Rotational Reverse Under Wind 07 Tension Control On Selected mode of Tension control is enabled 08 Zero Speed Below Zero Line speed set point 09 Diameter Calculation Active Future 10 Reserved 11 Reserved 12 Reserved 13 Reserved 14 Reserved 15 Reserved 16 Enable Loss Fault Drive Enable lost 17 Fail to Run fault Drive failed to start 18 Communication fault NA not support 19 Message fault NA not support 20 Motor Overload Fault Overload alarm from drive 21 Motor Overtemperature FIt Over temperature alarm from drive 22 Motor Blower Loss Fault Motor blower has stopped or tripped off 23 Reserved 24 Reserved 25 Reserved 26 Reserved 27 Reserved 28 Reserved 29 Reserved 30 Operate Permissive Use in line control logic to command a coordinated line ramp stop Loss of permissive resets start command 31 On Permissive The drive will coast stop or ramp stop depending on configuration Drive Application Software page 27 of 30 FM Inertia Compensation Appendix B Block Diagram fo 204 eee at
21. d 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 LineSpeedMtr Rpm MinCoreDiam in p GearRatio 12 LineSpeed Fpm 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 re
22. e 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 e Measured Diameter Input DiamCalc In10 e Minimum Measured Diameter DiamCalc In11 e Maximum Measured Diameter DiamCalc In12 e Minimum Measured Diameter DiamCalc In13 e 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 Incre
23. e 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 inch
24. es 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 DOC 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 596 to avoid unwanted limitation of the diameter calculator Usage Set
25. eter 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 PresetlncCmmd 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 calcula
26. ference 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 Type Range Description 1 CalcEnbl BOOL 0 to 1 Enable the Diameter Calculation 2 CalcEnblThresh FPM REAL 0 to 50 Diameter Calc low speed thresh hold 3 CalcUpdate Rev REAL 1 to 200 Number of revolutions per length count 4 SpeedLine FPM REAL 5000 Line Speed 5 SpeedMotor_RPM REAL 7200 Actual motor speed 6 GearRatio REAL 1 to 100 Motor RPM Roll RPM 7 DiamMinEC in REAL 0 to FR Minimum diameter Empty Core 8 DiamFR in REAL C to F
27. in Rxx None NA 2 0 yDiamPresetCmmd Bx DiamPresetCmmd DiamPreset NA yDiamPresetVal in Rxx DiamPresetVal in DiamPreset NA DiamRate inRev Rxx 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 APPLICATION SOFTWARE www rockwellautomation com for Drive Application Software www ab com drives drvappsw Corporate Headquarters Rockwell Automation 777 East Wisconsin Avenue Suite 1400 Milwaukee WI 53202 5302 USA Tel 1 414 212 5200 Fax 1 414 212 5201 Headquarters for Allen Bradley Products Rockwell Software Products and Global Manufacturing Solutions Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Rockwell Automation SA NV Vorstlaan Boulevard du Souverain 36 BP 3A B 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Headquarters for Dodge and Reliance Electric Products Americas Rockwell Automation 6040 P onders Court Greenville SC 29615 4617 USA Tel 1 864 297 4800 Fax 1 864 281 2433 Europe Rockwell Automation Br hlstra amp e 22 D 74834 Elztal Dallau Germany Tel 49 6261 9410 Fax 49 6261 17741 Asia Pacific Rockwell Automation 55
28. iption 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 Format Example B Boolean X 0 or 1 Integer X 123 R Real Float X X 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 Diame
29. is for maintenance purposes if the program is restored it will default to the standard direction setting Motor Tests NOTE the motor will run g Inertia Measure NOTE the motor will run h SpeedLimits 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 popo 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 us
30. 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 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 Const
31. le 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 MotorRevolutions GearRatio 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 th
32. n 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 PresetlncDecRate 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
33. o 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 7008 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 amp 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 Motor Data Enter all motor data for the attached motor check poles Feedback Config Select feedback type Pwr Circuit Diag Direction Test NOTE the motor will run recommend always changing wires and not software this
34. on 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 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 Range Example B Boolean BOOL X 0 to 1 0 or 1 Integer INT X 32767 8947 D Double INT DINT X 2097151 74364 R Real Float REAL X X 16777215 3 4 13 0 Applies to single precision accuracy 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 13396 In per unit the quantity is normalized to 1 3
35. roll diameter doubles the rotational speed must be reduced by half to maintain constant surface speed e Motor Speed Rpm s Surface Spd Fpm 4 8 12 16 20 24 28 32 36 40 44 48 52 Roll Diameter in RollDiameter ft RollDiameter in 12 Li F MotorSpeed Rpm aA pm iE RollDiameter ft p Drive Application Software page 8 of 30 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 e Surface Tension Ibs a Motor Torque Ibft c 9 17 c o LE o 3 S o E 12 16 20 24 28 32 36 40 44 48 52 Roll Diameter RollDiameter in RollDiameter ft ft D RollDiameter ft 2 RollRadius ft RollRadius ft Tension lbs Gearkatio MotorTorque Ibft 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 500
36. rresponding 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 amp In16 inputs yDiamPresetCmmdg amp 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 i
37. st 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 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
38. t 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 5 3 2 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
39. ter 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 amp In16 inputs yDiamPresetCmmd amp 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 PresetIncDecRate_inSec REAL 0 to 10 Manual Diameter Increase Decrease Rate adjustment Name Type Range Description 1 PresetiCmmd BOOL 0 to 1 Preset diameter to Preset1Val_in 2 Preset2Cmmd BOOL 0 to 1 Preset diameter to Preset2Val in 3 Preset3Cmmd BOOL 0 to 1 Preset diameter to Preset3Val in 4 Preset1Val_in REAL 0 to 500 Value of Preset 1 5 Preset2Val in REAL Oto 500 _ Value of Preset 2 6 Preset3Val_in REAL Oto 500 _ Value of Preset 3 7 PresetIncCmmd BOOL 0 to 1 Manual Diameter Increase 8 PresetDecCmmd BOOL 0 to 1 Manual Diameter Decrease 9 Return Parameters Name Type Range Description Diameter Preset Command to 1 DiamPresetCmmd BOOL 0 to 1 2 DiamCalc routine 2 DiamPresetVal in REAL 0 to 500 Diameter Preset Value
40. the input for the maximum rate of change for the application MaxWebThickness mils 2 1000 DiamRate_inRev 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 DiamCalc_in _ 12in 24 2 RadiusCalc ft Usage Typically used for calculating required motor torque or converting from FPM to RPM Torque lbft Tension _lb Radius _ ft Drive Application
41. tor using a decrease pushbutton 4 3 9 PresetlncDecRate 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 DiamlInc 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 DiamPresetCmm
42. ubroutine Outputs Retl Rx x DiamCalc in Calculated Diameter Inches Ret2 Rx x RadiusCalc ft Calculated Radius Feet Ret3 Rx x BuildUpRatio Normalized Diameter 1 0 Min Diam Ret4 Rx x BuildUpRatioRec Reciprocal of Normalized Diameter Ret S Rx x DiamMeas in Measured Diameter Inches Ret6 Rx x Constant RPMperFPM Calibration Constant RPM Per FPH Diameter Calculator JSR Jump To Subroutine Routine Name DiamCalc Input Par DLx DrvStatProclLln Input Par zDLx CalcEnblThresh FPM Input Par zDLx_CalcUpdate Rev Input Par DLx LineSpdRf FPM Input Par SpeedMotor RPM Input Par zbLx GearRatio Input Par zbLx DiamMinEC in Input Par zbLx DiamFR in Input Par Input Par D Input Par L Input Par 2 1 e Input Par Input Par Input Par DiamPresetCmmd Input Par DiamPresetVal in Input Par zbLx DiamRate inRev Input Par wDLx DrvCmmdProcLn 21 Input Par wDLx_DrvCmmdProcLn 22 Return Par DLx DiamCalc in Return Par DLx RadiusCalc ft Return Par DLx_BuildUpRatio Return Par DLx_BuildUpRatioRec lt Drive 0 UserDefinedRealData 0 gt Return Par DLx DiamMeas in Return Par DLx Constant RPMperFPM 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 7008 firmware 1 Download the RSLogix 5000 acd file t
43. ulated based on line speed and the number of roll rotations If the line speed input is below CalcEnbl Thresh 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 gt 62mils should be set lower and thinner webs 62mils should be set higher Using a who
44. ull Roll diameter 9 DiamMeasEnbl BOOL 0 to 1 Use DiamMeas value for actual Diam 10 DiamMeasInput REAL NA Measured diameter input Raw data 11 DiamMeasMin DC REAL NA Raw data minimum 12 DiamMeasMax DC REAL NA Raw data maximum 13 DiamMeasMin in REAL Oto 500 _ Actual diameter at DiamMeasMin DC 14 DiamMeasMax in REAL 0 to 500 Actual diameter at DiamMeasMax DC 15 yDiamPresetCmmd BOOL 0 to 1 Preset command from DiamPreset 16 yDiamPresetVal in REAL 0 to 500 Preset value form DiamPreset 17 DiamRate inRev REAL 0 00 to1 Maxallowed diameter rate of change 18 DiamIncEnbl BOOL 0 to 1 Allow diameter calc to increment 19 DiamDecEnbl BOOL 0 to 1 Allow diameter calc to decrement Return Parameters Name Type Range Description 1 DiamCalc in REAL 0 to 500 Actual calculated diameter 2 RadiusCalc ft REAL 0 to 21 Actual calculated radius 3 BuildUpRatio REAL 1 to 20 Ratio of actual diameter to min core 4 BuildUpRatioRec REAL 0 05to1 1 BuildUpRatio 5 DiamMeas_in REAL 0 to 500 Scaled value of measured diameter 6 Constant_RPMperFPM REAL NA pec SR EE MO minimum 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 calc
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