Danfoss VLT AutomationDrive FC 360 Application Manual

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MAKING MODERN LIVING POSSIBLE

Application Guide

VLT® AutomationDrive FC 360

www.danfoss.com/drives

Contents Application Guide

Contents

1 Introduction

1.1 Purpose of the Manual

1.2 Additional Resources

1.3 Document and Software Version

1.4 Abbreviations and Conventions

2 Safety

2.1 Safety Symbols

2.2 Qualified Personnel

2.3 Safety Precautions

3 Center Winder Control

3.1 Introduction

3.2 Application Requirements

3.3 Wiring and Control Process

3.4 Parameters for Center Winder Control

4 Positioning Control

2 2 2 2 2

4 4 4 4

6 6 8 9

4.1 Introduction

4.2 Programming

4.3 Homing

4.4 Positioning

4.5 PROFIBUS Interface

4.6 Application Example

4.7 Parameters for Positioning Control

Index

14 14 15 16 16 17 20

Introduction

VLT® AutomationDrive FC 360

1 Introduction

1.1 Purpose of the Manual

This manual provides information on how to design and implement center winder control and positioning control applications with FC 360 frequency converters. It does not cover general design, installation and commissioning of the frequency converter.

VLT® is a registered trademark.

Prerequisites

The manual is intended for use by qualified personnel who are familiar with the functions of VLT® AutomationDrive FC

360 and have hands-on experience with installing and commissioning FC 360 frequency converters. The frequency converter should be installed and commissioned according to the FC 360 Quick Guide. Users of this manual should have the Quick Guide at hand for reference.

1.2 Additional Resources

Additional resources are available to understand frequency converter functions and programming.

VLT® AutomationDrive FC 360 Quick Guide,

•

provides information required to install and commission the frequency converter.

VLT® AutomationDrive FC 360 Design Guide,

•

provides detailed information about the design and applications of the frequency converter.

VLT® AutomationDrive FC 360 Programming Guide,

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provides information on how to programme and includes complete parameter descriptions.

Contact the local Danfoss supplier for the printed documentation.

1.3

Document and Software Version

This manual is regularly reviewed and updated. All suggestions for improvement are welcome. Table 1.1 shows the document version and the corresponding software version. In the frequency converter, read the software version in 15-43 Software Version.

1.4

Abbreviations and Conventions

AC Alternating current AEO Automatic energy optimisation ACP Application control processor AWG American wire gauge AMA Automatic motor adaptation °C DC Direct current

EEPROM

EMC Electromagnetic compatibility EMI Electromagnetic interference ETR Electronic thermal relay f

M,N

FC Frequency converter IP Ingress protection I

LIM

INV

M,N

VLT,MAX

VLT,N

LCP Local control panel MCP Motor control processor N.A. Not applicable P

M,N

PCB Printed circuit board PE Protective earth PELV Protective extra low voltage PWM Pulse width modulated R

Regen Regenerative terminals RPM Revolutions per minute RFI Radio frequency interference SCR Silicon controlled rectifier SMPS Switch mode power supply T

LIM

M,N

Table 1.2 Abbreviations

Degrees Celsius

Electrically erasable programmable read-only memory

Nominal motor frequency

Current limit Rated inverter output current Nominal motor current Maximum output current Rated output current supplied by the frequency converter d-axis inductance

Nominal motor power

Stator resistance

Torque limit Nominal motor voltage Main reactance

Version Remarks Software version

MG06E1 First version of the document. 1.4x

Table 1.1 Document and Software Version

Conventions

Numbered lists indicate procedures.

•

Bullet lists indicate other information.

•

Italicised text indicates

•

Introduction Application Guide

cross reference

link

parameter name

All dimensions are in mm (inch).

•

* indicates default setting of a parameter.

•

Safety

VLT® AutomationDrive FC 360

2 Safety

2.1 Safety Symbols

The following symbols are used in this document:

WARNING

Indicates a potentially hazardous situation that could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation that could result in minor or moderate injury. It can also be used to alert against unsafe practices.

NOTICE

Indicates important information, including situations that can result in damage to equipment or property.

2.2 Qualified Personnel

WARNING

UNINTENDED START

When the frequency converter is connected to AC mains, DC supply, or load sharing, the motor may start at any time. Unintended start during programming, service, or repair work can result in death, serious injury, or property damage. The motor can start via an external switch, a serial bus command, an input reference signal from the LCP, or after a cleared fault condition. To prevent unintended motor start:

Disconnect the frequency converter from the

•

mains. Press [Off/Reset] on the LCP before

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programming parameters. Fully wire and assembly the frequency

•

converter, motor, and any driven equipment before connecting the frequency converter to AC mains, DC supply, or load sharing.

Correct and reliable transport, storage, installation, operation, and maintenance are required for the troublefree and safe operation of the frequency converter. Only qualified personnel are allowed to install or operate this equipment.

Qualified personnel are defined as trained staff, who are authorised to install, commission, and maintain equipment, systems, and circuits in accordance with pertinent laws and regulations. Additionally, the personnel must be familiar with the instructions and safety measures described in this manual.

2.3

Safety Precautions

WARNING

HIGH VOLTAGE

Frequency converters contain high voltage when connected to AC mains input, DC supply, or load sharing. Failure to perform installation, start-up, and maintenance by qualified personnel can result in death or serious injury.

Installation, start-up, and maintenance must be

•

performed by qualified personnel only.

WARNING

DISCHARGE TIME

The frequency converter contains DC-link capacitors, which can remain charged even when the frequency converter is not powered. Failure to wait the specified time after power has been removed before performing service or repair work, could result in death or serious injury.

1. Stop the motor.

2. Disconnect AC mains, permanent magnet type motors, and remote DC-link power supplies, including battery back-ups, UPS, and DC-link connections to other frequency converters.

3. Wait for the capacitors to discharge fully, before performing any service or repair work. The duration of waiting time is specified in Table 2.1.

Minimum waiting time (minutes)

Voltage [V]

4 15

380–480 0.37–7.5 kW 11–75 kW High voltage may be present even when the warning LEDs are off.

Table 2.1 Discharge Time

Safety

Application Guide

WARNING

LEAKAGE CURRENT HAZARD

Leakage currents exceed 3.5 mA. Failure to ground the frequency converter properly can result in death or serious injury.

Ensure the correct grounding of the equipment

•

by a certified electrical installer.

WARNING

EQUIPMENT HAZARD

Contact with rotating shafts and electrical equipment can result in death or serious injury.

Ensure that only trained and qualified

•

personnel perform installation, start up, and maintenance.

Ensure that electrical work conforms to national

•

and local electrical codes. Follow the procedures in this document.

•

2 2

CAUTION

INTERNAL FAILURE HAZARD

An internal failure in the frequency converter can result in serious injury, when the frequency converter is not properly closed.

Ensure that all safety covers are in place and

•

securely fastened before applying power.

NOTICE

HIGH ALTITUDES

For installation at altitudes above 2000 m, contact Danfoss regarding PELV.

NOTICE

Use on Isolated Mains

For details about the use of the frequency converter on isolated mains, refer to section RFI Switch in the Design Guide. Follow the recommendations regarding the installation on IT-mains. Use relevant monitoring devices for ITmains to avoid damage.

Center Winder Control

3 Center Winder Control

VLT® AutomationDrive FC 360

3.1 Introduction

Center winders are widely used in the processing of materials such as cloth, plastics, paper, and sheet metal. Center winder control is to maintain a stable tension on the line or web of the material during the winding process.

The center winder control in FC 360 uses a speed-based method with tension feedback. The tension feedback is provided by either a load cell or a dancer. Illustration 3.1 shows the control diagram of a center winder system.

Instable tension may cause physical deformities of the material. Because the diameter of the roll changes constantly, the winding or unwinding speed must be adapted to maintain a stable tension.

Control principle

Illustration 3.1 Control Diagram of a Center Winder System

The center winder control calculates the roll diameter and feed the frequency converter with an open-loop speed reference. A PID amplifier compares the actual tension feedback with the tapered tension setpoint, and generates a speed signal based on the error. The speed signal is aggregated with the speed reference signal to determine the actual winder speed.

Roll diameter

This calculation needs to be performed fast, because the diameter of the roll changes faster when the roll is near the core. If the actual diameter changes faster than the diameter is calculated, the open-loop reference speed lags too far behind the required speed, and the tension PID will need to make up too much of the difference.

The tension PID updates every 16 ms. The calculated diameter is used by both the open-loop reference and as an input to the tension PID.

core diameter

Line speed

Winder speed

PID

Web speed at the

winder roll [m/sec]

Web speed at the

lead roll [m/sec]

Load cell or

dancer

Encoder

TensionFBHdl

TensionRefHdl

DiameterHdl

Feed Forward

Calculation

Feed Forward Accel Tension Loop Prole

Speed FB Handler M

Gear Ratio

Tension err

Tension

set point

Tension Feedback

Diameter

Winder speed

Line Speed

Speed Set Point

MOC

130BD801.10

Center Winder Control Application Guide

The tapered tension setpoint is the tension setpoint modified based on the roll diameter and the taper setpoint. Taper generally reduces the tension setpoint hyperbolically with a change in diameter. The PID amplifier output decreases as the diameter increases, because the same change in reference will have a larger surface speed change as the roll increases in diameter. Ideally, the open-loop reference signal is scaled at core so that the surface speed of the core matches line speed. The diameter value is calculated based on the equation below.

An encoder on the feed-roll or lead-roll motor provides the line speed. An encoder on the winder motor provides the motor speed. The winder speed is the current motor speed multiplies the gear ratio.

Illustration 3.2 shows the control diagram for center winder applications with FC 360 frequency converters. The amplitude of accommodation depends on the change of diameter and the difference between tension feedback and tension setpoint.

3 3

Illustration 3.2 Center Winder Control with FC 360

The frequency converter adjusts the operation of the winder based on the states of a roll, such as ready-to-run, end-of-roll, running-on-tension-loop and tension-over-limit. For example, a frequency converter can stop winding for a roll change.

The frequency converter can be controlled through either digital inputs or PROFIBUS.

Features

3.1.1

The following features are provided to increase the overall stability of the winder, and improve the control and monitoring of the winding process.

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Acceleration feed-forward: This function allows a shift in the tension/taper setpoint based on changes in line speed. It provides a tension boost

•

during initial acceleration to help compensate for system inertia.

Tension-taper setpoint ramp: The tapered tension setpoint generator integrates any changes to the

scans. A parameter is provided to increase or decrease response time.

Diameter calculator minimum speed: There is also

•

a minimum speed requirement to enable the diameter calculator. At low speeds, the line and winder speeds may not have enough resolution to accurately calculate diameter. A parameter is provided to define a minimum line speed required for the diameter calculator to function. Until that speed is reached, the diameter value will not change.

tension or taper setpoints over multiple program

Center Winder Control

VLT® AutomationDrive FC 360

Programmable analog inputs: Inputs 53 and 54

•

are analog inputs with a voltage range of 0–10 V DC or a current range of 0/4–20 mA. Use 6-19 Terminal 53 mode and 6-29 Terminal 54 mode to configure the inputs. The source of the tension and taper setpoints can be adjusted by either

analog inputs or parameter setting. Only analog inputs can be used for tension feedback and initial diameter measurement. Use parameters to select the source of each input. Do not program a single input for more than one functions.

Initial diameter measurement: 3 starting

•

diameters can be set and logically selected. For applications where the starting diameter changes regularly, the winder allows the initial diameter to be measured through an analog input signal.

Scaling parameters are provided to set the analog level at core and at full roll. This function assumes a linear change in the diameter measurement signal.

End-of-roll detection: The frequency converter

•

generates an output to indicate a preset diameter limit is met. This output can be used to stop winding for a roll change.

Tension limit detector: The winder includes a

•

tension limit detection (TLD) feature. This feature allows the winding machine to trip if a lowtension or high-tension feedback exists for a period of time. The trip delay includes a normal running delay as well as a secondary starting delay.

3.2 Application Requirements

For the center winder system to operate properly, the following requirements must be met:

Winder motor

•

The motor needs to be frequency converter duty with a wide speed range (>100:1). The motor should be geared or belted so that top motor speed at core does not exceed 4500 RPM. Generally, the maximum constant-horsepower speed of the motor is the limiting factor.

Tension feedback

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The tension feedback is provided from either a load cell or a dancer. If a load cell is used, it needs to be calibrated for a either a 0-20 mA or 0-10 V signal for 0 to maximum tension. If a dancer is used, the calibration should be 0–20 mA/0–10 V for bottom-to-top of the dancer movement.

Logic inputs

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Digital inputs are used as signals for statuses such as tension-on, over-tension, or undertension. They are 24 V DC sinking inputs, and only necessary when used for controlling. The frequency converter has a 24 V DC/200 mA supply available if dry contacts are used. It is possible to access logic parameters through PROFIBUS.

Tension and taper setpoints

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The tension and taper setpoints are available on the display of the local control panel (LCP) as parameters. They can also be set using 0–20 mA or 0–10 V DC input, or via PROFIBUS.

Parameter Value or range

Maximum winder motor speed Tension loop control cycle 16 ms TLD time resolution 25 ms Quick stop scan time 1 ms Coast scan time <1 ms MCB 102 frequency 100–410000 Hz 24 V encoder frequency 4–32000 kHz Digital inputs 24 V DC, sinking Analog tension and taper setpoints Load cell or dancer feedback 0–10 V DC, 0–20 mA DC

Table 3.1 Recommended Parameter Settings

Line speed

Create or simulate a line speed signal of winder mode. Ensure that 18-83 Line Speed shows the correct feedforward speed, which is a positive value. Otherwise check wiring and the parameters in parameter group 17.

Winder speed

Have the motor run in the direction of winding mode. Confirm that parameter 16-05 Main Actual Value [%] shows the correct motor speed, which is a positive value.

Tension feedback

Create or simulate a tension on the web. Confirms that 18-86 Tension Feedback shows the correct tension value. Otherwise check parameters 6-10 to 6-29.

Winder speed match scale

Enable the diameter calculator by setting

•

parameter 37-43 Diameter Calculator Min Speed to

0. Disable tension loop output by setting

•

parameter 37-51 Tension PID Out Limit to 0.

4500 RPM

0–10 V DC, 0–20 mA DC

Center Winder Control

Application Guide

Set parameter 37-57 Tension On/Off to [1] On, and

•

run the winding machine without material to the maximum speed.

Confirm that the diameter remains very close to

•

the core diameter value. Otherwise recalculate the value of parameter 37-46 Winder Speed Match Scale.

To set this parameter, the winding machine must run without material. If this is not possible, empirical calculations must be performed first. Set the winder speed match scale parameter by completing the steps below:

1. Mount the smallest empty core on the winding machine.

Ensure that the core size (parameter 37-24 Core1 Diameter) is set correctly. The value entered is a percentage of the full roll value. For example, if using a 20 inch full roll with a 3.75 inch core,

parameter 37-24 Core1 Diameter=3.75/20x100%=18.75.

3. Use core1 diameter as preset diameter and set parameter parameter 37-59 Diameter Reset to [1] On. Confirms that parameter 19-97 is the value set in parameter 37-24 Core1 Diameter.

Set parameter 37-57 Tension On/Off to [1] On and initiate a start signal.

Adjust parameter parameter 37-46 Winder Speed Match Scale to make sure core surface speed matches the surface speed of the main line selection.

Empirical calculation is performed as follows:

Parameter 37-46 Winder Speed Match Scale=Parameter 37-24 Core1 Diameter/lead roll diameter

To use DI for logic control, set parameter 37-40 Center Winder Cmd Src to [2] Digital input control, and select

functions in the corresponding DI input (parameters 5-10 to 5-16).

Using DI for logic control

There are 6 logic commands that can be sent via

•

digital inputs:

Core diameter source.

Select a new diameter.

Reset the diameter.

Center winder jog forward.

Center winder tension on.

Empirical calculation is performed as follows:

Parameter 37-46 Winder Speed Match Scale=parameter 37-24 Core1 Diameter/lead roll diameter

Tightening the slack web

•

1. Give an appropriate jog speed by

setting parameter 37-26 Winder Jog Speed.

Set parameter 37-57 Tension On/Off to [0] Off.

Set parameter 37-54 Winder Jog Reverse or parameter 37-55 Winder Jog Forward to 1 until the slack web is tightened.

Setting up starting diameter

•

If the winding machine starts with an empty core, set the value in parameter 37-24 Core1 Diameter to the starting diameter value. If the winding machine starts with a partial roll or unwinding, measure the diameter value and enter the value in parameter 37-23 Partial Roll Diameter Value. Select the partial roll diameter as the starting diameter.

Protecting the system from over-tension

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Set parameter 37-27 TLD Low Limit and parameter 37-28 TLD High Limit to applicable

values, so that the frequency converter stops if tension is out of the range defined in these 2 parameters.

3.3

Wiring and Control Process

Wiring

1. Connect the load cell or dancer to analog input

53.

2. Connect the line encoder to MCB 102.

3. Connect the winding machine encoder to 24 V encoder interface (digital inputs 12, 20, 32, 33).

4. Connect digital output 29 to the winding machine as end-of-roll signal source.

5. Connect digital output 27 to the winding machine as TLD-indicator signal source.

6. Connect digital output 45 to the winding machine as ready-to-run signal source.

7. If a dancer is used, connect analog output 42 to the winding machine as tapered-tension-setpoint signal source.

Control process

Wind up the machine, starting with an empty

•

core. Set up parameters as shown in Table 3.2. The

•

values in the table serve as examples only. Actual settings may differ and should be based on actual application situations.

Tighten the slack web until the tension is within

•

the valid range defined in parameter 37-27 TLD Low Limit and parameter 37-28 TLD High Limit.

Refer to chapter 3.2.1 Application Requirements for information about how to tighten a slack web.

3 3

+ 21 hidden pages

Danfoss VLT AutomationDrive FC 360 Application Manual

Specifications and Main Features

Frequently Asked Questions

User Manual