DCS800 Winder Description - ABB Ltd · DCS800 Winder Description ... Therefore it is important to adjust the torque- and compensation function blocks. ... parameters in function block

DCS800

DCS800 Winder Description Indirect Tension Control Package

DCS800 Drive Manuals All the documents available for the drive system DCS800 are listed below:

Language Public. number E D I ES F CN

DCS800 Quick Guide 3ADW000191 x p p p p DCS800 Tools & Documentation CD 3ADW000211 x DCS800 Converter module

Flyer DCS800 3ADW000190 x x p x p p Technical Catalogue DCS800 3ADW000192 x x x x p x Hardware Manual DCS800 3ADW000194 x x p p p p Firmware Manual DCS800 3ADW000193 x p p p p p Installation according to EMC 3ADW000032 x Technical Guide 3ADW000163 x Service Manual DCS800 3ADW000195 x p Planning and Start-up for12-Pulse converters 3ADW000196 p CMA-2 Board 3ADW000136 p Flyer Hard - Parallel 3ADW000153 p

Drive Tools

DriveWindow 2.x - User's Manual 3BFE64560981 x DriveOPC 2.x - User's Manual 3BFE00073846 x Optical DDCS Communication Link 3AFE63988235 x DDCS Branching Units - User´s Manual 3BFE64285513 x

DCS800 Applications

PLC Programming with CoDeSys CoDeSys_V23 x x x 61131 DCS800 target +tool description - Application Program 3ADW000199 x Winding with the DCS 800XXXXX 3ADW000058 Winder application description 3ADW000253 x Flyer magnetic application Magnetic application description

DCS800-E Panel Solution

Flyer DCS800-E Panel solution 3ADW000210 x Hardware Manual DCS800-E 3ADW000224 x

DCS800-A Enclosed Converters

Flyer DCS800-A 3ADW000213 x Technical Catalogue DCS800-A 3ADW000198 x p Installation of DCS800-A 3ADW000091 p p

DCS800-R Rebuild System

Flyer DCS800-R 3ADW000007 x x DCS800-R Manual 3ADW000197 x DCS500/DCS600 Size A5...A7, C2b, C3 and C4 Upgrade Kits 3ADW000256 x

Extension Modules

RAIO-01 Analogue IO Extension 3AFE64484567 x RDIO-01 Digital IO Extension 3AFE64485733 x AIMA R-slot extension 3AFE64661442 x

Serial Communication

Drive specific serial communication NETA Remote diagnostic interface 3AFE64605062 x Fieldbus Adapter with DC Drives RPBA- (PROFIBUS) 3AFE64504215 x Fieldbus Adapter with DC Drives RCAN-02 (CANopen) Fieldbus Adapter with DC Drives RCNA-01 (ControlNet) 3AFE64506005 x Fieldbus Adapter with DC Drives RDNA- (DeviceNet) 3AFE64504223 x Fieldbus Adapter with DC Drives RMBA (MODBUS) 3AFE64498851 x Fieldbus Adapter with DC Drives RETA (Ethernet) 3AFE64539736 x

x -> existing p -> planned Status 09.2007 DCS800 Drive Manuals-List_e.doc

3

Table of contents

3ADW000308R0201 DCS800 Winder Tens ctrl e b

Table of contents

DCS800 Drive Manuals.............................................................................................................. 02

Table of contents............................................................................................................................... 1 H3

DCS800 Winder.................................................................................................................................. 2 H5 Indirect tension control ............................................................................................................... 3 H5

Winder formulas and calculation..................................................................................................... 4 H6 Diameter .................................................................................................................................... 5 H6 Tension ...................................................................................................................................... 6 H7 Acceleration Torque................................................................................................................... 7 H8 Losses........................................................................................................................................ 8 H8 Winder motor ............................................................................................................................. 9 H9

Winder structure.............................................................................................................................. 1 0 H10 Interface DCS800 firmware and winder application ................................................................. 1 1 H10

Signal and Parameter list ............................................................................................................... 1 2 H16 Group 7......................................................................................................................... 1 3 H17 Group 8......................................................................................................................... 1 4 H18 Group 60....................................................................................................................... 1 5 H18 Group 61....................................................................................................................... 1 6 H21 Group 63....................................................................................................................... 1 7 H25 Group 64....................................................................................................................... 1 8 H27 Group 65....................................................................................................................... 1 9 H31 Group 66....................................................................................................................... 2 0 H34 Appendix ...................................................................................................................... 2 1 H35 Appendix ...................................................................................................................... 2 2 H35

Safety instructions .......................................................................................................................... 2 3 H36 What this chapter contains....................................................................................................... 2 4 H36 To which products this chapter applies.................................................................................... 2 5 H36 Usage of warnings and notes .................................................................................................. 2 6 H36 Installation and maintenance work........................................................................................... 2 7 H37

Grounding..................................................................................................................... 2 8 H38 Mechanical installation............................................................................................................. 2 9 H40 Operation ................................................................................................................................. 3 0 H41

Commissioning ............................................................................................................................... 3 1 H43 Guidance.................................................................................................................................. 3 2 H43 Control Bits (Example) ............................................................................................................ 3 3 H50

Appendix A - Application handling................................................................................................ 3 4 H51 Identification............................................................................................................................. 3 5 H51 Installation................................................................................................................................ 3 6 H51

4

Table of contents


Enable / disable application ..................................................................................................... 3 7 H52

5

DCS800 Winder


DCS800 Winder Winder drives can operate in

• velocity control • indirect tension control • direct tension control, equipped with a load cell • dancer control, equipped with a dancer roll

Winder control systems, except velocity control, needs the following conditions:

• The lead roll must be in velocity control • The velocity signal for the winder drive comes from the lead roll or is only a reference signal • Winder ratio should be lower than 1:12 • Quality of winding will be defined by the exactness of the calculation

This description contains the indirect tension control, which is also called as indirect torque control.

Indirect tension control With indirect tension control the tension feedback must be calculated based on diameter and motor torque. Therefore it is important to adjust the torque- and compensation function blocks. The tension ratio should not be higher than 1:10, because quality winding without feedback signals isn’t possible with a bigger ratio.

The following terms are necessary for this regulation scheme:

• Before starting, the actual diameter must be known • Actual line speed (or line speed reference) is necessary during running • Tension reference is necessary

M MT

nact Tref dact vref = nref

T

nact ... nref nref ramp

6

Winder formulars and calculation

3ADW000308R0101 DCS800 Winder Tens ctrl e a 3ADW000308R0201 DCS800 Winder Tens ctrl e b

Winder formulas and calculation With DCS800 Winder Library it is possible to design winder applications using CoDeSys. For wind-ers it is important that the following conditions are existing:

• The line speed (velocity) of the web is constant • The material tension is constant (oscillating isn’t allowed) • Motor speed must be adapted to actual diameter • Motor torque depends on the actual diameter

Diameter In most cases the actual diameter must be calculated, because a sensor to enter the physical di-ameter from the material roll doesn’t exist. But it is easy to calculate the diameter from the meas-ured velocity and motor speed.

π⋅=

nvD , unit: [ ] mD =

(1.1)

In DCS800 we calculate with relative values. So it isn’t essential to use the “PI”.

Diameter [D] = m Tension force [F] = N Motor speed [n] = rpm

Velocity [v] = m/s

Gear ratio [i] Motor : Load

V rewind

V unwind D

i nM

Dmin D Dmax

7



Tension For winders it is important that the tension to be in line with the web material. If the tension is to low, the material at the roll doesn’t wind correctly. When the tension is to powerful the web can be break. This is the hardest case, because the winder roll will accelerate, if there is no material break moni-toring. The tension is a force with units in Newtons. When the force is multiplied by the radius, the neces-sary torque for the selected tension can be calculated.

2DFTtension ⋅= , unit: [ ] NmTtension =

(1.2)

The equation shows that the most torque is needed with the maximum diameter.

Actual diameter [D] = m

Tension force [F] = N

Total Torque [T] = Nm

Tension Torque [Ttension] = Nm

Motor speed [n] = rpm

Gear ratio Motor : Load

Note: DCS800 Winder Software works with relative values (internal scaling). See scaling of the several parameters in function block description. For firmware structure the following rules applies:

• Velocity circuit is identical to speed circuit (100% velocity == 100% speed reference == 20000 internal scaling of 2.29)

• Tension circuit is identical to torque circuit (100% tension == 100% torque reference == 10000 internal scaling)

• Motor speed (100% == 20000 internal scaling) • Diameter (100% == 10000 internal scaling, range: 100…10000 allowed)

F

D

ZTM

T

8



Acceleration Torque During the winding operation the motor must have only the torque from tension. But to accelerate it is necessary to have a torque buffer. The acceleration torque depends on the inertia of motor, me-chanic, core and the material. If the diameter is small the inertia is also small. With increasing di-ameter the inertia will be bigger. That means more acceleration torque is needed. The problem in many applications is that the inertia isn’t available. But with tests it is possible to measure the accel-eration torque.

dtdJTacc

ω⋅= , unit: [ ] NmTacc = (1.3)

After acceleration the acceleration torque is zero! The acceleration torque depends extensive from the actual diameter. So the torque change with the fourth power.

)n(Tdtdv

Di2

iDD

32B

iJJJJ

i2DFT losses2

4min

4

23R2R1R

Mmax

Motor +⋅⋅⋅⎟⎟⎠

⎞⎜⎜⎝

⎛ −⋅π⋅ρ⋅+++++⋅⋅=

unit: [ ] NmTacc =

(1.4)

Torque inertia of core [JR1] = kg m²

Torque inertia of material roll [JR2] = kg m²

Torque inertia of gear box [JR3] = kg m²

Torque inertia of the motor [JM] = kg m²

Total torque inertia [Jc] = kg m²

Gear ratio Motor : Load

Losses The mechanics of the winder generates losses in the form of friction and torsion. These losses de-pend on motor speed and can be measured in an idle test. They are non-linear and must be saved in a characteristic curve with supporting points.

( )nfTlosses = , unit: [ ] NmTlosses = (1.5)

ZJR3

JR1

JR2

JM

9



Winder motor To select the motor power the velocity and the tension force are important values that are needed to calculate it. Other values which are not included in this equation are the power to accelerate and the losses. They depend on the mechanics of the winder!

Tension Force [F] = N

Velocity [v] = m/min

Motor Power [P] = kW

vFP ⋅= (1.6)

Winder characteristic curve:

n1cTL ⋅=

.constPL =

Note: Winder motors are overloaded during the acceleration time! Dimensioning is normally necessary for torque from tension and losses. Overload must be allowed!

V F

0 PL, TL

n

10

Winder structure


Winder structure Interface DCS800 firmware and winder application

DCS800 Firmware standard

new parameter

DCS800 Winder application

new parameter

+

DCS800 Firmware

SDCS-MEM-8principle FW winder interf.dsf

The DCS800 winder application is build as add-on to the DCS800 firmware. They interfaced by reading and writing parameters. The DCS800 winder application is located in the SDCS-MEM-8 memory card and are clearly sepa-rated in hardware wise. Detailed software structure diagrams are shown on the following pages.

11

Winder structure


11.1

2

11.0

6

AC

W B

6

Pul

se e

ncod

er 1

Ana

log

tach

o

EMF

M1B

aseS

peed

M1N

omVo

lt

Ref

1Sel

0 = open

SpeedRefExt1

2.17SpeedRefUsed

2.18

23.1

5

ACW

1 B

4

M1E

ncM

easM

ode

M1E

ncPu

lseN

o

M1T

achA

djus

t

M1T

acho

Vol

t100

0

Spee

dAct

Enc

Dire

ctSp

eedR

efSpee

dRef

3Sp

eedR

ef4

Dro

opR

ate

24.0

2

Torq

AccC

ompR

ef

Acce

lera

tion

com

pens

atio

n

AccC

ompD

erTi

me

AccC

ompF

iltTi

me

24.1

4

24.1

5

Spee

dCor

r23

.04

2.02

Torq

Ref

1

Torq

Min

All

Hol

dSpe

edC

trl

Spee

dSte

p

AC

W B

8

D23

.10

Torq

Ref

2

BalS

peed

Ctrl

BalR

ef

PI

24.1

1

PID

-con

trolle

r

Torq

Der

Ref

Torq

Prop

Ref

Lim

iter

Torq

Max

SPC

Torq

Min

SPC

Torq

Inte

gRef

2.08

2.20

KpSV

alM

inS

peed

TiSV

alM

inS

peed

Der

ivTi

me

Der

ivFi

ltTim

e

Torq

Ref

2 (2

.09)

24.1

7

24.1

024

.09

24.0

624

.05

24.0

4

24.0

3Kp

S

KpSM

in

KpSW

eakp

KpSV

alM

inSp

eed

KpST

iSM

inS

peed

KpSW

eakp

FiltT

ime

TiS

TiSI

nitV

alue

KpST

iSM

inS

peed

KpS

TiS

24.1

324

.12

24.2

024

.19

24.1

8

p-pa

rt, i-

part

TiSV

alM

inSp

eed

spee

dKp

STiS

Max

Spee

d

KpST

iSM

axSp

eed

p-pa

rtKp

S

KpSM

in

KpSW

eakp

KpSV

alM

inS

peed

TiSV

alM

inS

peed

Der

ivTi

me

Der

ivFi

ltTim

e

Torq

Ref

2 (2

.09)

KpS

KpSM

in

KpSW

eakp

KpSW

eakp

FiltT

ime

TiS

TiSI

nitV

alue

KpST

iSM

inS

peed

KpS

TiS

p-pa

rt, i-

part

spee

d

KpST

iSM

axSp

eed

p-pa

rtKp

S

KpSM

in

KpSW

eakp

+-

Panel, DW, DWL

20.0

120

.02

Spee

dRef

2301

AuxS

peed

Ref

AI1…

AI6

Fixe

dSpe

ed1

Fixe

dSpe

ed2

Mot

Pot

AuxR

ef-A

I1re

serv

edM

inAI

2AI4

Max

AI2

AI4

Ref

1Mux

Ope

nC

lose

DI1

…D

I8M

CW

Bit1

1…B

it15

ACW

Bit1

2…B

it15

2.30

Ref

2Sel

0 =

open

Spee

dRef

Ext2

Spee

dRef

2301

AuxS

peed

Ref

AI1…

AI6

Fixe

dSpe

ed1

Fixe

dSpe

ed2

Mot

Pot

AI2-

AI3

AI2+

AI3

AI2*

AI3

Min

AI2A

I4M

axA

I2AI

4

Ref

1Mux

Inve

rt110

2O

pen

Clo

seD

I1, …

, DI8

MC

W B

it11…

Bit1

5AC

W B

it12…

Bit

15

2.16

0000

2.01

Hol

d

Ram

p

Ram

pTim

eSca

le

Jog

Ram

p

JogD

ecTi

me

JogA

ccTi

me

22.1

2

22.1

3

23.0

2

23.0

3

2.32

Fixe

dSpe

ed1

Fixe

dSpe

ed2

Spee

dRef

2

E S

topR

amp

Shap

eTim

e

VarS

lope

Rat

e

BalR

ampO

ut

Ram

pByp

ass

BalR

ampR

ef

dv_d

t

Acc

/Dec

/Sha

peSp

eed

Ram

pOut

Spee

dAct

EMF

Spee

dAct

Tach

inte

rnal

sca

ling:

Spe

edS

cale

Act

(2.2

9) =

= 20

000

Mot

Spee

d

1 se

cond

Filte

r

Mot

Spee

dFilt

Win

derS

cale

Proc

Spee

d

Spee

dErrF

ilt

Win

dow

Intg

On

Win

Wid

thPo

s

Win

Wid

thN

eg

Win

dow

Ctrl

Mod

e

Win

dow

con

trol

2.03

Spee

dErrN

eg

23.0

6

-1

-

23.1

2

23.0

7

23.0

8

23.0

9

Spe

ed m

easu

rem

ent

Exte

rnal

M1S

peed

FbS

el

+

20.0

2

20.0

1

50.0

6

Filte

r

Spee

dFilt

Tim

e

AccT

ime1

Dec

Tim

e1

Torq

Max

All

2.19

-

Torq

ue s

elec

tor =

Add

-

Spe

ed re

fere

nce

sele

ctio

nS

peed

refe

renc

e se

lect

ion

Spe

ed ra

mp

Spe

ed a

ctua

l sel

ectio

nS

peed

act

ual s

elec

tion

Spe

ed c

ontro

ller

Spe

ed c

ontro

ller

SPEE

D R

EFE

RE

NC

E C

HAI

NSP

EED

CO

NTR

OL

2.31

Loca

l

AC

WB

2

MC

W B

4

MC

W B

6M

CW

B5

22.0

3

22.0

4

22.0

5

22.0

7

22.0

8

22.0

122

.02

AC

WB

3

23.0

123

.13

23.0

223

.03

23.0

123

.13

23.0

223

.03

Lim

iter

M1S

peed

Min

M1S

peed

Max

Lim

iter

M1S

peed

Max

M1S

peed

Min

+

2.07

2.05

2.04

2.06

20.0

7

20.0

8

2.09

50.0

4

50.0

2

99.0

299

.04

50.1

2

50.1

3

1.03

1.02

1.05

50.0

3

1.04

50.1

7

1.011.

41

Filte

r

AI1D

irect

+AI

2Dire

ct+

+

11.0

3

11.0

2

10.0

2D

irect

ion

-1

Jog2

(10.

18)

Jog1

(10.

17)

AC

W2

B10

MC

W B

8, B

9

24.1

3

2.19

24.1

3

Sig

nal

Par

amet

er

Par

amet

er is

usu

ally

writ

ten

to b

y Ad

aptiv

e P

rogr

am,

appl

icat

ion

prog

ram

or o

verr

idin

g co

ntro

lA

ttent

ion:

Th

e fir

mw

are

stru

ctur

e di

agra

ms

show

the

stan

dard

firm

war

e

Lege

nd

Pul

se e

ncod

er 2

Enc2

Mea

sMod

e

Enc2

Pul

seN

o50

.19

50.1

8

Spee

dAct

Enc2

1.42

Enc2

Dire

ct+

Enco

der2

23.0

5

DCS800_Fw_struct_winder_tens_ctrl_c.dsf

Adap

tGai

n

KpD

iaM

inTn

Dia

Min

KpD

iaM

ax

KpO

ut

TnD

iaM

axKp

Win

Mod

ef (

Cal

cDia

Act)Tn

Out

24.0

9

24.0

3

20.0

2

20.0

1

Dia

Cal

c

In1

Vel

oIn

2 N

act

Min

Cor

eDia

Tram

pWD

irTr

ampW

cDir

Rel

Vel

oLev

Rel

Spe

edLe

v

SelC

mdD

iaIn

itIn

it va

lue

Cal

cDia

Act

Win

Sca

le

Lim

Min

Lim

Max

-->

Velo

city

con

trol

--> V

ELO

CIT

Y C

ON

TRO

L

SelA

ctIit

2

SelD

iaIn

it1D

iaIn

it1AI

1...A

I6D

iaIn

it2 SelV

elR

ef

Velo

Ref

AI1.

..AI6

Enco

der 2

VelR

efIN Ve

loS

cale

Velo

Jog1

Velo

Jog2

SelJ

og1

SelJ

og2

Velo

WiP

rese

tScal

edV

elR

efO

ut

Win

Pos

Win

Neg

61.0

261

.01

61.0

361

.06

61.0

761

.08

61.0

961

.12

65.0

165

.04

65.0

565

.06

65.0

765

.08

65.2

0

61.2

0

65.1

265

.10

65.0

9

65.1

1

61.1

461

.15

61.1

661

.17

61.1

8

SpdF

iltTi

me

f (C

alcD

iaAc

t)

61.1

3

12

Winder structure


20.1

9

20.1

3M

1Cur

Lim

Brdg

2

Min

Torq

Use

dMax

Sel

Torq

Max

20.0

5AI

1, …

, AI6

Torq

Use

dMax

Torq

Use

dMin

Lim

6

6

Torq

Lim

Act

Torq

Ref

A25

01AI

1…AI

6

Torq

Ref

A S

el

+ +

0 01

2 3 45

Torq

ue s

elec

tor

Min

3

Max

4

Torq

Ref

Ext

2.24

Torq

Gen

Max

Torq

Ram

pUp

Torq

Ram

pDow

n

Torq

ue ra

mp

Lim

iter

Torq

Max

Tref

Torq

Min

Tref

Load

Com

p

Torq

ue li

mite

r

Torq

Max

All

Torq

Min

All

Gea

r bac

klas

h co

mpe

nsat

ion

Torq

Max

All

Torq

Min

All

26.0

1To

rqSe

l

25.0

1

Torq

Ref

4

25.0

2

Filte

r

Torq

Ref

A F

TC

25.0

3

Load

Shar

e

Torq

Ref

B

Add

5

Spee

d 1

Torq

ue 2

Torq

Ref

3G

earS

tartT

orq

Gea

rTor

qTim

e

Gea

rTor

qRam

p

Torq

Use

dMin

Sel

Torq

Min

20.0

6AI

1, …

, AI6

Neg

ate

2.23

=

2.22

* (-

1)

M1C

urLi

mBr

dg1

Flux

Ref

FldW

eak

Max

Torq

Ref

2

Torq

Ref

1

Not

Use

dD

I1, …

, DI1

1M

CW

Bit

11, …

, MC

W B

it15

ACW

Bit

12, …

, AC

W B

it 15

Torq

Mux

Torq

Sel2

601

(0…

6)Sp

eed/

Torq

(1 o

r 2)

Spee

d/M

in (1

or 3

)Sp

eed/

Max

(1 o

r 4)

Spee

d/Li

mit

(1 o

r 6)

Torq

Mux

Mod

e

+

+

Torq

Cor

r

Torq

Ref

Use

d

Not

Use

dAI

1, …

, AI6

Torq

Cor

rect

+

Torq

ue re

fere

nce

and

torq

ue s

elec

tion

Torq

ue li

mita

tion

TOR

QU

E C

ON

TRO

L C

HAI

N

25.0

4

25.0

5

25.0

6

20.0

9

20.1

0

2.19

2.20

2.09

2.08

2.10

26.0

2

20.0

5

20.1

2

3.24

2.11

26.0

8

26.0

9

26.1

0

2.22

20.2

2

2.19

2.20

2.26 2.14

2.13

20.0

6

2.23

97.0

1Ty

peC

ode=

2-Q

0%

25.1

0

26.0

526

.04

26.0

1Pa

nel,

DW

, DW

L an

dTo

rqR

ef2

2.09

20.1

8

26.1

5

-1

Loca

l


SelT

ensR

ef

Tens

Ref

AI1.

..AI6

63.0

263

.01

Tens

Ref Te

Ref

Out

Tens

Ref

TapT

ens

TapD

iaTe

Ref

Hol

dSe

lTeR

efH

ldTe

Ref

Min

63.0

363

.05

63.0

663

.07

63.0

8

63.2

0To

rqS

cale

In1

Torq

Scal

eOut

Torq

Scal

e

Cal

cDia

Act

66.0

3

AccF

iltAc

cFilt

Out

AccF

iltIn

AccF

iltAc

cTD

AccM

ulAc

cDiv

64.0

364

.04

64.0

564

.06

64.4

0Ac

cTor

q AccT

qOut

AccF

iltO

utAc

cTqZ

eroL

evAc

cMec

PosS

caAc

cMec

Neg

Sca

AccC

oiPo

sSca

AccC

oiN

egS

caAc

cCoi

Wid

thC

alcD

iaAc

t

64.1

264

.13

64.1

464

.15

64.1

6

64.4

3

64.1

7

Torq

Com

p

TrqC

ompO

ut

TqC

pSpI

nTq

CpS

p0Tq

CpT

q0Tq

CpS

p...

TqC

pTq.

..Tq

CpS

p6Tq

CpT

q6Tq

CpD

iaTq

CpA

dd

64.2

064

.21

64. .

..64

. ...

64.3

2

64.4

6

64.3

364

.34

SelD

eriIn

Der

In A

I1...

AI6

Spec

ial

Extra

64.0

164

.02

61.2

02.

32

1.04

64.1

9na

ct

13

Winder structure


ParC

hang

e

M1F

ldH

eatR

ef

FldH

eatS

el

M1F

ldR

efM

ode

Fiel

dcu

rren

tm

easu

rem

ent

Mot

1Fld

Cur

Rel

Mot

1Fld

Cur

1.29

1.30

Mot

or 1

fiel

d cu

rren

t con

trolle

r

M1K

pFex

M1T

iFex

M1F

ldR

efE

xt

FldC

urR

efM

1

inte

rnal

sca

ling:

I fnom

== 1

0000

M1P

osLi

mC

trl

Fiel

d cu

rren

t con

trol

Mot

or 1

Fie

ld

curr

ent m

easu

re-

men

t and

mot

orda

ta

44.0

445

.0610

.10

21.1

845

.05

44.0

2

44.0

3

3.30

45.0

2

M1N

omFl

dCur

M1

field

dat

a

99.1

299

.11

M1U

sedF

exTy

pe

Fiel

dre

vers

al(g

roup

45)

Opt

iTo

rque

Brid

ge

44.0

944

.10

44.0

744

.08

is s

et to

max

imum

flux

ifFl

dCtrl

Mod

e (4

4.01

) = F

ix

43.1

743

.18

43.1

943

.20

43.2

143

.22

1.04

Ope

rMod

eSel

M1A

rmL

M1A

rmR

SelB

ridge

6.05

M1N

omFl

dCur

M1U

sedF

exTy

pe

M1B

aseS

peed

If M

1Spe

edFb

Sel (

50.0

3) =

Ext

erna

l,th

en M

otS

peed

(1.0

4) c

an b

e w

ritte

n to

.

Ope

rMod

eSel

= F

ield

Con

v

PwrS

uppl

yRef

Ext

Cur

Ref

Slop

e

di/d

t lim

itatio

n

20.1

2M

1Cur

Lim

Brdg

1

20.1

3M

1Cur

Lim

Brdg

2

Cur

Ref

Use

dC

urre

nt c

ontro

ller

Con

trolM

odeS

el

M1K

pArm

Cur

M1T

iArm

Cur

M1D

isco

ntC

urLi

m

Mot

Cur

1.15

EMF-

calc

ulat

ion

Arm

Alph

a

Firin

g un

it

43.1

4R

evD

ly

M1N

omVo

lt

M1N

omC

ur

Mai

nsvo

ltage

mea

sure

men

t

Con

verte

rcu

rren

tm

easu

rem

ent.

Nom

Mai

nsV

olt

Mai

nsVo

ltAct

Rel

Mai

nsVo

ltAct

Con

vCur

Act

Rel

Con

vCur

Act

1.11

1.12

1.15

1.16

M

Mot

or 1

FldC

urFl

ux40

FldC

urFl

ux70

FldC

urFl

ux90

Flux

line

ariz

atio

n

EMF

Vol

tAct

Rel

1.17

EMF

cont

rolle

r

KpEM

FTi

EMF

Flux

con

trol

M1B

aseS

peed

Mot

Spee

d

inte

rnal

sca

ling:

Mn==

100

00M

max

= 3.

25 *

Mn

Flux

Ref

FldW

eak

3.24

Flux

Ref

Sum

Cur

Ctrl

Stat

1

Flux

Ref

EM

F

VoltC

orr

VoltR

efS

lope

V re

fm

odifi

catio

n

VoltR

ef2

FldW

eakD

yn

is s

et to

zer

oif

FldC

trlM

ode

(44.

01) =

Fix

EMF

Inte

rnal

VoltR

efE

xtAI

1, …

, AI6

EMF

Ref

Sel

EMF

Ctrl

Pos

Lim

EMF

Ctrl

Neg

Lim

97.0

9

Filte

rFi

lter

Mai

nsC

omp

Tim

e

Max

Cur

Lim

Spee

d

Mot

Spee

d

Arm

Cur

Lim

Spee

d1

Arm

Cur

Lim

Spee

d2

Arm

Cur

Lim

Spee

d3

Arm

Cur

Lim

Spee

d4

Arm

Cur

Lim

Spee

d5

Mai

nsVo

ltAct

Rel

Lang

uage

Mot

or d

ata

EMF

Act

FiltT

ime

44.2

5

44.2

6

Arm

atur

ecu

rren

tm

easu

rem

ent

Con

vCur

Act

Rel

Flux

Cor

r

-++

++

Arm

VoltA

ct

Arm

VoltA

ctR

el

Cur

rent

lim

itatio

nBr

idge

inte

rnal

sca

ling:

I mot

nom

== 1

0000

I max

= 3.

25 *

I mot

nom

FIEL

D C

UR

REN

T C

ON

TRO

L(o

ne fi

eld

exci

ter)

Mai

nsVo

ltAct

Rel

-

Rev

VoltM

argi

n Min

M1N

omVo

lt

B9=1 B9

=0

VoltR

ef1

Arm

atur

e cu

rren

t con

trol

EM

F an

d flu

x co

ntro

l

ARM

ATU

RE

CU

RR

ENT

CO

NTR

OL

Arm

atur

e cu

rrent

m

easu

rem

ent a

nd

mot

or d

ata

Con

vNom

Volt

4.04

Con

vNom

Cur

4.05

3.12

1.06

43.0

1

43.0

5

43.0

643

.07

43.0

843

.24

1.11

43.1

343

.12

20.1

520

.14

3.13

99.0

2

99.0

3

99.1

199

.12

99.0

499

.10

99.0

1

1.14

1.13

43.0

9

43.1

0

97.2

5

44.2

1

1.11

99.0

244

.22

3.25

1.04

99.0

444

.15

3.26

3.27

3.28

44.1

244

.13

44.1

4

44.2

7

43.0

4

43.0

1

Lim

iter

Arm

Alph

aMin

Arm

Alph

aMax

Uk

Firin

gLim

Mod

e

44.2

36.

03 B

9

Cur

Ref

311

Cur

Ref

Ext

AI1…

AI6

FexC

urR

efFl

uxR

efE

MF

Cur

Sel

Flux

Ref

FldW

eak

Scal

e

n

3.24

43.0

33.

11

43.0

2

3.30

3.27

12-p

ulse

mas

ter

42.0

2

Pane

l, D

W,

DW

L an

d

Loca

l

43.0

1


14

Winder structure


44.0

944

.10

44.0

744

.08

is s

et to

max

imum

flux

ifFl

dCtrl

Mod

e (4

4.01

) = F

ix

ParC

hang

e

M1F

ldH

eatR

ef

FldH

eatS

el

If M

1Spe

edFb

Sel (

50.0

3) =

Ext

erna

l,th

en M

otS

peed

(1.0

4) c

an b

e w

ritte

n to

.

M1F

ldR

efM

ode

Fiel

dcu

rren

tm

easu

rem

ent

Mot

1Fld

Cur

Rel

Mot

1Fld

Cur

1.29

1.30

Mot

or 1

fiel

d cu

rren

t con

trolle

r

M1K

pFex

M1T

iFex

FldC

urFl

ux40

FldC

urFl

ux70

FldC

urFl

ux90

Flux

line

ariz

atio

nEM

F co

ntro

ller

KpEM

FTi

EMF

Flux

con

trol

M1B

aseS

peed

Mot

Spee

d

Flux

Ref

FldW

eak

3.24

Flux

Ref

Sum

Cur

Ctrl

Stat

1

Flux

Ref

EM

F

VoltC

orr

VoltR

efS

lope

V re

fm

odifi

catio

n

VoltR

ef2

FldW

eakD

yn

is s

et to

zer

oif

FldC

trlM

ode

(44.

01) =

Fix

EMF

Inte

rnal

VoltR

efE

xtAI

1, …

, AI6

EMF

Ref

Sel

EMF

Ctrl

Pos

Lim

EMF

Ctrl

Neg

Lim

44.2

5

44.2

6

M1F

ldR

efE

xt

Flux

Cor

r

FldC

urR

efM

1

++

inte

rnal

sca

ling:

I fnom

== 1

0000

M1P

osLi

mC

trl

Mai

nsVo

ltAct

Rel

-

Rev

VoltM

argi

n Min

M1N

omVo

lt

B9=

1

B9=0

VoltR

ef1

EM

F an

d flu

x co

ntro

lFi

eld

curr

ent c

ontro

lM

otor

1 F

ield

cu

rren

t mea

sure

-m

ent a

nd m

otor

data

44

.21

1.11

99.0

244

.22

3.25

1.04

99.0

444

.15

3.26

3.27

3.28

44.1

244

.13

44.1

4

44.0

445

.0610

.10

21.1

845

.05

44.0

2

44.0

3

3.30

45.0

2

44.2

7

M1N

omFl

dCur

M1

field

dat

a

99.1

2

99.1

1M

1Use

dFex

Type

44.2

36.

03 B

9

Fiel

dre

vers

al(g

roup

45)

Opt

iTo

rque

Brid

ge

43.1

743

.18

43.1

943

.20

43.2

143

.22

1.04

Ope

rMod

eSel

M1A

rmL

M1A

rmR

SelB

ridge

6.05

M1N

omFl

dCur

M1U

sedF

exTy

pe

M1B

aseS

peed

Ope

rMod

eSel

= F

ield

Con

v

PwrS

uppl

yRef

Ext

Cur

Ref

311

Cur

Ref

Ext

AI1…

AI6

FexC

urR

efFl

uxR

efE

MF

Cur

Sel

Flux

Ref

FldW

eak

Cur

Ref

Slop

e

di/d

t lim

itatio

nSc

ale

20.1

2M

1Cur

Lim

Brdg

1

20.1

3M

1Cur

Lim

Brdg

2

Cur

Ref

Use

dC

urre

nt c

ontro

ller

Con

trolM

odeS

el

M1K

pArm

Cur

M1T

iArm

Cur

M1D

isco

ntC

urLi

m

Mot

Cur

1.15

EMF-

calc

ulat

ion

Arm

Alph

a

Firin

g un

it

43.1

4R

evD

ly

M1N

omVo

lt

M1N

omC

ur

Mai

nsvo

ltage

mea

sure

men

t

Con

verte

rcu

rren

tm

easu

rem

ent.

Nom

Mai

nsV

olt

Mai

nsVo

ltAct

Rel

Mai

nsVo

ltAct

Con

vCur

Act

Rel

Con

vCur

Act

1.11

1.12

1.15

1.16

EMF

Vol

tAct

Rel

1.17

inte

rnal

sca

ling:

Mn==

100

00M

max

= 3.

25 *

Mn

97.0

9

Filte

rFi

lter

Mai

nsC

omp

Tim

e

Max

Cur

Lim

Spee

d

Mot

Spee

d

Arm

Cur

Lim

Spee

d1

Arm

Cur

Lim

Spee

d2

Arm

Cur

Lim

Spee

d3

Arm

Cur

Lim

Spee

d4

Arm

Cur

Lim

Spee

d5

Mai

nsVo

ltAct

Rel

Lang

uage

Mot

or d

ata

EMF

Act

FiltT

ime

Arm

atur

ecu

rren

tm

easu

rem

ent

Con

vCur

Act

Rel

-++

Arm

VoltA

ct

Arm

VoltA

ctR

el

Cur

rent

lim

itatio

nBr

idge

inte

rnal

sca

ling:

I mot

nom

== 1

0000

I max

= 3.

25 *

I mot

nom

Arm

atur

e cu

rren

t con

trol

Arm

atur

e cu

rrent

m

easu

rem

ent a

nd

mot

or d

ata

Con

vNom

Volt

4.04

Con

vNom

Cur

4.05

3.24

43.0

33.

11

3.12

1.06

43.0

1

43.0

5

43.0

643

.07

43.0

843

.24

1.11

43.1

343

.12

20.1

520

.14

3.13

99.0

2

99.0

3

99.1

199

.12

99.0

499

.10

99.0

1

1.14

1.13

43.0

9

43.1

0

97.2

5

43.0

2

3.30

3.27

12-p

ulse

mas

ter

43.0

4

43.0

1

Lim

iter

Arm

Alph

aMin

Arm

Alph

aMax

Uk

Firin

gLim

Mod

e

M

Mot

or 1

M

Mot

or 2

42.0

2

Pane

l, D

W,

DW

L an

d

Loca

l

43.0

1

FIEL

D C

UR

REN

T C

ON

TRO

L(tw

o fie

ld e

xcite

rs)

ARM

ATU

RE

CU

RR

ENT

CO

NTR

OL

ParC

hang

e

M2F

ldH

eatR

ef

FldH

eatS

el

M2F

ldR

efM

ode

Mot

or 2

fiel

d cu

rren

t con

trolle

r

M2K

pFex

M2T

iFex

M2F

ldR

efE

xt

FldC

urR

efM

2 M2P

osLi

mC

trl

49.0

645

.1410

.10

21.1

845

.13

49.1

0

49.1

1

3.31

45.1

6

-

-145

.17

FldC

urTr

im

-Fi

eld

curr

ent

mea

sure

men

t

Mot

2Fld

Cur

Rel

Mot

2Fld

Cur

1.31

1.32

inte

rnal

sca

ling:

I fnom

== 1

0000

M2N

omFl

dCur

M2

field

dat

a

49.0

749

.05

M2U

sedF

exTy

pe

Brid

ge

Mot

or 2

Fie

ld

curr

ent m

easu

re-

men

t and

mot

or

data


15

Winder structure


7.04

Pan

el, D

W, D

WL

OnO

ff1

Com

man

dSel

10.0

1

Han

d/A

uto

Off2

E S

top

Sta

rtSto

p

&

Res

et

Used

MC

W

Bit0

On

(Off1

N)

Bit1

Off2

N (C

oast

Sto

p)

Bit2

Off3

N (E

-Sto

p)

Bit3

Run

Bit4

Ram

pOut

Zero

Bit5

Ram

pHol

dB

it6 R

ampI

nZer

oB

it7 R

eset

Bit8

Inch

ing1

Bit9

Inch

ing2

Bit1

0 R

emot

eCm

dB

it11…

Bit1

5 au

x. c

ontro

l

Mai

nCtr

lWor

d

Bit0

On

(Off1

N)

Bit1

Off2

N (C

oast

Sto

p)

Bit2

Off3

N (E

-Sto

p)

Bit3

Run

Bit4

Ram

pOut

Zero

Bit5

Ram

pHol

dBi

t6 R

ampI

nZer

oBi

t7 R

eset

Bit8

Inch

ing1

Bit9

Inch

ing2

Bit1

0 R

emot

eCm

dBi

t11…

Bit1

5 au

x. c

ontro

l

ABB

Driv

e pr

ofile

con

trol

10.1

5

10.0

8

10.0

9

10.1

6

10.0

3

Loca

l

Loca

l

Loca

l

Loca

l

Loca

l

10.0

8

10.0

9O

ff2

E S

top

10.0

7

≥

Aux

Ctr

lWor

dAu

xCtr

lWor

d

Bit0

Res

tartD

ataL

ogB

it1 T

rigD

ataL

ogB

it2 R

ampB

ypas

sB

it3 B

alR

ampO

utB

it4 L

imSp

eedR

ef4

Bit5

rese

rved

Bit6

Hol

dSpe

edC

trlB

it7 W

indo

wC

trlB

it8 B

alSp

eedC

trlB

it9 S

yncC

omm

and

Bit1

0 S

yncD

isab

leB

it11

Res

etSy

ncR

dyB

it12

aux.

con

trol

Bit1

3 au

x. c

ontro

lB

it14

aux.

con

trol

Bit1

5 au

x. c

ontro

l

Bit0

rese

rved

Bit1

rese

rved

Bit2

rese

rved

Bit3

rese

rved

Bit4

Dis

able

Brid

ge1

Bit5

Dis

able

Brid

ge2

Bit6

rese

rved

Bit7

rese

rved

Bit8

Driv

eDire

ctio

nBi

t9 re

serv

edBi

t10

Dire

ctSp

eedR

efBi

t11

rese

rved

Bit1

2 Fo

rceB

rake

Bit1

3 re

serv

edBi

t14

rese

rved

Bit1

5 R

eset

PID

Ctrl

Driv

e Lo

gic

Faul

tsAl

arm

sM

otSp

eed

Off1

Mod

eSt

opM

ode

E St

opM

ode

FlyS

tart

FanD

lyM

ainC

ontC

trlM

ode

FldH

eatS

el

Cur

Ctr

lSta

t1

Bit0

Fan

sOn

Cm

d.Bi

t1 re

serv

edBi

t2 re

serv

edBi

t3 m

otor

hea

ting

Bit4

fiel

d di

rect

ion

Bit5

Fie

ldO

n C

md.

Bit6

dyn

amic

bra

king

Bit7

Mai

nCon

tact

orO

n C

md

Bit8

Dyn

amic

Brak

ingO

n C

md

Bit9

driv

e ge

nera

ting

Bit1

0 re

serv

edBi

t11

firin

g pu

lses

Bit1

2 co

ntin

uous

cur

rent

Bit1

3 ze

ro c

urre

ntBi

t14

DC

-bre

aker

trip

cm

dBi

t15

DC

-bre

aker

trip

cm

d

Mai

nSta

tWor

d

Bit0

Rdy

On

Bit1

Rdy

Run

Bit2

Rdy

Ref

Bit3

Trip

ped

Bit4

Off2

NSt

atus

Bit5

Off3

NSt

atus

Bit6

OnI

nhib

ited

Bit7

Ala

rmBi

t8 A

tSet

poin

tBi

t9 R

emot

eBi

t10

Abov

eLim

itBi

t11

rese

rved

Bit1

2 re

serv

edBi

t13

rese

rved

Bit1

4 re

serv

edBi

t15

rese

rved

Aux

Stat

Wor

d

Bit0

Dat

aLog

Rea

dyBi

t1 O

utO

fWin

dow

Bit2

E-S

topC

oast

Bit3

Use

r1Bi

t4 U

ser2

Bit5

Syn

cRdy

Bit6

Fex

1Act

Bit7

Fex

2Ack

Bit8

Bra

keC

md

Bit9

Lim

iting

Bit1

0 To

rqC

trlBi

t11

Zero

Spee

dBi

t12

EMFS

peed

Bit1

3 Fa

ultO

rAla

rmBi

t14

Driv

eDire

ctio

nNeg

Bit1

5 Au

toR

eclo

sing

1.04

21.0

121

.03

21.0

421

.10

21.1

421

.16

21.1

8

7.02

7.03

7.01

&

≥

6.03

8.01

8.02

ABB

Driv

e pr

ofile

con

trol

Win

derC

trlW

ord

Bit

00

ReW

inde

r

Bit

01

Win

dDir

Bit

02

Win

derO

n

Bit

03

Dia

met

erIn

it

Bit

04

rese

rve

Bit

05

Tens

ionH

old

Bit

06

rese

rve

Bit

07

Velo

city

Sele

ct

Bit

08

Jog

1

Bit

09

Jog

2

Bit

10

Activ

ateI

nit2

Bit

11

Torq

ueP

uls

Bit

12

unus

ed

Bit

13

unus

ed

Bit

14

unus

ed

Bit

15

unus

ed

7.11

Use

d W

iCW

7.12

Bit 0

0 R

eWin

der

Bit 0

1 W

indD

ir

Bit 0

2 W

inde

rOn

Bit 0

3 D

iam

eter

Init

Bit 0

4 re

serv

e

Bit 0

5 Te

nsio

nHol

d

Bit 0

6 re

serv

e

Bit 0

7 V

eloc

itySe

lect

Bit 0

8 Jo

g 1

Bit 0

9 Jo

g 2

Bit 1

0 A

ctiv

ateI

nit2

Bit 1

1 To

rque

Puls

Bit 1

2 un

used

Bit 1

3 un

used

Bit 1

4 un

used

Bit 1

5 un

used

DI1

… A

CW

-B15

DI1

… A

CW

-B15

DI1

… A

CW

-B15

DI1

… A

CW

-B15

DI1

… A

CW

-B15

DI1

… A

CW

-B15

DI1

… A

CW

-B15

DI1

… A

CW

-B15

DI1

… A

CW

-B15

DI1

… A

CW

-B15

DI1

… A

CW

-B15

DI1

… A

CW

-B15

DI1

… A

CW

-B15

DI1

… A

CW

-B15

DI1

… A

CW

-B15

DI1

… A

CW

-B15

10.1

5 10.1

510.1

5 10.1

566.0

4 65.1

261.0

9 61.0

861.1

0 10.1

563.0

7 10.1

565.0

8 60.0

460.0

3 60.0

2W

inde

r Sta

tWor

d8.

16

Bit 0

0 R

eWin

der

Bit 0

1 W

indD

ir

Bit 0

2 W

inde

rOn

Bit 0

3 Te

nsio

nSel

Bit 0

4 Te

nsio

nOn

Bit 0

5 re

serv

ed

Bit 0

6 Jo

ggin

g

Bit 0

7 D

iaC

alcR

unni

ng

Bit 0

8 D

iaC

alcA

tLim

it

Bit 0

9 Ac

celZ

ero

Bit 1

0 D

iaLo

gicO

ut1

Bit 1

1 D

iaLo

gicO

ut2

Bit 1

2 O

utof

Win

dow

Bit 1

3 un

used

Bit 1

4 un

used

Bit 1

5 un

used

60.0

1

60.0

5

Win

derM

ode

JogB

ackl

ash

to W

inde

r FBs

Win

der l

ogic


65.1

6D

iaLe

vel1

DiaL

evel

Dia

Tim

e1

Dia

Leve

l2

Dia

Tim

e2

Cal

cDia

Act

Dia

Logi

cOut

1

Dia

Logi

cOut

265

.17

65.1

8

65.1

9

16

Signal and Parameter list


Signal and Parameter list Index Signal / Parameter name

min

. m

ax.

def.

unit

E/C

General scaling of values: Percental internal physical Velocity / line speed 100 % 20 000 x mps (also x mpm);

scaled with max. veloc-ity, which is needed to get the max. motor speed while running with min. diameter

Speed (motor speed) 100 % 20 000 x rpm scaled with pa-rameter 2.29

Diameter 100 % 10 000 x mm = value of Dmax Tension 100 % 10 000 x N depending on

torque scaling via parame-ter 66.03

Torque 100 % 10 000 x Nm depending on motor data

Current 100 % 10 000 x A = value of parame-ter 99.03 M1NomCur

Physical units of DCS800 standard parameters: RPM The region of speed reference, ramp generator up to speed controller

is defined as rpm. Unfortunately this physical unit of these parameters can not be modified. By using the winder application these region is working as velocity. The value in rpm can be calculated as following:

[ ] [ ] [ ][ ]rpm scaling speedm/svelocity max.rpm parameter of valuem/s value ⋅=

speed scaling via parameter 2.29

17



Index Signal / Parameter name

min

. m

ax.

def.

unit

E/C

Gro

up

7 Control Words

additional to standard firmware

7.11 Winder_CW (winder control word) The control word contains all winder depending commands Please see the bit description of parameter 7.12. Please note that all used bits can also be se-lected via parameters.

- - -

7.12 Used_WiCW (used winder control word) The used winder control word is read only and contains all winder depending commands, which sources are selectable (*1).

Bit Name Value Comment 0 ReWin 1 Set as rewinder (*1) 0 Set as unwinder (*1) 1 WinDir 1 counter clockwise turning (*1) 0 clockwise turning (*1) 2 WinOn 1 Activates winding mode according winding mode selection 0 Activates speed (velocity) controlled mode 3 DiaSet 1 set initial diameter as actual diameter value 0 diameter calculation will run in winding mode 4 - - - 1 no action 0 no action 5 TeReHld 1 Set an internal value as tension setpoint 0 Set the external value as tension setpoint 6 VelScale 1 Switch over to 100% scaling 0 Scaling by using parameter (default 100%) 7 VelSelect 1 reserved for selection of external reference; 0 no action; jog commands takes priority 8 WinJog1 1 Jog ref 1 selected 0 no action 9 WinJog2 1 Jog ref 2 selected 0 no action 10 DiaActInit2 1 value 2 is selected as initial diameter 0 value 1 is selected as initial diameter 11 TrqPuls 1 reserved for torque pulse will be activated 0 no action 12 - - - 1 no action 0 no action 13 - - - 1 no action 0 no action 14 - - - 1 no action 0 no action 15 - - - 1 no action 0 no action *1 changed signal take effect, if RdyRef is false (8.01:2=0); means “not running”.

- - -

18




min

. m

ax.

def.

unit

E/C

Gro

up

8 Status Words

additional to standard firmware

8.16 Winder_SW (winder status word) Status word of winder function with following bits:

Bit Name Value Comment 0 ReWinder 1 Winder is selected as rewinder 0 Winder is selected as unwinder 1 WinDirection 1 Web is coming from above 0 Web is coming from below 2 WinOn 1 Winding mode is active 0 Line speed mode is active 3 TenSel 1 Tension mode is pre selected 0 With WiOn the tension mode will not be active 4 TenOn 1 Tension mode is active 0 Tension mode is not active 5 CtrlOn 1 Tension controller is active 0 Tension controller is not active 6 WinJogAct 1 Jog command is given. 0 Jog command is not given. 7 DiaCalcRun 1 Diameter calculator is released and running 0 Diameter calculator is stopped 8 DiaAtLimit 1 Output of diameter calculation is in working range. 0 Output of diameter calculation is inside the limits. 9 AccTqZero 1 The derivated signal is lower than the level. So the acceleration

torque is zero. 0 The derivated signal is higher than the level. 10 WiLoOut1 1 Calculated diameter has just reached level 1 (impulse) 0 no action 11 WiLoOut2 1 Calculated diameter has just reached level 2 (impulse) 0 no action 12 OutofWindow 1 Delayed signal of out of window 0 no action 13..15 - - - 1 not used yet 0 not used yet

- - -

Gro

up

60 Applic Controls

Winder application

60.01 WinderMode (selector of winding mode) With this parameter the winding mode is to be selected:

0 = None 1 = Speed_Ctrl Without “Winder On” command the drive can always run in speed mode;

e.g. for jogging. 2 = Ind_Tension with “Winder On” command the indirect tension mode is running 3 Dir_Tension Not available in this application 4 = Dancer_Ctrl Not available in this application

Non

eD

ance

rC

trl

Ind

Ten

sion

-

19




min

. m

ax.

def.

unit

E/C

60.02 SelReWinder (selector of rewinder command) The source for this rewinder command will be selected by this parameter: Signal = 0 means running as un winder Signal = 1 means running as re winder 00 = Default according winder control word (7.11); here bit 0 of Used_WiCW (7.12) 01 = NotUsed constant 0 (false) 02 = On constant 1 (true) 03 = DI1 depending on digital input 1 04 = DI2 depending on digital input 2 05 = DI3 depending on digital input 3 06 = DI4 depending on digital input 4 07 = DI5 depending on digital input 5 08 = DI6 depending on digital input 6 09 = DI7 depending on digital input 7 10 = DI8 depending on digital input 8 11 = DI9 depending on digital input 9 12 = DI10 depending on digital input 10 13 = DI11 depending on digital input 11 14 = DI12 depending on digital input 12 15 = DI13 depending on digital input 13 16 = DI14 depending on digital input 14 17 = WiCW_Bit10 depending on winder control word (7.11), bit 10 18 = WiCW_Bit11 depending on winder control word (7.11), bit 11 19 = WiCW_Bit12 depending on winder control word (7.11), bit 12 20 = WiCW_Bit13 depending on winder control word (7.11), bit 13 21 = WiCW_Bit14 depending on winder control word (7.11), bit 14 22 = WiCW_Bit15 depending on winder control word (7.11), bit 15 23 = MCW_Bit00 depending on main control word (7.01), bit 00 24 = MCW_Bit03 depending on main control word (7.01), bit 03 25 = MCW_Bit08 depending on main control word (7.01), bit 08 26 = MCW_Bit09 depending on main control word (7.01), bit 09 27 = MCW_Bit11 depending on main control word (7.01), bit 11 28 = MCW_Bit12 depending on main control word (7.01), bit 12 29 = MCW_Bit13 depending on main control word (7.01), bit 13 30 = MCW_Bit14 depending on main control word (7.01), bit 14 31 = MCW_Bit15 depending on main control word (7.01), bit 15

Int. Scaling: 1 == 1 Type: C Volatile:

Def

ault

AC

WB

it15

Def

ault -

60.03 SelWinDir (selector of winder direction command) The source for this winder direction command will be selected by this parameter: Signal = 0 means winding clockwise Signal = 1 means winding counter clockwise 00 = Default according winder control word (7.11); here bit 1 of Used_WiCW (7.12) 01 = NotUsed constant 0 (false) 02 = On constant 1 (true) … = … 31 = please see more possible setting in parameter 60.02


Def

ault

AC

WB

it15

Def

ault

20




min

. m

ax.

def.

unit

E/C

60.04 SelWinderOn (selector of winder on command) The source for this winder on command will be selected by this parameter: Signal = 0 means running in line speed controlled mode Signal = 1 means running in indirect torque controlled mode 00 = Default according winder control word (7.11); here bit 2 of Used_WiCW (7.12) 01 = NotUsed constant 0 (false) 02 = On constant 1 (true) … = … 31 = please see more possible setting in parameter 60.02


Def

ault

AC

WB

it15

Def

ault

60.05 JogBacklash (Time of jog delay) This time will delay the switch over from jogging reference to the external reference.

Int. Scaling: 1 == 1ms Type: I Volatile:

0,00

1 30 2 s

21




min

. m

ax.

def.

unit

E/C

Gro

up

61 Velocity Control

Winder application

In

Scale

Scale

5000

SgnA1

Add1

ZYX ⋅X

YZ

10000

Sgn

Refs

Refp

Out

0

Jog1

Jog2

Act2

Act1

1≥&

OutSgn

JogAct

Select

Add2

Out1

Chng

AddWin

WinNeg

WinPosRefp

VelRef V1.1

61.04

61.02 Sel

61.01

61.03

61.05

61.06

61.07

61.09

61.08

61.10

61.12

61.20

61.01 VeloRef (Velocity reference; also called line speed) This value is used as incoming velocity reference of the winder application.

Int. Scaling: 20000 == 100 % Type: SI Volatile:

-327

6732

767 0

22




min

. m

ax.

def.

unit

E/C

61.02 SelVelRef (selector of velocity reference) Velocity reference selector for input as main reference (to function block VelRef): 0 = Def_Para VeloRef (Parameter 61.01) selected 1 = AI1 analog input 1 2 = AI2 analog input 2 3 = AI3 analog input 3 4 = AI4 analog input 4 5 = AI5 analog input 5 6 = AI6 analog input 6 7 = Special reserved 8 = Extra reserved 9 = AITAC tacho input 10 = Encoder2 encoder input 2


Def

Par

aE

ncod

er2

Def

Par

a -

61.03 VeloScale (scaling factor of velocity reference) Function block : VelRef Input : iScale


130

000

5000

-

61.06 VeloJog1 (Jog reference 1 as velocity reference ) Function block : VelRef Input : Jog1


-300

0030

000

1000

61.07 VeloJog2 (Jog reference 2 as velocity reference ) Function block : VelRef Input : Jog2


-300

0030

000

-100

0

23




min

. m

ax.

def.

unit

E/C

61.08 SelJog1 (selector of jog1 command ) Parameter selects the input of jog1 command; used in function block VelRef 00 = Default according winder control word ; here bit 8 of Used_WiCW (7.12). 01 = NotUsed constant 0 (false) 02 = On constant 1 (true) 03 = DI1 depending on digital input 1 04 = DI2 depending on digital input 2 05 = DI3 depending on digital input 3 06 = DI4 depending on digital input 4 07 = DI5 depending on digital input 5 08 = DI6 depending on digital input 6 09 = DI7 depending on digital input 7 10 = DI8 depending on digital input 8 11 = DI9 depending on digital input 9 12 = DI10 depending on digital input 10 13 = DI11 depending on digital input 11 14 = DI12 depending on digital input 12 15 = DI13 depending on digital input 13 16 = DI14 depending on digital input 14 17 = WiCW_Bit10 depending on winder control word (7.11), bit 10 18 = WiCW_Bit11 depending on winder control word (7.11), bit 11 19 = WiCW_Bit12 depending on winder control word (7.11), bit 12 20 = WiCW_Bit13 depending on winder control word (7.11), bit 13 21 = WiCW_Bit14 depending on winder control word (7.11), bit 14 22 = WiCW_Bit15 depending on winder control word (7.11), bit 15 23 = MCW_Bit00 depending on main control word (7.01), bit 00 24 = MCW_Bit03 depending on main control word (7.01), bit 03 25 = MCW_Bit08 depending on main control word (7.01), bit 08 26 = MCW_Bit09 depending on main control word (7.01), bit 09 27 = MCW_Bit11 depending on main control word (7.01), bit 11 28 = MCW_Bit12 depending on main control word (7.01), bit 12 29 = MCW_Bit13 depending on main control word (7.01), bit 13 30 = MCW_Bit14 depending on main control word (7.01), bit 14 31 = MCW_Bit15 depending on main control word (7.01), bit 15


Def

ault

Def

ault

AC

WB

it15 -

61.09 SelJog2 (selector of jog2 command ) Parameter selects the input of jog2 command; used in function block VelRef 00 = Default according winder control word ; here bit 9 of Used_WiCW (7.12). 01 = NotUsed constant 0 02 = On 03 = … see more in parameter 61.08


Def

ault

Def

ault

AC

WB

it15 -

61.12 VeloWiPreset (lead value of velocity during winding mode) Function block : VelRef Input : iAddWin


-300

0030

000

-100

0

24




min

. m

ax.

def.

unit

E/C

61.13 SpdFiltTime (filter time of speed feedback depending on diameter The value of filter time corresponds with the minimal diameter. The filter time will increase with growing diameter. With maximal diameter the following value will be active: max. filter time = value of 61.13 * max. diameter (100%) / value of 65.01 Note: The calculated value will be transmitted to parameter 50.06.

Int. Scaling: 1 == 1ms Type: SI Volatile:

020

00 1m

s

61.1461.15

61.1661.1761.18

24.0324.09

61.14 KpDiaMin (Kp value of speed controller with minimal diameter) Function block : AdaptGain0 Input : iKpMin Note: iKpOut will be transmitted to parameter 24.03.

Int. Scaling: 100 == 1 x Type: SI Volatile:

0.00

325.

005.

00-

61.15 TnDiaMin (Tn value of speed controller with minimal diameter) Function block : AdaptGain Input : iTnMin Note: iTnOut will be transmitted to parameter 24.09.

Int. Scaling: 1 == 1 ms Type: SI Volatile: 0

6400

025

00 ms

61.16 KpDiaMax (Kp value of speed controller with maximal diameter) Function block : AdaptGain Input : iKpMax Note: KpOut will be transmitted to parameter 24.03.


0.00

325.

005.

00-

61.17 TnDiaMax (Tn value of speed controller with maximal diameter) Function block : AdaptGain Input : iTnMax Note: KpOut will be transmitted to parameter 24.09.

Int. Scaling: 1 == 1 ms Type: SI Volatile:

064

000

2500 m

s

25




min

. m

ax.

def.

unit

E/C

61.18 KpWinMode (Kp value of speed controller during window mode) During tension mode the speed controller is running in window mode for limiting the speed range. Therefore a higher Kp value is desired. Note: In tension mode, this value will be transmitted to parameter 24.03.


0.00

325.

0010

.00

61.19 Unused

- - - -

61.20 ScaledVel (Scaled velocity (line speed) from “VelRef”) This parameter is the output iRefs of the winder function block VelRef.

Int. Scaling: 20000 == 100% Type: SI Volatile:

-300

0030

000 0 -

Gro

up

63 Tension Controls

Winder application

63.09

63.02 Sel

63.01

RefHld

Ref

Tap

DiaAct

DiaRed

Hold

RefMin

TRamp

Out

SetVal

Set

TensRef V1.1

63.04 Sel

63.03

63.07

63.05

63.06

63.08

63.10

63.20

63.01 TensRef ( input of tension reference )

Function block : TensRef Input : iRef

Int. Scaling: 100 == 1 % Type: SI

0.00

100.

000.

00 %

63.02 SelTensRef (selector of tension reference) Tension reference selector for input to function block TensRef: 0 = Def_Para TensRef (parameter 63.01) selected 1 = AI1 analog input 1 2 = AI2 analog input 2 3 = AI3 analog input 3 4 = AI4 analog input 4 5 = AI5 analog input 5 6 = AI6 analog input 6


Def

Par

aA

I6D

efP

ara -

26




min

. m

ax.

def.

unit

E/C

63.03 TapTens ( reduction of tension dependend on diameter ) Function block : TensRef Input : iTap


0.00

100.

000.

00 %

63.05 TapDia ( value as from the tension reduction begins ) Function block : TensRef Input : iDiaRed


1.00

100.

001.

00 %

63.06 TeRefHold ( tension reference if hold command is active ) This tension reference will be active instead of external tension reference, if the incoming com-mand, selected in 63.07, is active.


0.00

100.

0015

.00 %

63.07 SelTeRefHld (selector of hold tension command ) Parameter selects the input of tension hold reference command; used in function block TensRef 00 = Default according winder control word ; here bit 5 of Used_WiCW (7.12). 01 = NotUsed constant 0 (false) 02 = On constant 1 (true) 03 = … see more in parameter 61.08


Def

ault

Def

ault

AC

WB

it15 -

63.08 TeRefMin (minimal tension reference) Function block : TensRef Input : iRefMinw


0.00

100.

001.

00 %

63.20 TeRefOut (Tension reference output of TensRef) Function block : TensRef Input : iOut

Int. Scaling: 100 == 1 % Type: SI -3

20.0

032

0.00

0.00 %

27




min

. m

ax.

def.

unit

E/C

Gro

up

64 Inertia+Friction Control

Winder application

AccFilt V1.1

ZYX ⋅X

YZ

Dout

Mul

TF

TD

In

Div 64.06

64.04

64.03

64.05

64.4064.02 Sel

AI

64.01Enc

64.01 DeriIn (input value for derivation )

Int. Scaling: 1 == 1 Type: I

-300

0030

000 0 -

64.02 SelDeriIn (selector for input, which is to be derivated ) Velocity reference selector for input as main reference (to function block VelRef): 0 = Def_Para DeriIn (parameter 64.01) selected 1 = AI1 analog input 1 2 = AI2 analog input 2 3 = AI3 analog input 3 4 = AI4 analog input 4 5 = AI5 analog input 5 6 = AI6 analog input 6 7 = Special ScaledVal (value out of parameter 61.20) 8 = Extra Speed RampOut (value out of parameter 2.32) 9 = AITAC tacho input 10 = Encoder2 encoder input 2


Def

Par

aE

ncod

er2

Spe

cial -

64.03 AccFilter (PT1 filter time for incoming signal)


130

000

100

ms

64.04 AccTD (derivation time)


130

000

100

ms

64.05 AccMul (multiplier to scale output)

Int. Scaling: 1 == 1 Type: SI Volatile:

-327

6732

767 1 -

28




min

. m

ax.

def.

unit

E/C

64.06 AccDiv (devisor to scale output)

Int. Scaling: 1 == 1 Type: SI Volatile:

-327

6732

767 1 -

64.15

64.14

64.13

64.12

64.42

ZOut

AccTorq V1.1

In

ZeroLev

MecPos

MecNeg

CoiPos

CoiNeg

CoiWid

DiaAct

DiaRel

0

SumOut

MecTrq

CoiTrq

64.11 Sel

AI

64.10 Enc

64.17

64.16

64.41

64.12 AccTqZeroLev (Value below the output is set to zero) Function block : AccTorq Input : iZeroLev


020

000

100

64.13 AccMecPosSca (acceleration torque for mechanic part) Function block : AccTorq Input : iMecPos

Int. Scaling: 10 == 1 % Type: I

0.0

100.

00.

0 %

64.14 AccMecNegSca (deceleration torque for mechanic part) Function block : AccTorq Input : iMecNeg


0.0

100.

00.

0 %

64.15 AccCoiPosSca (acceleration torque for the coil) Function block : AccTorq Input : iCoiPos


0.0

100.

00.

0 %

64.16 AccCoiNegSca (deceleration torque for the coil) Function block : AccTorq Input : iCoiNeg


0.0

100.

00.

0 %

64.17 AccCoiWidth (width of the coil) Function block : AccTorq Input : iCoiWid

Int. Scaling: 100 == 1% Type: SI

0.00

100.

0010

0.00 %

29




min

. m

ax.

def.

unit

E/C

ZYX ⋅X

YZ

TqDia

DiaAct

DiaRel

InSp

SpX

TqX

AddOut

OTqSp

OTqD0

Sgn

Rel

TorqComp V1.1

63.34

26.02

63.20

63.33

...

64.19 TqCpSpIn (input of speed value) Read Only This parameter shows the actual speed in percent for easy setting of all TqCpSpx parameters. Function block : TorqComp Input : inSp Int. Scaling: 100 == 1% Type: I

020

000 0 %

64.20 TqCpSp0 (supporting point of speed value) Function block : TorqComp Input : iSpx

Int. Scaling: 100 == 1% Type: I

010

000 0 %

64.21 TqCpTq0 (supporting point of torque value) Function block : TorqComp Input : iTqx


0.00

100.

002.

00 %



0.00

100.

000.

50 %



0.00

100.

000.

00 %



0.00

100.

0020

.00 %

30




min

. m

ax.

def.

unit

E/C



0.00

100.

000.

00 %



0.00

100.

0040

.00 %



0.00

100.

000.

00 %



0.00

100.

0060

.00 %



0.00

100.

000.

00 %



0.00

100.

0080

.00 %



0.00

100.

000.

00 %



0.00

100.

0010

0.00 %



0.00

100.

000.

00 %

64.34 TqCpDia (torque value dependend on diameter) Function block : TorqComp Input : iTqDia


-100

.00

100.

000.

00 %

31




min

. m

ax.

def.

unit

E/C

64.39 TqSpeedCtrl (torque compensation also during speed control mode) 0 = No Torque compensation is active during tension controlled mode 1 = Yes Torque comp. is also active during normal speed controlled mode Int. Scaling: 1 == 1 Type: SI

No

Yes No -

64.40 AccFiltOut (output of derivated signal) Output signal of the derivated velocity signal, which can be used for accelerating torque.

Int. Scaling: 1 == 1 Type: SI

-300

0030

000 0 /

64.43 AccTqOut (output of acceleration torque)


-320

.00

320.

000.

00 %

64.46 TrqCpOut (totalized output of torque compensation)


-327

6732

767

0.00

-

Gro

up

65 Diameter calculator

Winder application

65.08 Sel

65.09

65.0165.02

65.0465.05

65.0665.07

65.2065.21

65.01 MinCoreDia (diameter relation = min. core diameter) Function block : DiaCalc Input : iDiaRel


1.00

100.

0010

.00 %

32




min

. m

ax.

def.

unit

E/C

65.02 DiaVmax (diameter with fastest line speed and max. speed) Function block : DiaCalc Input : iDVmax Note: This parameter has no influence, if the value is lower than value of 65.01.

Please let this value lower, because this feature is not tested inside the whole winder ap-plication.


1.00

100.

0010

.00 %

65.04 TrampDir (ramp time of calculation in winding direction) Function block : DiaCalc Input : iTWDir

Int. Scaling: 1 == 10 ms Type: SI

-300

.00

300.

0010

.00 s

65.05 TrampWcDir (Ramp time of calcul. in counter winding direct.) Function block : DiaCalc Input : iTWcDir

Int. Scaling: 1 == 10 ms Type: SI

-300

.00

300.

0010

.00 s

65.06 RelVeloLev (Release level of velocity (line speed)) Function block : DiaCalc Input : iLevIn1


032

000 20

65.07 RelSpeedLev (Release level of actual motor speed) Function block : DiaCalc Input : iLevIn2


032

000 20

65.08 SelDiaInit (selector of initialization command ) Parameter selects the input of initialization command for setting the initial value. 00 = Default according winder control word ; here bit 3 of Used_WiCW (7.12). 01 = NotUsed constant 0 (false) 02 = On constant 1 (true) 03 = … see more in parameter 61.08


Def

ault

Def

ault

AC

WB

it15 -

65.09 DiaInit 1 (parameter for initial diameter value 1) Instead of this value other analogue inputs can be selected, please see parameter 65.10


1.00

100.

0010

.00 %

33




min

. m

ax.

def.

unit

E/C

65.10 SelDiaInit1 (selector of initial value 1) Velocity reference selector for input as main reference (to function block VelRef): 0 = Def_Para DiaInit1 (parameter 65.09) selected 1 = AI1 analog input 1 2 = AI2 analog input 2 3 = AI3 analog input 3 4 = AI4 analog input 4 5 = AI5 analog input 5 6 = AI6 analog input 6


Def

Par

aA

I6D

efP

ara -

65.11 DiaInit 2 (parameter for initial diameter value 2) This value can be selected via parameter 65.12.


1.00

100.

0010

.00 %

65.12 SelActInit2 (selector of activation initial value 2) Parameter selects the switch over between initial value 1 and 2. 00 = Default according winder control word ; here bit 10 of Used_WiCW (7.12). 01 = NotUsed constant 0 (false) 02 = On constant 1 (true) 03 = … see more in parameter 61.08


Def

ault

Def

ault

AC

WB

it15 -

65.16 DiaLevel1 (diameter level 1 for output signal) Function block : WinLogO Input : iIn


1.00

100.

0050

.00 %

65.17 DiaTime1 (time for diameter level 1 output) Function block : WinLogO Input : iTime1

Int. Scaling: 1000 == 1 s Type: I o.

000

30.0

002.

000 s

65.18 DiaLevel2 (diameter level 2 for output signal) Function block : WinLogO Input : iLogIn1


1.00

100.

0050

.00 %

65.19 DiaTime2 (time for diameter level 2 output) Function block : WinLogO Input : iTime2

Int. Scaling: 1000 == 1 s Type: I

o.00

030

.000

2.00

0 s

65.20 CalcDiaAct (signal: calculated diameter) Function block : DiaCalc Input : iSetVal


1.00

100.

001.

00 %

34




min

. m

ax.

def.

unit

E/C

65.21 WinScale (output of diameter calculator) Function block : DiaCalc Input : iWScale


1.00

100.

0010

0.00 %

Gro

up

66 Torque Control

Winder application

ZYX ⋅X

YZ

ZYX ⋅X

YZ

SetPuls

TPuls

0

InPuls

In1

In2

10000

DiaAct

0

10000

Scale

Out

PulsAct

TorqScale V1.1

66.01

66.02

66.10

66.11

66.03

66.01 TorquePuls (Value of start impulse) Function block : TorqScale Input : iInPuls


0.00

320.

000.

00 %

66.03 TorqueScale (Scaling factor of torque sum) Function block : TorqScale Input : iScale


-320

.00

320.

00 0 %

66.10 TrqScaOut (Actual output signal of torque scaling) Function block : TorqScale Input : iPulsAct


-320

.00

320.

000.

00 %

66.11 TePulsAct (Actual signal of tension puls) Function block : TorqScale Output :


-320

.00

320.

000.

00 %

35




min

. m

ax.

def.

unit

E/C

Ap

pen

dix

Writing values of standard parameters

This winder application is overwriting the following standard parameters: 07.02 AuxCtrlWord 07.03 AuxCtrlWord2 22.08 BalRampRef 23.01 SpeedRef 23.08 WinWidthPos 23.09 WinWidthNeg 23.15 DirectSpeedRef 24.03 KpS 24.09 TiS 25.01 TorqRefA 26.02 LoadComp 50.06 SpeedFiltTime 50.17 WinderScale Please don’t write on these parameters, too!

Ap

pen

dix

Presetting values of standard parameters

This application needs the following basic presetting, compared to the factory setting: 23.12 WinCtrlMode = SpeedActWin 26.01 TorqSel = Add 26.03 TorqSelMod = Fix 90.02 DsetXVal2 = 6101 90.03 DsetXVal3 = 6401

36

Safety instructions


Safety instructions

What this chapter contains This chapter contains the safety instructions you must follow when installing, oper-

ating and servicing the drive. If ignored, physical injury or death may follow, or damage may occur to the drive, the motor or driven equipment. Read the safety instructions before you work on the unit.

To which products this chapter applies The information is valid for the whole range of the product DCS800, the converter

modules DCS800-S0x size D1 to D7, field exciter units DCF80x, etc. like the Re-build Kit DCS800-R00-9xxx.

Usage of warnings and notes There are two types of safety instructions throughout this manual: warnings and

notes. Warnings caution you about conditions which can result in serious injury or death and/or damage to the equipment, and advise on how to avoid the danger. Notes draw attention to a particular condition or fact, or give information on a sub-ject. The warning symbols are used as follows:

Dangerous voltage warning warns of high voltage which can cause physical injury or death and/or damage to the equipment.

General danger warning warns about conditions, other than those caused by electricity, which can result in physical injury or death and/or damage to the equipment.

Electrostatic sensitive devices warning warns of electrostatic dis-charge which can damage the equipment.

37

Safety instructions


Installation and maintenance work These warnings are intended for all who work on the drive, motor cable

or motor. Ignoring the instructions can cause physical injury or death and/or damage to the equipment. WARNING!

• Only qualified electricians are allowed to install and maintain

the drive! • Never work on the drive, motor cable or motor when main power is

applied. Always ensure by measuring with a multimeter (impedance at least 1 Mohm) that:

1. Voltage between drive input phases U1, V1 and W1 and the frame is close to 0 V.

2. Voltage between terminals C+ and D- and the frame is close to 0 V.

• Do not work on the control cables when power is applied to the drive or to the external control circuits. Externally supplied control circuits may cause dangerous voltages inside the drive even when the main power on the drive is switched off.

• Do not make any insulation resistance or voltage withstand tests on the drive or drive modules.

• Isolate the motor cables from the drive when testing the insulation resistance or voltage withstand of the cables or the motor.

• When reconnecting the motor cable, always check that the C+ and D- cables are connected with the proper terminal.

Note:

• The motor cable terminals on the drive are at a dangerously high voltage when the main power is on, regardless of whether the mo-tor is running or not.

• Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V) may be present on the relay outputs of the drive system (e.g. SDCS-IOB-2 and RDIO).

• DCS800 with enclosure extension: Before working on the drive, isolate the whole drive system from the supply.

38

Safety instructions


Grounding

These instructions are intended for all who are responsible for the

grounding of the drive. Incorrect grounding can cause physical injury, death and/or equipment malfunction and increase electromagnetic in-terference. WARNING!

• Ground the drive, motor and adjoining equipment to ensure per-

sonnel safety in all circumstances, and to reduce electromagnetic emission and pick-up.

• Make sure that grounding conductors are adequately sized and marked as required by safety regulations.

• In a multiple-drive installation, connect each drive separately to protective earth (PE ).

• Minimize EMC emission and make a 360° high frequency ground-ing (e.g. conductive sleeves) of screened cable entries at the cabi-net lead-through plate.

• Do not install a drive equipped with an EMC filter to an un-grounded power system or a high resistance-grounded (over 30 ohms) power system.

Note:

• Power cable shields are suitable as equipment grounding conduc-tors only when adequately sized to meet safety regulations.

• As the normal leakage current of the drive is higher than 3.5 mA AC or 10 mA DC (stated by EN 50178, 5.2.11.1), a fixed protective earth connection is required.

39

Safety instructions


Printed circuit boards and fiber optic cables

These instructions are intended for all who handle the circuit boards

and fiber optic cables. Ignoring the following instructions can cause damage to the equipment.

WARNING! The printed circuit boards contain components sensitive to electrostatic discharge. Wear a grounding wrist band when handling the boards. Do not touch the boards unnecessarily.

Use grounding strip:

ABB order no.: 3ADV050035P0001

WARNING! Handle the fiber optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt. The minimum allowed bend radius is 35 mm (1.38 in.).

40

Safety instructions


Mechanical installation These notes are intended for all who install the drive. Handle the unit

carefully to avoid damage and injury. WARNING!

• DCS800 sizes D4 ... D7: The drive is heavy. Do not lift it alone. Do

not lift the unit by the front cover. Place units D4 and D5 only on its back. DCS800 sizes D5 ... D7: The drive is heavy. Lift the drive by the lifting lugs only. Do not tilt the unit. The unit will overturn from a tilt of about 6 degrees.

• Make sure that dust from drilling does not enter the drive when in-stalling. Electrically conductive dust inside the unit may cause damage or lead to malfunction.

• Ensure sufficient cooling. • Do not fasten the drive by riveting or welding.

41

Safety instructions


Operation These warnings are intended for all who plan the operation of the drive

or operate the drive. Ignoring the instructions can cause physical injury or death and/or damage to the equipment. WARNING!

• Before adjusting the drive and putting it into service, make sure

that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive. The drive can be adjusted to operate the motor at speeds above and below the base speed.

• Do not control the motor with the disconnecting device (discon-

necting mains); instead, use the control panel keys and , or commands via the I/O board of the drive.

• Mains connection You can use a disconnect switch (with fuses) to disconnect the electrical components of the drive from the mains for installation and maintenance work. The type of disconnect switch used must be as per EN 60947-3, Class B, so as to comply with EU regula-tions, or a circuit-breaker type which switches off the load circuit by means of an auxiliary contact causing the breaker's main contacts to open. The mains disconnect must be locked in its "OPEN" posi-tion during any installation and maintenance work.

• EMERGENCY STOP buttons must be installed at each control desk and at all other control panels requiring an emergency stop function. Pressing the STOP button on the control panel of the drive will neither cause an emergency stop of the motor, nor will the drive be disconnected from any dangerous potential. To avoid unintentional operating states, or to shut the unit down in case of any imminent danger according to the standards in the safety instructions it is not sufficient to merely shut down the drive via signals "RUN", "drive OFF" or "Emergency Stop" respectively "control panel" or "PC tool".

• Intended use The operating instructions cannot take into consideration every possible case of configuration, operation or maintenance. Thus, they mainly give such advice only, which is required by qualified personnel for normal operation of the machines and devices in in-dustrial installations. If in special cases the electrical machines and devices are in-tended for use in non-industrial installations - which may require stricter safety regulations (e.g. protection against contact by chil-dren or similar) - these additional safety measures for the installa-tion must be provided by the customer during assembly.

42

Safety instructions


Note:

• When the control location is not set to Local (L not shown in the status row of the display), the stop key on the control panel will not stop the drive. To stop the drive using the control panel, press the

LOC/REM key and then the stop key .

43

Commissioning


Commissioning After hardware installation, the drive must be commissioned. The following tools are recommended for commissioning:

• DriveWindow light (start-up assistant) See also DCS800 Quick Guide 3ADW000191 • DriveWindow 2.2 (actual value recording and analysis) COM8-board needed!

Guidance Please check that the steps can be done in terms of electrical and mechanical construction of your application. The preconditions of the following steps are the default parameter setting of DCS800 firmware and the software application. Partition: Standard, Application, Winder • S01 Connect DriveWindow light and open the start-up assistant “Wizard”.

Follow the instructions! For more Wizard support please see DCS800 Quick Guide 3ADW000191

• S02 Please take care that the winder is equipped with the empty core, because the maximum motor speed will be reached with the following steps.

• S03 1. Name plate data

Special hints for winder application: 20.02 The maximum (20.01 as invers minimum) speed is the value, which is

needed for the maximum velocity (line speed) measured on the core (mini-mum diameter)

iD

vn ⋅⋅

=min

maxmax π

If the calculated value nmax can not be handled by the motor, the maximum motor speed from motor name plate is to be set into 20.02 (invers value in 20.01). In this case the maximum line speed can not be reached with mini-mum diameter.

30.16 Please account for overspeed value also a preset of 10% (default value).

Check the higher value of e.g. 115..120%, that also of motor datas and me-chanical point of view.

• S04 2. Macro assistant Special hints for winder application: Deselect here digital inputs, which are used for winder application control

• S05 3. Autotuning field current controller ( follow the instructions)

• S06 4. Autotuning armature current controller ( follow the instructions)

nmax maximal needed motor speed in rpm vmax maximum velocity (line speed) in m/min Dmin minimum diameter (core) in m i gear ratio (motor / load)

44

Commissioning


• S07 5. Speed feedback assistant ( follow the instructions)

• S08 6. Autotuning speed controller ( follow the instructions) Set the step response inside the range of Slow and Normal

• S09 7. Field weakening assistant ( follow the instructions)

• S10 Advanced: Activate all built in options, like field bus adapter an additional IOs.

• S11 It is recommended to save the parameters settings, before continuing with winder appli-cation software! Please write down also the values of parameters 24.03 and 24.09.

• A01 Switch off the electronic supply of DCS800. Plug in the MemoryCard SDCS-MEM-8. Switch on the electronic supply of DCS800 again.

• A02 By using the MemoryCard with ready loaded application please go to point A03 Loading application by using DWL (DriveWindow light) • Take care that the PC is connected via COM-1 port to the DCS800. • Set DWL in Offline mode. • Select the Tools menu and then “CoDeSys Application Download” • “Select…” the desired application program file (extension PRG). • “Send” it to the DCS800. • After finishing “Close” the current “ABB Download Tool” window. Loading application by using ControlBuilder DCS800 (use instruction concerning the training)

• A03 Activate the application by using parameter 16.06 with “Enable application”.

• A04 Close DriveWindow (light). A restart of the tool is necessary to get also the parameters of the winder application. A restart of the DCS800 is necessary to get also the parameters via COM-8 board to DriveWindow.

• W01 Open DriveWindow (light).

• W02 Preset the following parameters out of the DCS800 firmware: 23.12 WinCtrlMode = SpeedActWin 26.01 TorqSel = Add 26.03 TorqSelMod = Fix 90.02 DsetXVal2 = 6101 90.03 DsetXVal3 = 6401 90.04 DsetXplus2val1 = 0 90.05 DsetXplus2val2 = 0 Preset of the following values (written down in step S11): 61.14 KpDiaMin = value of 24.03 61.15 TnDiaMin = value of 24.09

45

Commissioning


• W03 Calculate the diameter relation:

_______________%100maxmin01.65 =⋅==

DDMinCoreDia

Only if the calculated value nmax (see step S03) is higher than the maximum motor speed, then parameter 65.02 is to be set higher than 65.01:

_________________%100max02.65maxmax

max =⋅⋅⋅

==D

invD

MotorV

π

• W04 Winder control and presetting: Please set also the digital inputs as desired: 60.01 WinderMode = Ind.Tension 60.02 SelReWinder = your selection 60.03 SelWinDir = your selection 60.04 SelWinderOn = your selection 61.02 SelVelRef = your selection 61.08 SelJog1 = your selection 61.09 SelJog2 = your selection 65.08 SelDiaInit = your selection 65.09 DiaInit1 = value of 65.01

• W05 Measure loss compensation parameters with only core load. Set the diameter to minimum value. Set also the parameter 64.39 TqSpeedCtrl = Yes, so that the loss compensation will also work in velocity controlled mode. It is easier con-cerning polarities to measure in the condition with rewinder (=ON) and the WinDir (winder direction = NotUsed). In this case also the local reference can be used, which value is to be set in rpm. For this test it is necessary to measure with warm conditions of the mechanic! After warm-up the speed range should be split into 7 supporting points and the actual motor torque is accommodated in this points. During measuring the actual speed can be read out of parameter 64.19 TqCpSpIn. This value is in percent, same unit as speed depending parameters of TqCpSpx. The torque value of parameter 2.09 can be used as values of TqCpTqx. Note: Measuring of these points should be done without oscillation of torque or speed.

46

Commissioning


The following values show the speed depending supporting points as default.

• 64.32 TqCpSp6 = 100,0% 64.33 TqCpTq6 = measured value






• 64.20 TqCpSp0 = 0,0% 64.21 TqCpTq0 = measured value (adhesion)

• W06 Acceleration: Derivation of velocity reference

The derivative signal can either created out of the velocity reference or can be taken as value depending on the superior ramp generator.

• … either derivative velocity signal The output ScaledVal of the velocity reference function block is the default input source. This assumes that the winder drive gets a ramped reference. During commissioning this ramped reference is mostly not free available. So the ac-celerating adjustment can also be done by using the DCS800 internal ramp genera-tor, if the shortest ramp time is known.

• Therefore set the selector via parameter 64.02 SelDeriIn to “Spec 2”, which con-nects the input to the signal SpeedRampOut (2.32).

• Please take care: For the next steps the minimum diameter has continuously be set. If no other values known, start with 64.03 AccFilT= 40ms and 64.04 AccTD = 100ms.

• Let the reference ramp up and down. Observe the wave form of output 64.20 AccFiltOut. If necessary do an adaptation with the parameters 64.03 and 64.04.

• For increasing the amplitude to the necessary value of ±30000 as highest value for the shortest ramp time, please use the parameters 64.05 AccMult and 64.06 AccDiv for adaptation. Take care that a regular value will not generate a value higher than ±30000.

• … ramp depending value By using a derivative value of a superior ramp generator set the following parame-ters: 64.02 SelDeriIn = ? select the input 64.04 AccTD = 0 function block will not do a derivation

• For increasing the amplitude to the necessary value of ±30000 as highest value for the shortest ramp time, please use the parameters 64.05 AccMult and 64.06 AccDiv for adaptation. Take care that a regular value will not generate a value higher than ±30000.

47

Commissioning


• W07 Accelerating compensation of winder mechanics Let the reference ramp up and down. Observe the output of speed controller, parameter 2.09, and write the values of ramping up and down into parameter 64.13 and 64.14: 64.13 AccMecPosSca = value of 2.09 during ramping up 64.14 AccMecNegSca = value of 2.09 during ramping down. Stop and switch off the winder drive.

• W08 Big coil needed For the next steps the coil (reel) with the maximum values of this winder drive has to be mounted. If the values (diameter, width) is lower, than please set the correct value into the pa-rameters. 64.17 AccCoiWidth = 100% or the real mounted percental width 65.09 DiaInit1 = 100% or the real mounted percental diameter Take care that the new diameter init value is set and take care that the web is fixed, be-cause the coil will turn up to maximum line speed.

• W09 Tuning of speed controller with maximum diameter If parameter 64.39 TqSpeedCtrl is set to No, the adjustment can be done without losses and mechanical accelerating torque. Let the winder run and increase carefully the speed up to the maximum line speed, not the maximum motor speed. Measure the line speed on the surface of the coil. Adjust the speed controller, which works as line speed controller. The following values are used: 61.16 KpDiaMax = value of proportional part of controller 61.17 TnDiaMax = value of integral part of controller Please note:

• The filter of actual speed is increased depending on diameter. • The controller with this settings are used while e.g. jogging and E-Stop.

• W10 Set parameter 61.18 KpWinMode The value of this parameter is only responsible during window control, which is activated while running in tension controlled mode. A preset value could be: 61.18 KpWinMode = 5 times of value of 61.16 KpDiaMax

• W11 Accelerating compensation of the coil The diameter and the width are still to be set to the current values as described in point W08. Set also parameter 64.39 TqSpeedCtrl to Yes.

48

Commissioning


Calculate according the following equation:

( )Motor

4min

4max

max T100%

dtdv

i1DD

DπWρ64.1664.15 ⋅⋅⋅−⋅⋅

⋅⋅==

Velocity ⎥⎦⎤

⎢⎣⎡

sm dv Strip density ⎥⎦

⎤⎢⎣⎡

3mkg ρ Acceleration time [ ]s dt

Diameter [ ]m D Web width [ ]m W Gear ratio [ ]- i

Nominal motor torque [ ]Nm TMotor

Set the reference ramp up and down. Observe the output of speed controller, parameter 2.09. If necessary adjust the parame-ters 64.15 and 64.16 so, that the speed controller output stays near zero.: 64.15 AccCoiPosSca = value of 2.09 during ramping up 64.16 AccCoiNegSca = value of 2.09 during ramping down. Finally stop and switch off the winder drive.

• W12 Diameter calculation

The calculated signal will be ramped with following parameters>

65.04 TrampWDir = ramp time of the expected output slope

65.05 TrampWcDir = ramp time of counter expected output slope

If a clue is needed, please use the following equation:

Rampt0.465.04 ⋅= δ2vπDt

2max

Ramp⋅⋅⋅≈

Rampt0.865.05 ⋅=

Velocity ⎥⎦⎤

⎢⎣⎡

sm v Thickness [ ]m δ Diameter [ ]m D

Perhaps these ramp values have to be modified during running under production.

49

Commissioning


• W13 Torque scaling

The tension reference (also called tension set point) has to be scaled. This is done with

parameter 66.03 TorqueScale

Motor

maxmax

T100%

i2DF66.03 ⋅⋅⋅=

Tension [ ]N F Diameter [ ]m D Gear ratio [ ]- i

Nominal motor torque [ ]Nm TMotor

• W14 Set back parameters A few parameters are set to other values for supporting this commissioning. Set them back: 64.02 SelDeriIn = Spec 1 (default) or as desired; see W06 64.39 TqSpeedCtrl = No (default) or as desired

• W15 Further commissioning Up to now it has been a basic commissioning. Further settings are to be done yet, if desired.

50

Commissioning


Control Bits (Example) The following table shows one possibility of controlling this winder application. In some cases it could be necessary to take other combinations.

Com

man

ds

Con

trol

Wor

d:B

it

New

sta

rt

Sw

itch

On

Jogg

ing

1

Jogg

ing

2

Run

w/o

win

ding

Sto

p w

/o w

indi

ng

Win

din

g

E-s

top

Res

et

ON 7.04:00 0 1 1 1 1 1 1 1 0

E-off 7.04:01 1 1 1 1 1 1 1 1 1

E-stop 7.04:02 1 1 1 1 1 1 1 0 1

RUN 7.04:03 0 0 1 1 1 0 1 1 0

RpOutZero 7.04:04 0/1 0/1 1 1 1 1 1 1 0/1

RpHold 7.04:05 0/1 0/1 1 1 1 1 1 1 0/1

RpInZero 7.04:06 0/1 0/1 1 1 1 1 1 1 0/1

Reset 7.04:07 0/1 0 0 0 0 0 0 0 1

Remote 7.04:10 1 1 1 1 1 1 1 1 1

WinOn 7.12:02 0/1 0 0 0 0 0 1 0/1 0/1

WinJog1 7.12:08 0 0 1 0 0 0 0 0/1 0/1

WinJog2 7.12:09 0 0 0 1 0 0 0 0/1 0/1

DiaInit 7.12:03 1 0/1 0/1

0/1 0/1

0/1 0 0/1 0/1

Status / Mode

Off

Mai

n co

nt. o

n

Vel

ocity

con

trol

in

t. re

fere

nce

Vel

ocity

con

trol

ex

t. re

fere

nce

Vel

ocity

con

trol

re

fere

nce

= 0

Ten

sion

con

trol

Sto

ppin

g as

se-

lect

ed

Res

et fa

ults

51

Appendix A - Application handling


Appendix A - Application handling Identification Parameter 4.03 With running winder application, the parameter 4.03 shows:

4.03 ApplicName = DEABBDC-WiIT

Parameter 4.12 With running winder application, the parameter 4.12 shows:

4.12 ApplicVer = 1.1

Installation Installation of the SDCS-MEM8 (memory card) is possible in slot 4 of the

CON-4 board (see picture). Installation or changing memory cards is only allowed if the electronic supply is switched off.

52

Appendix A - Application handling


Enable / disable application The application can be enabled and disabled by using parameter 16.06:

• Enable application (activate application program) • Disable application (deactivate application program)

After the activation of the memory card, all application parameters will be visi-ble and active.

ABB Automation Products Wallstadter Straße 59 68526 Ladenburg • Germany Tel: +49 (0) 62 03-71-0 Fax: +49 (0) 62 03-71-7609 www.abb.com/motors&drives

*308R0201A8210000**308R0201A8210000*

Iden

t. N

o.: 3

AD

W00

0308

R02

01 R

ev. B

05

_200

8

Documents

DCS800 Winder Description - ABB Ltd · DCS800 Winder Description ... Therefore it is important to adjust the torque- and compensation function blocks. ... parameters in function block