ConfigEd Lite DC Applications Pack User Manual
Contents
1. i 100 Tension Setpoint A5 m Torque Mode C4 Tension Enable AT Reverse C Over Wind L Setpoint Sum1 Figure 4 12 Torque ConfigEd Lite DC Applications Pack 4 1 C4 sc p65 11 1 23 2003 4 29 PM COUT CES Chapter 4 Section Control Reverse The motor rotation can be reversed by terminal C8 REVERSE This SC configuration only works when in torque draw or ratio mode To provide a section reverse ability for tension feedback modes change the configuration to route the line speed reference and trim signals through SETPOINT SUM 1 parameters INPUT 0 and INPUT 1 Anti reverse If it is necessary to ensure that a section does not reverse even if reversing would be required to maintain tension or dancer position then use the Anti reverse function Set SPEED LOOP SETPOINTS MIN DEMAND to 0 00 to achieve anti reverse Anti reverse causes the tension control loop integral to saturate if the control loop asks for reverse speed Anti reverse only operates with a unidirectional section If terminal C8 REVERSE is selected the setpoint will be clamped to zero Agitate Use parameter RAMPS MIN SPEED to set the agitate speed MIN SPEED should be set to about 5 percent When the drive section is started the speed ramps up to MIN SPEED When the line speed exceeds this agitate speed the section will follow the line MIN SPEED will only have an effect if the lin2. Max Value Min Value _ Min Value Calibration E Calibration Draw Ratio AIX 1 Draw Ratio JA2 XIS 1 al Ke Line SpeedRef A4 x e gt A8 Line SpeedRef HA4 X va Ratio 0 100 Ratio O 100 Figure 4 9 Cascade Draw Master Draw Draw Section Section 2 Max Value Max Value Min Value _ Min Value Calibration Calibration Draw Ratio A21X 1 Draw Ratio A2 XI 1 gt X i mX jj R Line Speed Ref H 5703 x 5703H Line Speed Ref 5703 x gt Ratio O 100 Ratio 0 100 Figure 4 10 Digital Draw ConfigEd Lite DC Applications Pack 4 9 C4 sc p65 9 1 23 2003 4 29 PM COUT CES Chapter 4 Section Control to the draw setting of the first section to be passed to following sections while maintaining their relative speeds Digital Draw Using draw with non extensible materials requires very small speed differences between line drive sections which in turn requires very precise speed control Analog inputs and outputs may not provide adequate precision or stability The digital 590 DRV s speed accuracy can be greatly improved by direct serial connection between drives using the 5
3. Digital input terminal C6 OVERWIND selects the winding direction ON for overwinding and OFF for underwinding For a rewind set VALUE TRUE 0 01 and VALUE FALSE 0 00 For an unwind set VALUE TRUE 0 00 and VALUE FALSE 0 01 Diameter Preset For a simple rewind the only diameter preset required may be one core di ameter This diameter can be set directly by changing RESET VALUE in the DIAMETER CALC block in Config For an unwind or rewind using varying new core sizes or parent roll sizes the diameter must be set for each roll Terminal A2 is connected to the RE SET VALUE parameter in the DIAMETER CALC block A 0 to 10 volt signal at A2 now provides the preset where 10 volts is the full or maximum roll diameter That signal can be generated by an operator potentiometer an ultrasonic transducer that measures roll diameter or another diameter input device NOTE The DIAMETER PRESET must be set accurately The diameter calculator does not calculate diameter at zero speed Poorly set preset diameters can cause large tension variations in the web when the machine is started Preset Enable 24 VDC at digital input terminal C7 selects PRESET ENABLE When ON it loads the value of DIAMETER PRESET into the diameter memory Current Limit CUR LIMIT SCALER is set to 200 percent Set MAIN CURR LIMIT to suit the application normally 120 percent ConfigEd Lite DC Applications Pack 2 5 C2 cpw p65 5 1 23 2003 4 29 P
4. Draw mode is the nearest approximation Master Draw to an old fashioned line shaft with its section mechanical variators It works well even when the section has little or no grip on the web although in those applications it will not control tension In draw mode the slave drive is speed controlled with a percentage difference from the line speed reference The speed difference or draw which is usually small stretches the web X if it is extensible and the speed difference Draw is positive or permits the web to contract Figure 4 3 Draw if the speed difference is negative When draw is used with non extensible webs very accurate speed control is required to provide acceptable tension control With these materials a very small speed difference either causes the web to be too loose or too tight This application uses the Digital Draw feature discussed later in this chapter Ratio Ratio control is speed control It is similar to draw except that it is specified as a ratio of the line speed instead of a percentage difference Ratio control generally varies over a much wider operating range than draw Ratio is typically used by sections that have no effect on web tension but is required by the manufacturing process for example on coater applicators and metering rolls 4 2 C4 sc p65 ConfigEd Lite DC Applications Pack 2 1 23 2003 4 29 PM CO IT CES I
5. Chapter 3 Closed Loop Winder and VALUE FALSE 0 00 For an unwind set VALUE TRUE 0 00 and VALUE FALSE 0 01 Tension Enable Digital input C8 TENSION ENABLE switches the drive from a speed mode to a loadcell or dancer trim mode tension control This input should be ON when the winder is started and OFF when it is jogged Jog JOG is selected by digital input C4 STARTUP PROCEDURE The following procedures describe the steps for starting up SPW winders The user will need the following information e Absolute minimum roll diameter e Absolute maximum roll diameter e Absolute maximum line speed e Motor maximum speed at the smallest roll diameter and maximum line speed Speed Mode Initial Setup These steps customize the drive for the calibration phase 1 Install the spw_v 4 5 7 590 configuration using ConfigEd Lite 2 Set the MIN DIAMETER to the core as a percentage of full roll If there is more than one core size it should be set to the smallest for example if the smallest core is 3 5 inches and the maximum full roll is 42 inches then the MIN DIAMETER is 3 5 42 100 8 33 3 Set OVERWIND to ON by connecting 24 volts to terminal C6 4 Save the parameters Calibration This section calibrates the drive in speed mode ConfigEd Lite DC Applications Pack 3 5 C3 spw p65 5 1 23 2003 4 29 PM COUT CES T Chapter 3 Closed Loop Winder 1 Calibratethe feedback device a Lo
6. Similarly pay out allows the operator to introduce slack in the web such as when performing a splice Jog Many sections need individual jog for positioning clearing wrap ups or cleaning Ramp A section ramp independent from the main line ramp allows an individual section to accelerate gradually This permits it to speed up to match the main line and to decelerate smoothly as required by the process Raise Lower Motor Operated Potentiometer Function The Raise Lower function uses digital inputs to increase and decrease Draw Ratio or Tension This permits gauge controls or other automatic systems with logic outputs to connect directly with the drive 4 4 ConfigEd Lite DC Applications Pack C4 sc p65 4 1 23 2003 4 29 PM CO IT CES Im Chapter 4 Section Control INPUT SIGNAL DESCRIPTIONS This section describes the functions of the terminals used in the SC configuration WARNING The control terminals of the drive are fully isolated from all power circuits and should not be connected to other non isolated circuits Draw Ratio The draw ratio signal is connected to terminal A2 It should read 10 volts for maximum draw or ratio The CALIBRATION parameter for terminal analog input 2 can convert the input signal to the desired output range 5 percent maximum draw for example Line Reference A line speed reference is required because the feedback device provides only a speed trim signal It should be s
7. TENSION SETPOINT and A6 TAPER SETPOINT to produce a diameter compensated tension demand It produces either the tension setpoint for loadcell applications or dancer loading signal for dancer applications TAPER SETPOINT is not used in unwind applications Loadcell For example Eurotherm Amplifier Drives unit 5530 or 5532 Tension __ Feedback de ae me FRS TD 5 gt gt 5 S Ext Line Tension Setpointa 2 z 7 Diameter Speed eel 2 Preset y 2 Oj N Y Al A2 A3 A4 AS A8 B3 C4 C6 C7 C9 vOV i 10 V 24V Diameter Figure 3 1 Unwind SPW Application with Loadcell Feedback ConfigEd Lite DC Applications Pack 3 1 1 1 23 2003 4 29 PM COUT CE Im Chapter 3 Closed Loop Winder Terminal C6 OVERWIND switches the speed demand sign for overwinding or underwinding The winder can change directions by changing the LINE SPEED signal at terminal A4 to the opposite sign Loadcell Applications In loadcell applications the controller attempts to keep the tension at the loadcell constant by varying the winder speed The setting at terminal AS TENSION SETPOINT sets the desired loadcell tension In TAPER CALC the tension setpoint is compensated for diameter and taper The output TOT TENS DEMAND is the PID setpoint signal at PID INPUT 1 PID compares the setpoint PID INPUT 1 with TENSION F
8. demand input 2 6 ConfigEd Lite DC Applications Pack C2 cpw p65 6 1 23 2003 4 29 PM CO TT CE Im Chapter 2 Open Loop Winder 4 Load an empty core into the winder and match the core surface speed to the line speed using the 590 encoder or tachometer calibration as appropriate Field Weakening This is used for extended speed range motors frequently used in winding applications 1 Under SPEED FEEDBACK SELECT ensure that the drive is set for encoder or analog tach feedback 2 In the field Control block enable FIELD WEAKENING 3 For MIN VALUE in the RAISE LOWER block enter the base speed of the motor as a percentage of maximum speed of the application At this point the drive and winder should be functioning correctly in speed control When starting up turret winders repeat the above proce dure for the second spindle Tension Mode The winder is calibrated in two phases first the static losses are determined and then the dynamic losses WARNING Some of the following procedures require manually turning or stopping the spindles Any suggestions of turning or stopping the winder spindle by hand while the motor is energized should only be performed by experienced personnel who are capable of evaluating the potential hazards and who are totally satisfied that the procedure is safe NOTE Unwind applications require loss compensations to be negative Static Losses 1 In the CURRENT LOOP menu s
9. drive with control features required for a line drive section It uses drive terminals for all inputs and outputs both analog and digital These terminals may need to be re configured depending on the functions required for the particular application A typical web process line will have a master or lead drive that sets the speed of the line and other slave drives which follow in a variety of ways The primary control requirement is usually to maintain a reasonable tension between sections Section control may be achieved in a number of ways Drive Section Up Stream Down Stream Loadcell Loadce For example Eurotherm Loadcell Drives units 5530 or 5532 Amplifier Tension f Feedback N E a ds ee Tension Setpoint O o 9 Draw Line gt a A _ Ratio Speed y re aan AT A2 A4 A5 A6 A7 A8 B3 C4 C6 C7 C9 Yoy i 10V 24V Section Total Speed Speed Setpoint Figure 4 1 Loadcell Application ConfigEd Lite DC Applications Pack 4 1 1 1 23 2003 4 29 PM COUT CES Chapter 4 Section Control Drive Section de Down Stream ancer Dancer Dancer Position g Draw Line _ Ratio Speed Feedback 2 T T Reverse PID Enable Al A2 A4 A6 A7 A8 B3 C C7 C9 y i 10 V 24V Section Total Speed Speed Setpoint Figure 4 2 Dancer Position Application Draw
10. error at all line speeds Reduce INT TIME CONST to improve response however if the time is set too short instability will occur Derivative is useful for improving stability particularly where the PID has a wide control range that is the trim range is large If the position loop is under damped increase DERIVATIVE TC slowly until achieving critical damping NOTE Loadcell feedback should not require DERIVATIVE TC so leave it set to zero PID OUTPUT can be monitored in the DIAGNOSTICS menu of the MMI This can be very useful when diagnosing problems If the speed tracking is incorrect PID OUTPUT will rise because the PID must provide an increas ing trim as speed rises If the web is slipping at the tension control section PID OUTPUT will saturate at 100 percent since the trim cannot produce tension If the trim polarity is incorrect PID OUTPUT will saturate and the web will be either too tight or too loose ConfigEd Lite DC Applications Pack 4 7 C4 sc p65 7 1 23 2003 4 29 PM COUT CES Chapter 4 Section Control OTHER SETTINGS Trim Range O P SCALER TRIM scales the PID output to produce the speed trim It sets the amount of overspeed the PID trim produces and the polarity of the trim The polarity should be positive when the feedback devices are upstream of the ive and ne ati ive when stream of the drive Ei dancer a a i ae CYeedba ck Signal should be connected to be more positive when the
11. unused terminal by re configuring a digital input to tag 228 This feature is only useful when DRAW or RATIO mode are in use Raise Lower The Raise Lower block provides a MOP function It can be used to set draw or tension setpoints by using digital inputs Two digital input terminals need to be re configured one to RAISE INPUT tag 261 and the other to LOWER INPUT tag 262 The output of the Raise Lower function is connected to SETPOINT SUM 1 RATIO 1 tag 6 or SETPOINT SUM 2 INPUT 0 tag 444 The analog input that is replaced either A2 DRAW RATIO or A5 TENSION SETPOINT must have its destination tag set to zero Extensible Non extensible Webs When using loadcell tension control the PID trim loop O P SCALER TRIM needs to be higher for extensible web than for non extensible web For machines running a variety of materials it may be necessary to be able to select different gains A digital input can be used to select two values of trim range In the CONFIGURE I O menu select an unused digital input set VALUE FOR TRUE to 10 percent for example and VALUE FOR FALSE to 5 percent and DESTINATION TAG to 407 O P SCALER TRIM Now the operator can select the extensible trim range by setting the digital input high VALUE FOR TRUE and VALUE FOR FALSE must be adjusted to give the best trim ranges for extensible and non extensible webs ConfigEd Lite DC Applications Pack 13 1 23 2003 4 29 PM 4 13 Chapter 4 Section Con
12. up the drive as described in the 590 product manual that is AUTOTUNE the current loop etc 6 Match the roll surface speed of the line drive section to the master drive surface speed using the 590 encoder or tachometer calibration as appropri ate At this point the loadcell or dancer drive and drive sections should be functioning properly 4 6 ConfigEd Lite DC Applications Pack C4 sc p65 6 1 23 2003 4 29 PM CO IT CES Im Chapter 4 Section Control PID Adjustment Set INT DEFEAT to ON to provide proportional control only Set O P SCALER TRIM to suit the type of web As a rough guide use 2 to 5 percent for a non extensible web and 5 to 10 percent for an extensible web With a web in the machine run the line at a low speed with the PID enabled terminal C7 Check the tension loop performance by making step changes in tension and monitoring the feedback Increasing PROP GAIN gives faster response but at some point the section will become unstable When the section becomes unstable reduce PROP GAIN a little until it regains stability a For loadcell feedback check the performance by making step changes in the tension demand and monitoring the tension feedback b For dancer feedback check the performance by manually moving the dancer and watching it return to the center position After achieving stable proportional control set INT DEFEAT to OFF The integral action ensures a zero steady state
13. 10 V 24V Winder Diameter Spee Figure 2 2 Rewind Application ConfigEd Lite DC Applications Pack C2 cpw p65 2 1 23 2003 4 29 PM CO IT CES Im Chapter 2 Open Loop Winder 10 Dynamic Comp portional to speed It compensates for the dynamic loss or windage Figure 2 3 shows the static and dy namic compensations The com bined losses increase torque de mand in rewinds and decrease it in unwinds Static Comp TORQUE CALC uses the torque demand from SETPOINT SUM 2 to control the current limits It Figure 2 3 Friction Loss controls the positive or negative Compensation current limits depending on the selection of overwinding or underwinding The current limit is only controlled by the torque demand when tension mode is enabled otherwise the current limit is at the normal maximum value for speed mode Torque Percent Speed 199 Turret Winder Applications Turret winders use two spindles to transfer the web from one spindle to the other without stopping the line Each spindle requires its own drive An unwind splices from the emptying roll to a new full roll A rewind transfers Li the web from the full roll to a new core To achieve this the winders must operate in two modes speed mode and tension mode Speed mode is required to match the surface speed of the new core or new full roll to the line speed for the splice Tension mode is required after the splice or transfer Before startin
14. 29 PM COUT CES Chapter 4 Section Control Reverse Reverse terminal C6 changes the direction of the line section It is connected to OVER WIND and SETPOINT SUM 1 SIGN 0 and SIGN 1 for changing directions in torque and speed modes Other tension modes require configuration changes to assure the speed demand changes correctly PID Enable The PID needs to be enabled for the tension loop to operate The enable input is at terminal C7 PID ENABLE It cannot be permanently connected to 24 volts or the integral will saturate and cause poor initial performance Usually the PID should be enabled when the drive is started tension control is selected and the section nip is closed STARTUP PROCEDURE The following procedures describe a methodology for starting and tuning a tension control line drive section The first steps assure the drive section parts are calibrated correctly The PID setup steps tune the section for best performance Initial Setup 1 Install the sc_v 4 5 7 590 configuration using ConfigEd Lite 2 Disable PID ENABLE at terminal C7 3 Verify SETPOINT SUM 1 RATIO 0 is set to 100 00 percent and set terminal A2 DRAW RATIO to 0 volts 4 Calibrate the feedback device a When using loadcell feedback see the manufacturer s manual for calibration instructions b When using dancer feedback verify that the dancer polarity is correct and the dancer position setpoint is for mid position 5 Start
15. 703 Peer to Peer interface This interface should be used with digital speed feedback from an encoder or the 5701 microtach Refer to the 590 product manual for use of the 5703 To use draw with the 5703 re configure the drive as follows Menu Parameter Setting CONFIGURE O ANALOG INPUTS ANIN 3 A4 DESTINATION TAG O CONFIGURE 5703 SOURCE TAG 63 DESTINATION TAG 5 SYSTEM PORT P3 5703 SUPPORT SETPT RATIO 1 0000 SETPT SIGN POSITIVE 5703 MODE MASTER or SLAVE Remember to save the changes with the PARAMETER SAVE menu in the drive Ratio Ratio mode sets the section speed to the line speed multiplied by the ratio input To select ratio mode set SETPOINT SUM 1 RATIO 0 to 0 00 percent Terminal A4 LINE SPEED REFERENCE supplies the line speed signal Terminal A2 DRAW RATIO receives the ratio setpoint It is multiplied by the line speed to produce the speed demand Master Ratio Section Max Value Min Value Calibration Ratio O 0 00 Draw Ratio A2H XH Ratio 1 ESR Line Speed Ref A4 x f Figure 4 11 Ratio 4 10 ConfigEd Lite DC Applications Pack C4 sc p65 10 1 23 2003 4 29 PM CO IT CES Im Chapter 4 Section Control The maximum range of terminal A2 is 300 to 300 percent To set a ratio range of 50 to 200 percent set ANIN 1 A2 CALIBRATION to 2 0000 MAX VALUE t
16. CO IT CES Im o title p65 ConfigEd Lite DC Applications Pack version 5 for Windows 3 x 95 98 NT User Manual Copyright Eurotherm Drives Inc 2003 All rights strictly reserved No part of this document may be stored in a retrieval system or transmitted in any form Although every effort has been taken to ensure the accuracy of this manual it may be necessary without notice to make amendments or correct omissions in this document Eurotherm Drives Inc cannot accept responsibility for damage injury or expenses resulting therefrom Procedures detailed in this manual are designed to be performed by personnel with sufficient training and or experience Only sufficiently qualified personnel familiar with the construction and operation of industrial drive equipment and the dangers of working with high voltage electrical systems should attempt installation adjustment operation or service of this equipment Failure to follow these guidelines could result in damage to the equipment and severe injury or loss of life to personnel If you are unsure of your qualifications or do not understand certain procedures in this manual contact Eurotherm Drives Customer Service for assistance Before attempting any procedures in this manual including installation verify that the model numbers on the product and in this manual match If any discrepancy is found contact Customer Service immediately Printed in the United States of America
17. EEDBACK from terminal A3 The output PID OUTPUT is the tension loop trim used in SETPOINT SUM 2 Dancer Position Applications In dancer position applications the controller attempts to keep the dancer stationary by varying the winder speed TAPER CALC uses signals from terminals AS TENSION SETPOINT and A6 TAPER SETPOINT to produce the dancer loading Dancer loading affects web tension by setting the force the dancer exerts on the web The PID setpoint PID INPUT 1 is a fixed value set in the MMI representing the desired position of the dancer The user must remove the connection to PID INPUT 1 to manually set the dancer position PID compares PID INPUT 1 with the actual dancer position TENSION FEEDBACK at terminal A3 The output PID OUTPUT is the position loop trim used in SETPOINT SUM 2 NOTE Reconnect TAPER CALC TOT TENS DEMAND to an unused parameter for example AUX I O ANOUT 1 to keep the TAPER CALC function block turned on Figure 3 2 Rewind SPW Application with Dancer Position Feedback 3 2 ConfigEd Lite DC Applications Pack C3 spw p65 2 1 23 2003 4 29 PM CO IT CES Im Chapter 3 Closed Loop Winder Turret Winder Applications Turret winders use two spindles to transfer the web from one spindle to the other without stopping the line Each spindle requires its own drive An unwind splices from the emptying roll to a new full roll A rewind transfers the web from the full roll to a ne
18. HA352747A003 Issue 4 1 1 23 2003 4 29 PM CM IT h6hL Im toc p65 ConfigEd Lite DC Applications Pack Contents Chapter 1 INTRODUCTION Software Compatibility Applications Chapter 2 OPEN LOOP WINDER CPW Description 2 2 Turret Winder Applications 2 3 Input Signal Descriptions 2 4 Startup Procedure 2 6 Speed Mod 1 8 4 2 6 Tension Mode nn 2 7 i 9 9 Chapter 3 CLOSED LOOP WINDER SPW DSS Cri POPI OM stsetstcessesscis tui enaena a a a 3 1 Loadcell Applications 3 2 Dancer Position Applications 3 2 Turret Winder Applications 3 3 Input Signal Descriptions 3 3 Startup Procedure 3 5 Speed Mode 3 5 Tension Mode nn 3 6 Wi Siete EEA EE te eat tec dit aah eel te ee 3 8 Chapter 4 SECTION CONTROL SC Control Modes nn 4 1 Additional Features 4 4 Input Signal Descriptions 4 5 Startup Procedure 4 6 Other Selfings nee n 4 8 Other Features nn 4 8 Appendix A Simple Winder Equations Appendix B Template Configuration Drawings ConfigEd Lite DC Applications Pack Cont 1 1 1 23 2003 4 29 PM Cont 2 toc p65 2 ConfigEd Lite DC Applications Pack 1 23 2003 4 29 PM COUT CE Im Chapter 1 Introduction Chapter 1 INTRODUCTION This manual describes the use of the template configurations shipped with the ConfigEd Lite DC Applications pack There are three di
19. M COUT CES Chapter 2 Open Loop Winder STARTUP PROCEDURE The user will need the following information Absolute minimum roll diameter Absolute maximum roll diameter e Absolute maximum line speed e Motor maximum speed at the smallest roll diameter and maximum line speed Speed Mode Initial Setup These steps customize the drive for the calibration phase 1 Install the cpw_v 4 5 7 590 configuration using ConfigEd Lite 2 Set MIN DIAMETER to the core as a percentage of full roll If there is more than one core size it should be set to the smallest for example if the smallest core is 3 5 inches and the maximum full roll is 42 inches then MIN DIAMETER is 3 5 42 100 8 33 percent 3 Set OVERWIND to ON by connecting 24 volts to terminal C6 4 Save the parameters Calibration This section calibrates the drive in speed mode 1 Connect 24 VDC to terminal C7 DIAMETER PRESET ENABLE to force the diameter hold to stay on this is for initial calibration only 2 Ensure C4 is OFF tension mode and monitor SPECIAL BLOCKS DIAMETER CALC DIAMETER to see that the diameter is preset to core If the diameter does not equal the minimum diameter momentarily jumper 24 volts to C7 DIAMETER PRESET ENABLE 3 Start up the drive as described in Chapter 4 of the 590 DRV product manual that is AUTOTUNE the current loop optimize the speed loop etc Use terminal A4 LINE SPEED REFERENCE as the speed
20. PS block and goes to the LINE SPEED INPUT of the DIAMETER CALC block NOTE It is very important that the web does not slip If it does the diameter calculation will not be accurate resulting in poor winder performance Diameter Preset For a simple rewind the only diameter preset required may be one core diameter This diameter can be set directly by changing RESET VALUE in the DIAMETER CALC block in Config For an unwind or rewind using varying new core sizes or parent roll sizes the diam eter must be set for each roll Terminal A2 is connected to the RESET VALUE pa rameter in the DIAMETER CALC block A 0 to 10 volt signal at A2 now provides ConfigEd Lite DC Applications Pack 3 3 C3 spw p65 3 1 23 2003 4 29 PM COUT CES Chapter 3 Closed Loop Winder the preset where 10 volts is the full or maximum roll diameter That signal can be generated by an operator potentiometer an ultrasonic transducer that measures roll diameter or another diameter input device NOTE The DIAMETER PRESET must be set accurately The diameter calculator does not calculate diameter at zero speed Poorly set preset diameters can cause large tension variations in the web when the machine is started Preset Enable 24 VDC at digital input terminal C7 selects PRESET ENABLE When ON it loads the value of DIAMETER PRESET into the diameter memory Tension Feedback The loadcell tension feedback or dancer position signal is conn
21. adcells Follow the loadcell manufacturer s manual to calibrate the loadcells The tension signal should be positive on terminal A3 of the drive and 9 volts at full tension b Dancers Check the dancer position feedback Optimally it should change from 0 volts when the dancer is in the fully tight position to 10 volts in the fully loose position A smaller range is acceptable but may require resetting the dancer position setpoint For example if the swing is from 5 volts to 9 volts then the setpoint should be set at 70 percent to control the dancer at mid position Dancer loading if controlled from the drive should be checked and calibrated at the voltage to pressure transducer The drive dancer loading output is 9 volts at full tension This can be adjusted using the ANOUT 1 TO GET 10V value for analog output A7 DANCER LOADING 2 Ensure terminal C8 TENSION ENABLE is OFF and monitor SPECIAL BLOCKS DIAMETER CALC DIAMETER is preset to core Ifthe diameter does not equal the minimum diameter momentarily jumper 24 volts to C7 DIAMETER PRESET ENABLE 3 Start up the drive as described in the 590 product manual that is AUTOTUNE the current loop optimize the speed loop etc Use terminal A4 LINE SPEED REFERENCE as the speed demand input 4 Load an empty core into the winder and match the core surface speed to the line speed using the 590 encoder or tachometer calibration as appropriate At this point the feedback devic
22. caled to 10 volts at full speed and connected into terminal A4 LINE SPEED REFERENCE The 5703 Peer to Peer communications unit may alternatively be used for a digital line reference Tension Setpoint K The tension setpoint of 0 to 10 volts scaled internally using CALIBRATION connects to terminal A5 TENSION SETPOINT Typically this signal comes from a potentiometer supplied from the drive s 10 volt terminal B3 For dancer position applications this input is not required The user can enter a 50 setpoint directly in INPUT 1 of the PID block and delete the connection that already exists at Input 1 Tension Feedback The tension feedback signal from a loadcell must be scaled using a loadcell amplifier such as the Eurotherm Drives 5530 before connecting into terminal A6 TENSION FEEDBACK on the 590 At full tension the output should be adjusted to read 9 volts to allow 10 percent over range The dancer position is the tension feedback in dancer applications The dancer uses a position transducer with a signal range of 0 to 10 volts The simplest type of transducer is a potentiometer coupled to the dancer shaft and supplied with 10 volts by the drive s terminal B3 The optimum mechanical arrangement provides nearly full potentiometer rotation for the full dancer travel Less rotation is acceptable down to a minimum of about 30 percent or 3 volts change ConfigEd Lite DC Applications Pack 4 5 C4 sc p65 5 1 23 2003 4
23. can be monitored at SPECIAL BLOCKS DIAMETER CALC DIAMETER ConfigEd Lite DC Applications Pack 3 7 C3 spw p65 7 1 23 2003 4 29 PM COUT CES Chapter 3 Closed Loop Winder 14 At this point PROP GAIN probably needs to be increased to produce optimum performance at full roll If this is the case adjust MIN PRO FILE GAIN to give optimum performance throughout the roll MIN PROFILE GAIN should bereduced by the amountthe PROP GAIN was increased as shown in the equation below MIN PROFILE GAINnew PROP GAINorp PROP GAINnew 100 For example if the PROP GAIN at core was 10 percent and it was increased to 20 percent at full roll reduce MIN PROFILE GAIN from the default 100 percent to 50 percent 15 MODE allows the change of proportional gain with diameter to be varied The winder performance should be monitored throughout the buildup of the roll at various line speeds MODE would be changed so the proportional gain at each diameter fits the required gain profile better The higher the setting for MODE the lower the gain is kept at the smaller diameters NOTE This table shows initial settings for PID parameters used in these configurations PID Parameter Dancer Value Loadcell Value PROP GAIN 5 0 10 INT TIME CONST 5 00 Sec 5 00 Sec DERIVATIVE TC 0 0 0 0 MIN PROFILE GAIN 20 00 20 00 MODE 16 Save parameters Unwinds Follow the same procedure used for rewinds except as follows Spe
24. controlled by a profiler using PROP GAIN MIN PROFILE GAIN and MODE The default for MODE is 0 causing PROFILED GAIN to equal PROP GAIN It keeps the gain at PROP GAIN throughout the diameter range As a result adjust PROP GAIN during initial tests at standstill with an empty core Once stable proportional control is achieved set the INT DEFEAT to OFF The integral action ensures a zero steady state error at all line speeds INT TIME can be reduced to improve response however if the time is set too short instability will occur Derivative action may be useful to increase the response of the tension loop especially with large rolls Adjust DERIVATIVE TC as necessary For loadcell tension control DERIVATIVE TC should not be required so leave it set to zero Start the line and increase the speed to about 10 percent of full speed Monitor the tension control and adjust the tuning as required With the proportional gain optimized at core record the PROP GAIN value Now it is necessary to check the performance at full roll Either run the line until a full roll is wound or stop the line and replace the empty core with a full roll and re attach the web Before performing the stability tests with a full roll the full roll diameter must be preset Set the input to terminal A2 EXTERNAL DIAMETER PRESET to 10 volts for full roll diameter 24 volts at terminal C7 PRESET ENABLE sets the diameter to 100 percent The diameter
25. ding It can control unwinds or rewinds for single spindle and turret winders The configuration uses four function blocks in the SPECIAL BLOCKS menu of the 590 drive DIAMETER CALC TAPER CALC TORQUE CALC TENSION amp COMP RAISE LOWER and SETPOINT SUM 2 NOTE Only the cpw_v 4 5 7 590 configuration supports jog and field weakening 590SP s and older versions of the 590 do not support jog and extended speed ranges using field weakening A current programmed winder provides constant tension center winder control by programming the motor armature current The tension control is open loop that is it does not use a dancer or loadcell feedback signal The drive maintains constant tension by controlling motor torque It keeps the torque proportional to the tension demand and compensates for changing roll diameter with additional compensations for frictional losses NOTE For accurate tension control frictional losses must be small and repeatable compared to the torque required to provide web tension Figure 2 1 Unwind Application ConfigEd Lite DC Applications Pack 2 1 C2 cpw p65 1 1 23 2003 4 29 PM COUT CES Chapter 2 Open Loop Winder DESCRIPTION Figures 2 1 and 2 2 show typical rewind and unwind applications The diameter is reset before starting a new roll by using terminal A2 EXTER NAL DIAMETER PRESET for the diameter setting and C7 PRESET ENABLE to select the preset diameter The drive starts
26. djust DY NAMIC COMP if the speed changes at low speeds adjust STATIC COMP until they are opti mized 8 Reset JOG SLACK TAKE UP 1 to 10 percent 9 Set EXTERNAL PRESET ENABLE C6 to OFF 10 Save the parameters Unwind After completing the initial start up verify the unwind is accurately tuned for all diameters and speeds by using the following procedure 1 Web the line from the full roll 2 Verify the diameter is preset to full roll 3 Set TENSION SETPOINT to a suitable value for the web material 4 Start the unwind 2 8 ConfigEd Lite DC Applications Pack C2 cpw p65 8 1 23 2003 4 29 PM CO IT CES Im Chapter 2 Open Loop Winder X 6 Rewind Check the tension at standstill Start the line and check the running tension As the roll builds down verify the diameter calculator output is operating correctly The line must be running above MIN SPEED for the diameter calculator to operate After completing the initial start up verify the rewind is accurately tuned for all diameters and speeds by using the following procedure 1 un Fit an empty core 2 Web the line and transfer onto the winder core 3 4 Set TENSION SETPOINT and TAPER SETPOINT to suitable values Verify the diameter is preset to core for the web material Start the rewind Check the tension at standstill Start the line and check the running tension As the roll builds up verify the diameter calculato
27. e drive and winder should be functioning correctly When starting up turret winders repeat the above procedure for the second spindle Tension Mode 1 Thread the web through the machine and attach it to the core 2 Initially set INT DEFEAT to ON to provide proportional control only 3 Set terminal A5 TENSION SETPOINT to a reasonable value for the web 4 With the line stopped start the winder with the TENSION ENABLE set ON The winder should control tension if not check the polarity of the feedback and trim 3 6 ConfigEd Lite DC Applications Pack C3 spw p65 6 1 23 2003 4 29 PM CO IT CES Im Chapter 3 Closed Loop Winder gt 10 11 13 The scaled PID OUTPUT can be monitored in DIAGNOSTICS in the MMI Monitoring the PID trim output can be very useful for diagnosing problems because it shows the state of the PID Two other diagnostic parameters are also available for monitoring the PID state PID CLAMPED and PID ERROR However remember effects of the O P SCALER TRIM For example if O P SCALER TRIM is set to 10 percent then reading 10 percent on PID OUTPUT will indicate the PID has saturated Check the tension loop performance by making step changes to the tension demand and monitoring the tension feedback Increasing the proportional gain gives faster response but at some point the winder will become unstable If this occurs reduce the gain until it regains stability The proportional gain is
28. e speed is reduced again below the agitate value NOTE The nip must be opened and the tension disabled when the line speed is below the agitate speed Ramp The line reference signal sent to the drive goes through a ramp This ramp controls the acceleration to agitate speed if used and allows the section to be started and stopped while the line is running The ramp parameters are located in SETUP PARAMETERS RAMPS NOTE The ramp accelerate and decelerate times should be set faster than the line ramp so that the section can always keep up with the line Jog The jog function is not provided in this SC configuration 4 12 ConfigEd Lite DC Applications Pack C4 sc p65 12 1 23 2003 4 29 PM CO IT CES Im C4 sc p65 Chapter 4 Section Control Slack Take up pay out Slack Take up pay out is a speed increase while running to take up slack web It can only be used in draw or ratio mode Ifthe drive is running and the jog terminal C4 is energized the drive speed increases by an amount set in parameter TAKE UP 1 This configuration uses this feature to provide the overspeed in torque mode The parameters are found in SETUP PARAMETERS JOG SLACK TAKE UP 1 or TAKE UP 2 or MODE The speed increase is ramped to provide smooth control of the section and any cascaded sections TAKE UP SLACK 2 can be set negative to pay out slack and is selected by MODE in the JOG SLACK menu This function can be controlled by an
29. ected to terminal A3 TENSION FEEDBACK Full tension should be scaled to be 9 volts to allow a 10 percent over range When a dancer is used the drive requires a minimum excursion of three volts KA Tension Setpoint The tension setpoint of 0 to 10 volts scaled internally to 90 percent using param eter ANIN 4 A5 CALIBRATION is connected to terminal AS TENSION SP Typically this signal could come from a potentiometer supplied from the drive s 10 volt terminal B3 This signal is connected to parameter TENSION SPT in the TAPER CALC block Ifthe serial communications option is installed the tension setpoint could be generated by a PLC or supervisory computer Taper Setpoint A taper setpoint if required of 0 to 10 volts should be connected to A6 TAPER SETPOINT The range of taper can be set by the MAX VALUE and MIN VALUE in the ANALOG INPUT 5 function block This signal is connected to TAPER in the TAPER CALC block If the serial communications option is installed the taper setpoint could be generated by a PLC or supervisory computer NOTE The higher the TAPER SETPOINT setting the greater the reduction in tension as the diameter increases negative taper Overwind Underwind Digital input terminal C6 OVERWIND selects the winding direction ON for overwinding and OFF for underwinding For a rewind set VALUE TRUE 0 01 3 4 ConfigEd Lite DC Applications Pack C3 spw p65 4 1 23 2003 4 29 PM CO IT CES Im
30. ed Mode 2a Set O P SCALER TRIM to 10 percent This sets the correct loop polarity so that the loadcell or dancer feedback remain unchanged 2b Set terminal C7 PRESET ENABLE to ON Initially set terminal A2 EXTERNAL DIAMETER PRESET to core Tension mode An unwind cannot run at any speed with an empty core As a result after completing the test at standstill with an empty core step 8 skip directly to full roll tests step 13 3 8 ConfigEd Lite DC Applications Pack C3 spw p65 8 1 23 2003 4 29 PM Chapter 3 Closed Loop Winder ConfigEd Lite DC Applications Pack C3 spw p65 9 3 9 1 23 2003 4 29 PM Chapter 3 Closed Loop Winder 3 10 C3 spw p65 ConfigEd Lite DC Applications Pack 1 23 2003 4 29 PM CO IT CES Im C4 sc p65 Chapter 4 Section Control Chapter 4 SECTION CONTROL SC A typical process line contains a number of sections using one or more control modes This configuration provides the standard features required by a line drive section to perform Draw Ratio Loadcell Dancer position or Torque control It also includes Reverse Anti reverse Agitate Slack take up pay out Jog Ramp and Raise Lower Pull rolls coaters ovens treaters laminators presses and more can be controlled with the 590 DRV Figures 4 1 and 4 2 illustrate typical loadcell and dancer control applications respectively CONTROL MODES Section Control provides the
31. et the CUR LIMIT SCALER to 200 and enable BIPOLAR MODE 2 Set tension enable C3 and C4 to ON 3 Set TENSION SETPOINT A5 and TAPER SETPOINT A6 to zero ConfigEd Lite DC Applications Pack 2 7 C2 cpw p65 7 1 23 2003 4 29 PM COUT CES Chapter 2 Open Loop Winder EN Start the winder with the tension enabled by connecting 24 volts into terminal C3 RUN The winder should not turn because there is no tension demand and as yet no compensations Slowly increase STATIC COMP under TENSION amp COMP until the spindle turns and then reduce it gradually until it just stops turning Now the motor should have nearly enough current to make the spindle break away It should be possible to start and stop the spindle by hand with very little effort Un Dynamic Losses 6 Set JOG SLACK TAKE UP 1 to 100 percent and increase the tension setpoint signal The spindle should run up to full speed N Reduce the tension setpoint signal to 0 00 and monitor DIAGNOS TICS CURRENT DEMAND Dial in a small amount of DYNAMIC COMP under TENSION amp COMP Now the motor should have just enough current to keep the spindle running If the friction is increased slightly using light pressure on the shaft it should be possible to reduce the speed and the spindle should maintain the reduced speed after removing the pressure Check the loss compensation throughout the speed range If the speed changes at high speeds a
32. f 100 and 100 percent If a draw range of more than 100 percent is required the clamps must be increased accordingly The clamps can be set to lower values if asymmetric draw is required For positive draw only limit the input at A2 to 0 to 10 volts 4 8 C4 sc p65 ConfigEd Lite DC Applications Pack 8 s 1 23 2003 4 29 PM CO IT CES Im Chapter 4 Section Control Master Draw Section Max Value Min Value Calibration Draw Ratio AXE Ratio x EEA LL y Line Speed Ref A4 Ratio O 100 T Figure 4 8 Draw Cascade Draw When two or more draw sections follow in line after a master drive section cascading their line speed references instead of having each section following the master can be more useful To cascade the speed references connect the total speed setpoint signal terminal A8 from the first draw section to the line speed reference input terminal A4 of the second section Similarly take the second section s total speed setpoint into the line speed reference of the third section etc This allows a change Master Draw Draw Section Section 2 Max Value
33. fferent types of templates for each drive and firmware version They are Current Programmed Winder CPW This configuration is an open loop center winder control using torque clamps for tension control Speed Programmed Winder SPW This configuration is a closed loop center winder control using either loadcell or dancer feedback for tension control Section Control SC This configuration provides all the features required by a line drive section to perform Draw Ratio Loadcell Dancer position or Torque control Templates with the SPD extensions are to be used with the 590SP single phase digital drive Templates with the 590 extensions and version 3 or 4 are to be used with the 590D three phase drives Templates with the 590 extensions and version 5 or 7 are to be used with the 590 three phase drives SOFTWARE COMPATIBILITY Use this applications pack with ConfigEd Lite version 5 17 or later The 590 controller must be firmware version 3 2 or later All 590SP and 590 versions are supported NOTE Users should be familiar with using and configuring the 590 controller and ConfigEd Lite APPLICATIONS Five function blocks are used to add winder and section control capability to the 590 They are DIAMETER CALC TAPER CALC TORQUE CALC SETPOINT SUM 2 and PID They can be used as required for other ConfigEd Lite DC Applications Pack Te C1 intro p65 1 1 23 2003 4 29 PM ENT oo Chapter 1 Introduct
34. g in speed mode the operator sets the diameter to core for a rewind or to the diameter of the new roll for an unwind by entering the cor rect value in terminal A2 EXTERNAL DIAMETER PRESET Setting C7 PRESET ENABLE to ON keeps the diameter at the preset diameter until the transfer is completed Then the spindle is started using terminal C3 RUN The drive ramps up to the correct speed so the roll s surface speed matches the line speed The splice or transfer can occur at that point When the web is transferred to the new roll or core tension mode is enabled by setting terminal C4 to ON and the old roll is stopped At this point C7 is set OFF to allow the diameter calculator to calculate the correct diameter The new roll continues in tension mode until the next roll change ConfigEd Lite DC Applications Pack 2 3 C2 cpw p65 3 1 23 2003 4 29 PM COUT CES Chapter 2 Open Loop Winder INPUT SIGNAL DESCRIPTIONS Line Speed Reference A line speed signal is required for the diameter calculator to work It should be scaled to produce 10 volts at full speed and connected into terminal A4 LINE SPEED If this signal comes from a source other than a Eurotherm Drives motor controller it may need to be scaled and isolated This sig nal passes through the RAMPS block and goes to the LINE SPEED IN PUT of the DIAMETER CALC block NOTE It is very important that the web does not slip If it does the diameter calculation will
35. ion applications For detailed descriptions of these function blocks see the 590 product manual These configurations attempt to standardize the functions of the control terminals Figure 1 1 lists the types and functions of the terminals when using Current Programmed Winder Speed Programmed Winder or Section Control configurations described in this manual WARNING The control terminals of the drive are fully isolated from all power circuits and should not be connected to other non isolated circuits Current Speed Programmed Programmed Winder Function Winder Function og Input 1 Preset Diameter Preset Diameter Draw Ratio Tension Dancer og Input 2 Feedback Not Connected Ana Analog Input 3 Line Speed Reference Line Speed Reference Line Speed Reference Analog Input 4 Tension Setpoint Ana Ana ne Section Control Function Drive Software Terminal Reference Tension Feedback Section Speed Total Speed Setpoint Torque Mode Reverse Preset Enable Not Connected Digital Input 3 PID Enable Figure 1 1 Terminal Functions 1 2 ConfigEd Lite DC Applications Pack C1 intro p65 2 1 23 2003 4 29 PM zz IT CES Im Chapter 2 Open Loop Winder Chapter 2 OPEN LOOP WINDER CPW The cpw_v 4 5 7 590 configuration provides standard features used in center winder applications including diameter calculation with memory and preset tension and taper loss compensation and over under win
36. m C4 sc p65 Chapter 4 Section Control Torque Torque control is an open loop method of controlling tension because there is no direct tension measurement It assumes that the process losses are small so the web tension will be proportional to torque at the motor shaft The drive section torque is proportional to motor armature current and the speed is determined by the web speed assuming the drive section does not slip NOTE To achieve constant tension throughout the speed range use a constant torque motor A motor with a field range will produce less torque as the speed increases above its base speed Tension Draw controls speed but does not directly control tension Tension control uses an outer control loop to adjust the section speed The loadcell provides the feedback signal for the control loop Speed is adjusted to keep the feedback signal from the loadcell at a fixed value the tension setpoint Dancer Position Dancer position control also uses an outer control loop to adjust the section speed The dancer applies force to the web throughout its range of movement Loading the dancer usually by using pneumatics determines the force and therefore the tension in the web To keep the web tension constant the drive section must control the web speed so that the dancer stays in a fixed position Master Ra
37. not be accurate resulting in poor winder performance Tension Setpoint The tension setpoint of 0 to 10 volts is connected to terminal A5 TEN SION SP Typically this signal could come from a potentiometer fed from the drive s 10 volt terminal B2 This signal is connected to the TENSION SPT input of the TAPER CALC block If the serial communications option is installed the tension setpoint could be generated by a PLC or supervisory computer Taper Setpoint A taper setpoint if required of 0 to 10 volts should be connected to A6 TAPER SETPOINT The range of taper can be set by the MAX VALUE and MIN VALUE for the A6 terminal input This signal is connected to the TAPER input of the TAPER CALC block Ifthe serial communications option is installed the taper setpoint could be generated by a PLC or supervi sory computer NOTE The higher the TAPER SETPOINT setting the greater the reduction in tension as the diameter increases negative taper Tension Enable Connecting 24 VDC to terminal C3 and C4 selects tension mode When used with a run signal at terminal C3 C4 adds an overspeed TAKE UP in 2 4 ConfigEd Lite DC Applications Pack C2 cpw p65 4 1 23 2003 4 29 PM CO IT CES Im Chapter 2 Open Loop Winder the JOG SLACK block to saturate the speed loop Set this to 5 for a rewind and 5 for an unwind Jog Connecting 24V to C4 keeping C3 low implements the jog function Overwind Underwind
38. o 200 00 and MIN VALUE to 50 00 Now 0 to 10 volts on input A2 produces a ratio of 50 to 200 The overall speed demand is clamped to a maximum of 105 so ratios of more than 100 can only be used at less than full line speed Torque Torque mode is armature current control To achieve current control an overspeed is added to the line speed demand Since the actual section speed is held at line speed by the web the speed loop saturates causing the current demand to equal the current limit This function is similar to that discussed earlier in this chapter s CPW section 24 VDC at terminal C4 selects torque mode JOG SLACK TAKE UP 1 sets the overspeed It determines how much faster than line speed the section runs if it is not held back by the web for example if the web breaks Current loop parameter BIPOLAR CLAMPS must be set to ENABLED and CUR LIMIT SCALER set to 200 percent The signal at terminal AS TENSION SETPOINT sets the initial tension demand It is combined with the loss compensations to produce the current limit Follow the instructions in the CPW section Chapter 3 for setting up the loss compensation parameters Terminal C6 REVERSE is connected to TORQUE CALC OVER WIND 24 VDC at terminal C6 switches the current limits permitting the section to run in reverse NOTE Set PID ENABLE to OFF when running in torque mode Master Torque Section
39. r output is operating correctly The line must be running above MIN SPEED for the diameter calculator to operate ConfigEd Lite DC Applications Pack 2 9 C2 cpw p65 9 1 23 2003 4 29 PM Chapter 2 Open Loop Winder 2 10 ConfigEd Lite DC Applications Pack C2 cpw p65 10 1 23 2003 4 29 PM zz IT CEE Im C3 spw p65 Chapter 3 Closed Loop Winder Chapter 3 CLOSED LOOP WINDER SPW The spw_v 4 5 7 590 configuration for a speed programmed winder SPW provides closed loop center winder control It programs the motor speed using either loadcell or dancer feedback for tension control This configuration provides standard features used in center winder applications including diameter calculation with memory and preset tension and taper PID for loadcell tension or dancer position control and over under winding It can control unwinds or rewinds for single spindle and turret winders The configuration uses four function blocks in the SPECIAL BLOCKS DIAMETER CALC TAPER CALC SETPOINT SUM 2 and PID DESCRIPTION Figures 3 1 and 3 2 show typical SPW applications SPW applications use closed loop trim to modify the winder speed Line speed is conditioned in RAMPS before being combined with the tension trim in SETPOINT SUM 2 The result SPT SUM OUTPUT is scaled by DIAMETER and MIN DIAMETER in SETPOINT SUM 1 to produce the speed demand TAPER CALC TOT TENS DEMAND uses inputs to terminals A5
40. tio Section r J Ratio Figure 4 4 Ratio Master Torque Section Torque _ Setpoint Figure 4 5 Torque Master Slave Section Loadcell Master Figure 4 6 Tension Slave Section Dancer Figure 4 7 Dancer Position ConfigEd Lite DC Applications Pack 4 3 1 23 2003 4 29 PM COUT CES Chapter 4 Section Control ADDITIONAL FEATURES Line sections often require additional control features The SC configuration has the following features built in See the Using Section Control section for details on their use Reverse Reversing allows sections such as coaters and laminators to reverse directions to accommodate a web path change to coat the other side of the web Anti reverse Anti reverse is required where reversing a section may cause mechanical damage to the machine or may be hazardous to the operator Agitate Agitate or Sunday drive is a feature used for coater and printer sections to keep the coater turning at a low speed when the line has stopped to prevent the coating material from solidifying Slack Take up pay out A line in draw control such as a paper machine can be difficult to get running It often needs the ability to speed up or slow down one section relative to another to remove loops of slack web without disturbing the preset draw Slack take up offers this capability
41. trol 4 14 C4 sc p65 ConfigEd Lite DC Applications Pack 1 23 2003 4 29 PM CO IT CES Im Appendix Equations Appendix A SIMPLE WINDER EQUATIONS Below are equations used to determine winder torque and horsepower requirements Unwind Master Section Rewind Tension Line Speed Reference Tension ip gt Diameter N 4 Torque gt CS Speed _1 Line Speed ft min Diameter ft T Wine Speed rpm Diameter ft Torquetension If Tension lbf x _ Torquergiqi Ibf Torquetansion Ibf Torquer iction Ibf Torquelnertiq lbf Line Speed ft min x Tension lbf Horsepowery LE SPEEGNM MINE x ENSION TON eee eee 33000 _ Diameter Build up Horsepower winder Horsepower webx Constant Hp Range Horsepowerpiciiont Horsepower inertia Horsepower 27 x Motor Speed rpm x Motor Torque Ibf 33000 Figure A 1 Winder Equations ConfigEd Lite DC Applications Pack App A 1 A equat p65 1 1 23 2003 4 29 PM Appendix A Equations App A 2 A equat p65 2 ConfigEd Lite DC Applications Pack 1 23 2003 4 29 PM
42. w core To achieve this the winders must operate in two modes speed mode and tension mode Speed mode is required to match the surface speed ofthe new core or new full roll to the line speed for the splice Tension mode is required after the splice or transfer Before starting in speed mode the operator sets the diameter to core for a rewind or to the diameter of the new roll for an unwind by inputting the correct value in terminal A2 EXTERNAL DIAMETER PRESET Setting C7 PRESET ENABLE to ON keeps the diameter at the preset diameter until the transfer is completed Then the spindle is started using terminal C3 RUN The drive ramps up to the correct speed so the roll s surface speed matches the line speed The splice or transfer can occur at that point When the web is transferred to the new roll or core tension mode is enabled by setting terminal C8 TENSION ENABLE to ON and the old roll is stopped At this point C7 is set OFF to allow the diameter calculator to calculate the correct diameter The new roll continues in tension mode until the next roll change 6 INPUT SIGNAL DESCRIPTIONS Line Speed Reference A line speed signal is required for the diameter calculator to work It should be scaled to produce 10 volts at full speed and connected into terminal A4 LINE SPEED If this signal comes from a source other than a Eurotherm Drives motor controller it may need to be scaled and isolated This signal passes through the RAM
43. when terminal C3 RUN is set ON Setting terminal C4 to ON selects jog mode For TENSION ENABLE both C3 and C4 should be ON Once the line gets above a minimum speed the diameter calculator begins calculating the roll diameter In tension mode an overspeed underspeed for unwinds is added to saturate the speed loop because the web holds the winder at line speed With the speed loop saturated the drive is current limited by the torque demand If the web breaks the winder increases to the speed loop limits preventing a runaway Terminal C6 OVERWIND changes the polarity of the torque demand and overspeed for overwinding or underwinding For unwinds set Value for True 0 00 and Value for False 0 01 TAPER CALC uses signals from terminals AS TENSION SETPOINT and A6 TAPER SETPOINT to produce the tension demand SETPOINT SUM 2 multiplies the tension demand by diameter to produce the torque demand The torque demand is then combined with compensations for frictional losses to produce the final torque used to control the drive Loss compensations have static and dynamic components The static part is a fixed value for overcoming static loss or stiction The dynamic part is pro 2 Tension Setpoint a rH 8 3 gt g 2 Ext Line y c 5 5 Diameter Speed 21 zg Preset Taper Setpoint a D 5 8 TTT Al A2 A4 A5 A A7 A8 B3 C4 C C7 C9 VOV ft t
44. wi is tight and less positive when the web is slack In this arrangement dancer feedback will increase the speed when the web is slack The trim range value depends on the nature of the web It needs to be greater for an extensible web than for a non extensible web In addition the extensible web requires a higher control loop gain which comes with the greater trim range If required trim ranges for two different types of web can be selected by configuring an unused digital input to set two different values of trim range see Extensible Non extensible Webs Tension The tension in dancer applications is determined by the air pressure or weight loading on the dancer The drive only controls the dancer position OTHER FEATURES This section explains how to use the many features available in the SC configura tion Draw To select draw mode set SETPOINT SUM 1 RATIO 0 to 100 percent The input at terminal A2 DRAW RATIO sets the amount of draw by adjusting SETPOINT SUM 1 RATIO 1 Itis multiplied by the line speed terminal A4 and then added to the line speed to produce the speed demand Calibrating analog input 1 sets the draw range In draw mode the draw range is normally set to about 5 to 5 percent To set a 5 percent range set ANIN 1 A2 CALIBRATION to 0 0500 Then 10 volts on A2 produces 5 draw and 10 volts produces 5 draw Terminal A2 can also be limited by MAX VALUE and MIN VALUE clamps with defaults o
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