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,

•

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

•

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.

•

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

•

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

•

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

•

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

•

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

Center Winder Control

VLT® AutomationDrive FC 360

Input the tension reference in parameter

•

parameter 37-21 Tension Set Point. Set parameter parameter 37-57 Tension On/Off to

•

[1] On, parameter parameter 37-59 Diameter Reset to [0] Off, and then initiate a start signal.

Parameter Value

3-03 Maximum Reference 3-41 Ramp 1 Ramp Up Time 3-42 Ramp 1 Ramp Down Time 5-30 Terminal 27 Digital Output 5-31 Terminal 29 Digital Output 5-70 Term 32/33 Pulses Per Revolution 5-71 Term 32/33 Encoder Direction 6-10 Terminal 53 Low Voltage 6-11 Terminal 53 High Voltage 6-14 Terminal 53 Low Ref./ Feedb. Value 6-15 Terminal 53 High Ref./ Feedb. Value 6-19 Terminal 53 mode 6-70 Terminal 45 Mode Parameter 6-72 Terminal 45 Digital Output 6-90 Terminal 42 Mode 6-91 Terminal 42 Analog Output 6-93 Terminal 42 Output Min Scale 6-94 Terminal 42 Output Max Scale 7-00 Speed PID Feedback Source 7-07 Speed PID Feedback Gear Ratio 17-10 Signal Type 17-11 Resolution (PPR) Parameter 37-00 Application Mode Parameter 37-20 Winder Mode Selection Parameter 37-22 Taper Set Point Parameter 37-23 Partial Roll Diameter Value Parameter 37-24 Core1 Diameter Parameter 37-25 Core2 Diameter Parameter 37-26 Winder Jog Speed Parameter 37-27 TLD Low Limit Parameter 37-28 TLD High Limit

0.05

0.05 [174] TLD indicator [173] End of roll Based on the winder encoder.

Based on the winder encoder.

0 10 0

100

[1] Voltage mode [2] Digital Output [176] Ready to run

[0] 0–20 mA [162] Tapered tension set point

100

[1] 24V encoder

Based on the application.

Based on the line encoder. Based on the line encoder. [0] Drive mode

[0] Wind

5.000%

Based on the application.

0 90

Parameter 37-29 TLD Timer Parameter 37-30 TLDOnDelay Parameter 37-31 Diameter Limit Detector Parameter 37-32 Initial Diameter Measurement Parameter 37-33 Diameter Measurement Input Parameter 37-34 Reading at Core Parameter 37-35 Reading at Full Roll Parameter 37-36 Tension Set Point Input Parameter 37-37 Taper Set Point Input Parameter 37-38 Tension Feedback Input Parameter 37-39 Tension Feedback Type Parameter 37-40 Center Winder Cmd Src Parameter 37-41 Diameter Change Rate Parameter 37-42 Tapered Tension Change Rate Parameter 37-43 Diameter Calculator Min Speed Parameter 37-44 Line Acceleration Feed Forward Parameter 37-45 Line Speed Source Parameter 37-46 Winder Speed Match Scale Parameter 37-47 Tension PID Profile Parameter 37-48 Tension PID Proportional Gain Parameter 37-49 Tension PID Derivate Time Parameter 37-50 Tension PID Integral Time Parameter 37-51 Tension PID Out Limit Parameter 37-52 Tension PID Der Gain Limit Parameter 37-53 Tension PID Anti Windup Parameter 37-54 Winder Jog Reverse Parameter 37-55 Winder Jog Forward Parameter 37-56 New Diameter Select

1 1 90

[0] Set diameter when diameter reset (default) [0] No function

0.00

[0] Par.3721

[0] Par.3722

[1] Input 53(0–10 V DC or 0–20 mA ) Based on the application.

[1] Parameter 19-61–19-67 control the functions

0.02

0.2

0.5

[2] MCB102

1.000

Based on the application.

0.00%

Based on the application.

[1] Enable

[0] Core Diameter

Center Winder Control Application Guide

Parameter 37-57 Tension On/Off Parameter 37-58 Core Select Parameter 37-59 Diameter Reset

Table 3.2 Parameter Settings

[0] Off

[0] Core1 diameter [1] On

3.4 Parameters for Center Winder Control

37-20 Winder Mode Selection

Use the machine for either winding or unwinding.

Option: Function:

[0] * Wind [1] Unwind

37-21 Tension Set Point

Set the desired running tension.

Range: Function:

0 %* [0 - 100 %]

37-22 Taper Set Point

Use this parameter to change the tension setpoint while the diameter increases.

Range: Function:

0 %* [-110 - 110 %]

37-23 Partial Roll Diameter Value

Use this parameter to preset the diameter when a partial roll is loaded on the winder. For unwinding applications, use this parameter to set the full roll diameter.

Range: Function:

5 %* [5 - 100 %]

37-24 Core1 Diameter

Set the main core value to be used on the winder. This parameter must be set for the smallest core diameter for both winding and unwinding applications.

Range: Function:

5 %* [5 - 100 %]

37-25 Core2 Diameter

Set a secondary core diameter for winding applications, or a secondary full roll diameter for unwinding applications.

Range: Function:

5 %* [5 - 100 %]

37-26 Winder Jog Speed

Set the winder jog speed percentage. This percentage value is used for both forward and reverse jogging speed.

Range: Function:

0 %* [0 - 100 %]

37-27 TLD Low Limit

Set the low limit for the tension limit detection.

Range: Function:

0 %* [0 - 100 %]

37-28 TLD High Limit

Set the high limit for the tension limit detection.

Range: Function:

0 %* [0 - 100 %]

37-29 TLD Timer

Sets the time within which the tension must exceed the high or low tension limit.

Range: Function:

0.001 s* [0.001 - 5 s]

37-30 TLDOnDelay

Enable this parameter to allow time for the winder to stabilize the web tension. As soon as the tension moves within the low and high tension limits, the TLD function begins operating normally. This function can be useful during a quick machine start with a slack web. This function is only active while running.

Option: Function:

[0] Disabled [1] * Enabled

37-31 Diameter Limit Detector

When the calculated roll diameter reaches the set diameter, the corresponding digital output will be turned on to indicate the end of the roll. This indicates a full roll when winding and an empty roll when unwinding.

Range: Function:

100 %* [0 - 100 %]

37-32 Initial Diameter Measurement

It is possible to connect a roll diameter sensor to one of the frequency converter analog inputs. This signal can be used to make the controller use a measured initial diameter, rather than a diameter size set by parameters.

Option: Function:

[0] * Set diameter when

diameter reset

[1] Set diameter based on

analog signal

37-33 Diameter Measurement Input

Use this parameter to set the analog input used for diameter measurement.

Option: Function:

[0] * No Function [1] Input53(0~10 VDC or 0~20

mA )

[2] Input54(0~10 VDC or 0~20

mA )

3 3

Center Winder Control

VLT® AutomationDrive FC 360

37-34 Reading at Core

Use this parameter to set the analog input signal reading at the smallest core used.

Range: Function:

0* [0 - 10 ]

37-35 Reading at Full Roll

Use this parameter to set the analog input signal reading at the full roll size used.

Range: Function:

0 V* [0 - 20 V]

37-36 Tension Set Point Input

Use this parameter to set the source of the tension set point.

Option: Function:

[0] * Par.3721 [1] Input53(0~10 VDC or 0~20 mA ) [2] Input54(0~10 VDC or 0~20 mA )

37-37 Taper Set Point Input

Use this parameter to set the source of the taper set point.

Option: Function:

[0] * Par.3722 [1] Input53(0~10 VDC or 0~20 mA ) [2] Input54(0~10 VDC or 0~20 mA )

37-38 Tension Feedback Input

Use this parameter to set analog input used for tension feedback.

Option: Function:

[0] * No Function [1] Input53(0~10 VDC or 0~20 mA ) [2] Input54(0~10 VDC or 0~20 mA )

37-42 Tapered Tension Change Rate

Sets the amount of tapered tension that can change during each scan period. This function ramps the tapered tension setpoint to the preset value when the user changes either the tension or taper setpoints. This ensures stability during step changes in setpoints.

Range: Function:

0.1 %* [0.1 - 1 %]

37-43 Diameter Calculator Min Speed

Sets the minimum line speed to be achieved before the diameter calculator is activated. At low line speeds, the resolution of the line and winder speed will be too low for the diameter to be accurately calculated.

Range: Function:

0 %* [0 - 100 %]

37-44 Line Acceleration Feed Forward

Sets the feed forward speed that helps compensate for tension changes caused by line speed acceleration and deceleration.

Range: Function:

0* [-20 - 20 ]

37-45 Line Speed Source

Use this parameter to set the input for line speed.

Option: Function:

[0] * No function [1] 24V encoder [2] MCB102 [3] MCB103 [4] Analog input 53 [5] Analog input 54 [6] Frequency input 29 [7] Frequency input 33

37-39 Tension Feedback Type

Selects the device type used for tension feedback.

Option: Function:

[0] * Load cell [1] Dancer

37-46 Winder Speed Match Scale

This parameter is used to match the surface speeds of line and winder at smallest core while running line at 100 % speed.

Range: Function:

1* [0.001 - 1000 ]

37-40 Center Winder Cmd Src

Use this parameter to configure the command source for controlling.

Option: Function:

[0] Digital and parameter [1] * Parameter 3754~3759 control the

functions

[2] Digital input control

37-41 Diameter Change Rate

Sets the amount of changes allowed for the diameter in each program scan.

Range: Function:

0.001 %* [0.001 - 0.05 %]

37-47 Tension PID Profile

Allows scaling the tension loop PID output to compensate for roll diameter. Ideally, the output from the tension loop PID amplifier is halved each time the diameter doubles, which is considered fully profiled. In some cases, it might be desirable to be less than fully profiled, which would give over compensation when the diameter increases.

Range: Function:

0 %* [0 - 100 %]

37-48 Tension PID Proportional Gain

Sets the proportional gain for tension loop PID amplifier.

Range: Function:

0* [0 - 10 ]

Center Winder Control Application Guide

37-49 Tension PID Derivate Time

Sets the derivative time for tension loop PID amplifier.

Range: Function:

0 s* [0 - 20 s]

37-50 Tension PID Integral Time

Sets the integral time for tension loop PID amplifier.

Range: Function:

501 s* [0.01 - 501 s]

37-51 Tension PID Out Limit

Sets the maximum tension PID loop output that can be added to the open loop speed reference. The value is normally set to limit the contribution of the tension PID loop to 10 % of the maximum reference speed.

Range: Function:

0 %* [0 - 100 %]

37-52 Tension PID Der Gain Limit

Sets the limit for derivation gain in tension loop PID amplifier.

Range: Function:

5* [1 - 50 ]

37-53 Tension PID Anti Windup

Activates the anti-wind-up function in tension loop PID amplifier.

Option: Function:

[0] Disabled [1] * Enabled

37-57 Tension On/Off

Turns the tension controller on or off.

Option: Function:

[0] * Off [1] On

37-58 Core Select

Selects 1 of the 2 preset core sizes.

Option: Function:

[0] * Core1 diameter [1] Core2 diameter

37-59 Diameter Reset

Resets the diameter to a new value. If the new diameter select is energized, the partial core diameter value is used, otherwise the diameter is reset to core1 or core2 values based on the selected core.

Option: Function:

[0] * Off [1] On

3 3

37-54 Winder Jog Reverse

Jogs the winder in the reverse winding direction at the speed set in parameter 37-26 Winder Jog Speed.

Option: Function:

[0] * No Function [1] Jog reverse

37-55 Winder Jog Forward

Jogs the winder in forward winding direction at the speed set in parameter 37-26 Winder Jog Speed.

Option: Function:

[0] * No function [1] Jog forward

37-56 New Diameter Select

Selects partial roll diameter as the preset starting diameter when the diameter reset is energized, rather than using one of the 2 preset core diameters.

Option: Function:

[0] * Core diameter [1] Partial roll diameter

Positioning Control

VLT® AutomationDrive FC 360

4 Positioning Control

Select the feedback source in 37-01 Pos. Feedback

4.1 Introduction

FC 360 supports positioning control. To use the function, set parameter 37-00 Application Mode to [2] Position control.

When positioning control is enabled, the frequency converter runs in VVC+ control mode. It is important to perform an AMA with correct motor data prior to positioning control.

Position feedback signals are sent to FC 360 via MCB102 or MCB103. 24 V encoder to terminals 32/33 is not supported in position control mode.

Positioning control in FC 360 provides the following features:

Supports both relative and absolute positioning.

•

Can be controlled via digital outs or PROFIBUS.

•

Supports direct positioning (via PROFIBUS) and

•

indexed positioning (via digital inputs). Up to 8 fixed positions.

•

Supports homing function (without z index).

•

Uses MCB102 or MCB103 as signal feedback

•

source. Supports both software and hardware limit

•

settings.

4.2

Programming

4.2.1 Preparation

Complete the following tasks before starting the positioning control.

•

Source and 7-00 Speed PID Feedback Source.

MCB102

•

Set 17-10 Signal Type and 17-11 Resolution (PPR) according to the specifi-

cation of the actual encoder used. MCB103

•

Set 17-50 Poles, 17-51 Input Voltage, 17-52 Input Frequency, and 17-53 Transformation Ratio according to the

specification of the resolver. Set 17-59 Resolver Interface to [1] Enabled to enable MCB103 for capture resolver.

Monitor the value of 34-50 Actual Position, rotate the motor shaft manually in the positive direction, then 34-50 Actual Position should show an increasing value. If the value is descending with an incremental encoder, exchange the feedback encoder track A+ with B+, and A- with B-. If no value is displayed, check the wiring of the encoder.

Set ramp time

•

Set the activated ramp-up time in 3-41 Ramp 1 Ramp Up Time, 3-51 Ramp 2 Ramp Up Time, 3-61 Ramp 3 Ramp up Time, and 3-71 Ramp 4 Ramp up Time to be 75% of the minimum value in 37-05 Pos. Ramp Up Time. Set the activated ramp-down time in 3-42 Ramp 1 Ramp Down Time, 3-52 Ramp 2 Ramp Down Time, 3-62 Ramp 3 Ramp down Time and 3-72 Ramp 4 Ramp Down Time to be 75% of the minimum

value in 37-06 Pos. Ramp Down Time. Select Auto On mode via LCP or GLCP.

•

Ensure that there are no alarms.

•

Basic Settings

Check the motor phase

•

In Hand on mode, set the frequency to a low positive value. For example, +3 Hz. Make sure the motor rotates in the positive direction. If it rotates in the negative direction, exchange the motor phases.

Remove all signals to inputs.

•

Select Off mode via the local control panel (LCP

•

or GLCP). Initialise the frequency converter in 14-22

•

Operation Mode. Perform an AMA.

•

Set 37-00 Application Mode to [2] Position Control.

•

4.2.2

Selecting the positioning control source

Select [0] DI or [1] Fieldbus in 37-14 Pos. Ctrl. Source.

Limit settings

Block 1 direction, or set position or velocity limits to achieve better safety.

Direction block

•

If necessary, block forward or reverse direction in 37-15 Pos. Direction Block.

Position limit

•

There are 2 types of position limits: hardware limits and software limits. Hardware limits are set by digital inputs. Software limits are set via parameter settings.

Positioning Control

Select [155] HW Limit Positive or [156]

HW Limit Negative in parameters 5-10 to 5-16.

Enable or disable the software positive

and negative limits in 33-44 Positive Software Limit Active and 33-43 Negative Software Limit Active respectively.

For both hardware and software limits, set the positive position in user units in 33-42 Positive Software Limit, and negative position in user units in 33-41 Negative Software Limit.

Maximum allowed velocity

•

Set the maximum allowed velocity in 32-80 Maximum Allowed Velocity.

Fault handling

Set the fault behavior in 37-17 Pos. Ctrl Fault Behaviour. Fault reasons can be read out from 37-18 Pos. Ctrl Fault Reason.

Brake settings

Enable or disable the auto brake control in 37-07 Pos. Auto Brake Ctrl. Set brake time in 37-09 Pos. Coast Delay, 37-11 Pos. Brake Wear Limit, and 37-12 Pos. PID Anti Windup.

Defining a User Unit

4.2.3

The frequency converter measures distance in quad-count (QC) internally. It is possible to define a user unit by using

parameter 32-11 User Unit Denominator and parameter 32-12 User Unit Numerator according to the

following formula:

QC=UU*32-12 User Unit Numerator/32-11 User Unit

Denominator

For example, if the user unit is mm and, based on measurement, 100.25 mm corresponds to 2000 QC.

2000 QC=100.25 UU, therefore:

QC=(100.25/2000)UU=(401/8000)UU.

Parameter 32-11 User Unit Denominator and parameter 32-12 User Unit Numerator can be set to 8000

and 401 respectively.

4.3

Homing

Application Guide

4.3.1 Selecting Homing Mode

[0] Not forced mode

•

In this mode, homing is not conducted prior to positioning. If the go to home position command is issued by digital inputs or PROFIBUS, the frequency converter sets the current position as home position.

[1] Forced manual mode

•

In this mode, homing is conducted prior to positioning. The homing direction is determined by the sign of parameter 33-03 Homing Velocity. Find out the current position, and decide whether it is in the forward or backward direction relative to the home position.

[2] Forced automated mode

•

 In this mode, the homing process starts with the velocity set in parameter 33-03 Homing Velocity, and the velocity will be reversed automatically whenever the hardware position limit is reached until the home position is found. If the home position is not found after the hardware limits are reached twice, the alarm position ctrl. fault will be reported with fault reason can not find home

position, which can be viewed in parameter 37-18 Pos. Ctrl Fault Reason.

Homing Settings

4.3.2

Set the home offset in parameter 33-01 Home

•

Offset. Set the homing velocity in parameter 33-02 Home

•

Ramp Time. Set the homing ramp time in

•

parameter 33-03 Homing Velocity. Select the homing type in

•

parameter 33-04 Homing Behaviour. Select 1 digital input as home reference switch

•

input by setting the corresponding digital input parameter (5-10 to 5-16) to [151] Home Ref. Switch. Home reference switch input is used for marking the home position. Switching on indicates the home position is reached, and switching off indicates the position is not reached.

4.3.3

Homing Control

You can control the homing process via digital inputs or PROFIBUS.

4 4

FC 360 provides 3 homing modes. Select the homing mode in parameter 33-00 Homing Mode.

The 3 modes are described in details as follows.

Digital inputs

•

Select a particular digital input as homing switch by setting the corresponding parameter (5-10 to 5-16) to [151] Home Ref. Switch. In forced manual and automatic modes, switching on the digital

Positioning Control

VLT® AutomationDrive FC 360

input would start the homing process, and switching off the digital input stops the homing process. In unforced mode, switching on the digital input would set the current position as the home position. See Homing Modes for details about the 3 homing modes.

PROFIBUS

•

If 33-00 Homing Mode is set to [1] Forced

  Send control word PCD 1:0x0084 to the frequency converter to set current actual position as the home position.

4.4

Positioning

Settings before Positioning

There are 8 preset target positions. Configure the attributes of the positions in parameters 37-02 to 37-06.

Set the target window size in 33-47 Target Position Window. When this parameter is set to 0, the default target window size, which is 1/256 PPR (pulse per revolution), is used.

Configure the PID factor in 7-33 Process PID Proportional

Gain, 7-34 Process PID Integral Time, and 7-35 Process PID Differentiation Time based on actual requirements.

Positioning Control Process Control via digital inputs

Assume that digital input 18 is used to start and stop the positioning process, while digital inputs 19 and 27 are used to indicate bit0 and bit1 of an indexed position. The parameters need to be set as follows:

5-10 Terminal 18 Digital Input=[160] Go To Target

•

Pos. 5-11 Terminal 19 Digital Input=[162] Pos. Idx Bit0.

•

5-12 Terminal 27 Digital Input=[163] Pos. ldx Bit1.

•

Control the positioning process as follows:

Use different combinations of index bit values to

•

select the desired position.

Manual Modeor [2] Forced Automated Mode:

Send control word PCD 1:0x00A0 to the frequency converter to reset home status. Send control word PCD 1:0x0084 to the frequency converter to start homing. Send control word PCD 1:0x0080 to the frequency converter to stop homing.

If 33-00 Homing Mode is set to [0] Home

Not Forced:

Switch both digital input 19 and 27 off

to select position 0. Switch digital input 19 on and 27 off to

select position 1.

Control via PROFIBUS

Positioning Setup

After the set-up is completed, send PCD 2–6 to the frequency converter.

To start absolute positioning:

To start relative positioning:

To stop positioning:

4.5

FC 360 frequency converters support Profibus. The Profibus module is integrated in the control cassette with Profibus. If Profibus is needed:

In both cases, ensure that the firmware version is higher than 1.20.

Switch on digital input 18 to start the positioning

•

process. Switch off digital input 18 to stop the positioning

•

process.

Set PCD 2 to high 16 bit of the target position in

•

UU. Set PCD 3 to low 16 bit of the target position in

•

UU. Set PCD 4 to expected velocity in RPM.

•

Set PCD 5 to expected ramp-up time in ms.

•

Set PCD 6 to expected ramp-down time in ms.

•

1. Send control word PCD 1:0x0084 to the frequency converter, and wait 100 ms.

2. Send control word PCD 1:0x0481 to the frequency converter to start the positioning process.

1. Send control word PCD 1:0x0084 to the frequency converter, and then wait 100 ms.

2. Send control word PCD 1:0x0881 to the frequency converter to start the positioning process.

Send control word PCD 1:0x0084 to the

•

frequency converter.

PROFIBUS Interface

Order a new frequency converter on which the

•

control cassette with Profibus is pre-installed. Or order a control cassette with Profibus to

•

replace the standard control cassette on an existing frequency converter.

Switch digital input 19 off and 27 on to

select position 2. Switch both digital input 19 and 27 off

to select position 3.

Positioning Control Application Guide

The PROFIBUS interface in FC 360 uses type 5 of parameter process data objects (PPO). Set the PPO type in parameter 9-22 Telegram Selection.

PCD definitions

Control and status words are transferred via the process data channel (PCD) of the PROFIBUS interface. FC 360 uses PPO Type 5 for PROFIBUS communication.

PCD (word.bit)

1.1

1.2

1.3 Start Homing/ Stop

1.5

1.6

1.8

1.11

1.12

1.16 Change Sign On Quick Bus

2 Quick Bus Target

3 Quick Bus Target

4 Quick Bus Velocity(rpm) 5 Quick Bus Ramp Up Time

6 Quick Bus Ramp Dwon Time

Description Usage

Quick Bus Go To Target (↑1)) Reset Error (↑)

Positioning(↑)/ Start Positioning(↓2))

Automatic (↑) / Manual(↓) mode

Reset Home Status (↑) Quick Stop (↓) Quick Bus Type Absolute (↑) Quick Bus Type Relative (↑)

Target Position(↑)

Position(msb)

Position(lsb)

(ms)

In forced manual mode or forced automated mode, this word-bit is used to start or stop homing. In unforced mode, it is used to start or stop QuickBus positioning. Set to manual mode for homing and QuickBus positioning.

Typical hexadecimal control words in PCD1 are listed in Table 4.3.

Hexadecimal value of control word in PCD1

0x0080-->0x0000 Quick stop. 0x0080-->0x0082 Reset positioning alarm. 0x00A0 Reset home status. 0x0084

0x0080 Stop homing. 0x0084-->0x0481 Start absolute positioning. 0x0481-->0x0480 Stop absolute positioning. 0x0084-->0x0881 Start relative positioning. 0x0084-->0x0880 Stop relative positioning. 0x0084 Stop positioning.

Table 4.3 Typical Control Words in PCD1

Function

Start homing if parameter 33-00 Homing Mode is set to [1] Forced Manual Mode or [2] Forced Automated Mode, and reset the home position if parameter 33-00 Homing Mode is set to [0] Not Forced Mode.

4.6 Application Example

4.6.1 Introduction

The drawing below shows a layout of a pallet conveyor system. Loaded pallets are coming from four different product lines via the pallet inlet conveyors. Each pallet must be transported from one of the four inlet conveyors to the one of the two outlet conveyors. To do this a movable pallet conveyor cart is used.

4 4

Table 4.1 PROFIBUS Control Signals

↑

indicates active at rising edge.

2) ↓ indicates active at falling edge.

PCD (word.bit)

1.1

1.2

1.3

1.4

1.7

1.8 3 Actual Position (MSB) 4 Actual Position (LSB) 5 Position Error Status

Table 4.2 PROFIBUS Status Words

Description Homing Done (↑) Target Position Reached (↑) Error Occurred (↑) Mechanical Brake Output (↑) Positive Hardware Limit (↑) Negative Hardware Limit (↑)

Positioning Control

Illustration 4.1 Pallet Conveyor System (Example)

A typical work process is:

1. Moves the (empty) pallet conveyor cart to pallet

VLT® AutomationDrive FC 360

Parameter Value

5-10 Terminal 18 Digital Input

5-11 Terminal 19 Digital Input 5-12 Terminal 27 Digital Input 5-13 Terminal 29 Digital Input 5-16 Terminal 31 Digital Input

Parameter 5-40 Function Relay

Parameter 6-92 Terminal 42 Digital Output

Parameter 6-72 Terminal 45 Digital Output

Parameter 33-41 Negative Software Limit Parameter 33-42 Positive Software Limit Parameter 33-43 Negative Software Limit Active Parameter 33-44 Positive Software Limit Active Parameter 32-80 Maximum Allowed Velocity Parameter 37-17 Pos. Ctrl Fault Behaviour Parameter 37-07 Pos. Auto Brake Ctrl Parameter 37-08 Pos. Hold Delay Parameter 37-09 Pos. Coast Delay Parameter 37-10 Pos. Brake Delay Parameter 37-11 Pos. Brake Wear Limit

[160] Go To Target Pos [162] Pos. Idx Bit0 [163] Pos. Idx Bit1 [150] Go To Home [151] Home Ref. Switch Array element 0: Array element 1: [170] Homing Completed [171] Target Position Reached *-500,000 UU *500,000 UU [0] *Inactive

[0] *Inactive

*1,500 RPM

[0] *Ramp Down Brake [0] Disable *0 *200 ms *200 ms *0

inlet no. 1 to pick up a loaded pallet.

2. Waits until the pallet is successfully transferred to

Table 4.4 Parameter Set-up

the cart.

Homing

3. Moves to pallet outlet no. 2.

4. Waits until the pallet is successfully transferred to

4.6.4

Set the parameters for homing as described in Table 4.5.

the outlet conveyor and so on.

Parameter Value Description

Electrical Connection

4.6.2

Use encoder to MCB102 as feedback source.

Use digital inputs 18 and 19 to specify the index of the preset position.

Mark 0 position and connect the home switch to digital input 31.

4.6.3

Settings

Set the parameters as described in the table below.

Parameter 33-00 Ho ming Mode

Parameter 33-01 Ho me Offset Parameter 33-02 Ho me Ramp Time Parameter 33-03 Ho ming Velocity

Parameter 33-04 Ho ming Behaviour

[1] Forced Manual Mode

*10ms

-100 RPM Assume the

[1] *Reverse no index

Must complete homing before positioning.

beginning position is positive, then the homing velocity should be negative

Table 4.5 Homing Set-up

Perform the homing process as follows:

Positioning Control

Application Guide

Select Auto On mode via LCP/GLCP.

2. Switch on digital input 29 to start homing. The motor will rotate and move the conveyor cart to the home position.

3. Wait until digital out 42 is changed to high level.

4. Swtich off digital input 29 to stop homing.

4.6.5 Positioning

Set the parameters for positioning as described in Table 4.6.

Parameter Array Index Value Description

Parameter 37-02 Pos. Target

Parameter 37-03 Pos. Type

0 5800 UU Position 0,

inlet 1.

1 3800 UU Position 1,

inlet 2.

2 1800 UU Position 2,

inlet 3.

3 2300 UU Position 3,

outlet.

4–7 *0 UU Not used in

this example. 0 *[0] Absolute 1 *[0] Absolute 2 *[0] Absolute

Parameter 37-06 Pos. Ramp Down Time

Parameter 33-47 Target Position Window

PID Settings

7-33 Process PID Proportional Gain 7-34 Process PID Integral Time 7-35 Process PID Differentiation Time

Table 4.6 Positioning Parameter Set-up

0 1000 ms Considering 1 1000 ms 2 1000 ms 3 2000 ms

4–7 *5000 ms Not used in

– 20 UU Set to a value

– 0.5 These are only

– 20

– 0

the velocity settings, set the rampdown time of position 3 to be relatively long.

this example.

based on the actual situation of the application.

empirical settings, should be adjusted following the situation of commissioning in real system.

4 4

Parameter 37-04 Pos. Velocity

Parameter 37-05 Pos. Ramp Up Time

3 *[0] Absolute

4–7 *[0] Absolute Not used in

this example. 0 300 RPM The cart is full

to outlet, but 1 300 RPM

2 300 RPM

3 120 RPM

4-7 *100 RPM

0 1000 ms Considering 1 1000 ms 2 1000 ms 3 2000 ms

4-7 *5000 ms Not used in

empty to inlet.

It means the

load to Pos3 is

larger than to

Pos0/1/2. So

we set Pos3’s

velocity to be

a little lower

than others.

the velocity

setting, set the

ramp-up time

of position 3

to be

relatively long.

this case.

Operating procedure of positioning

Go to position 0 to get a pallet:

1. Switch off digital inputs 19 and 27 to select position 0.

2. Swith on digital 18 to move to position 0.

3. Wait until digital out 42 is turned on, which means the target position is reached. Make sure the pallet transfer starts after the position is reached. Otherwise, adjust the system or parameters.

4. Switch off digital input 18 to stop positioning.

5. Wait until the pallet is transferred to the cart.

Go to position 1 to get a pallet:

1. Switch on digital input 19 and switch off digital input 27 to select position 1.

2. Swith on digital 18 to move to position 1.

3. Wait until digital out 42 is turned on, which means the target position is reached. Make sure the pallet transfer starts after the position is reached. Otherwise, adjust the system or parameters.

4. Switch off digital input 18 to stop positioning.

5. Wait until the pallet is transferred to the cart.

Positioning Control

VLT® AutomationDrive FC 360

Go to position 2 to get a pallet:

1. Switch off digital input 19 and switch on digital input 27 to select position 2.

2. Swith on digital 18 to move to position 2.

3. Wait until digital out 42 is turned on, which means the target position is reached. Make sure the pallet transfer starts after the position is reached. Otherwise, adjust the system or

parameters.

4. Switch off digital input 18 to stop positioning.

5. Wait until the pallet is transferred to the cart.

Go to position 3 to deliver the pallet:

1. Switch off digital input 19 and switch on digital input 27 to select position 3.

2. Swith on digital 18 to move to position 3.

5-14 Terminal 32 Digital Input

Option: Function:

[0] * No operation Functions are described in parameter

group 5-1* Digital Inputs.

[82] Encoder input B

5-15 Terminal 33 Digital Input

Option: Function:

[0] * No operation Functions are described in parameter

group 5-1* Digital Inputs.

[32] Pulse time based [81] Enocder input A

5-16 Terminal 31 Digital Input

Option: Function:

[0] No operation Functions are described in parameter group

5-1* Digital Inputs.

3. Wait until digital out 42 is turned on, which means the target position is reached. Make sure the pallet transfer starts after the position is reached. Otherwise, adjust the system or parameters.

4. Switch off digital input 18 to stop positioning.

5. Wait until the pallet is transferred to the cart.

4.7

Parameters for Positioning Control

37-00 Application Mode

Option: Function:

[0] * Drive mode [1] Center winder [2] Position control

4.7.1 Digital Input and Output Settings

5-10 Terminal 18 Digital Input

5-11 Terminal 19 Digital Input

Option: Function:

[10] * Reversing Functions are described in parameter group

5-1* Digital Inputs.

5-40 Function Relay

Option: Function:

[0] No operation Default setting for all digital and

relay outputs.

[1] Control Ready The control card is ready.

[2] Drive ready The frequency converter is ready to

operate. Mains and control supplies are OK.

[3] Drive rdy/rem ctrl The frequency converter is ready for

operation, and is in Auto On mode.

[4] Stand-by / no

warning

Ready for operation. No start or stop commands have been applied. No warnings are active.

Option: Function:

[8] * Start

Functions are described in parameter group 5-1* Digital Inputs.

5-11 Terminal 19 Digital Input

Option: Function:

[10] * Reversing Functions are described in parameter group

5-1* Digital Inputs.

5-12 Terminal 27 Digital Input

Option: Function:

[2] * Coast inverse Functions are described in parameter group

5-1* Digital Inputs.

5-13 Terminal 29 Digital Input

Option: Function:

[14] * Jog Functions are described in parameter

group 5-1* Digital Inputs.

[32] Pulse time based

[5] Running The motor is running and a shaft

torque is present.

[6] Running / no

warning

[7] Run in range/no

warn

[8] Run on ref/no warn The motor runs at reference speed.

[9] Alarm An alarm activates the output. No

[10] Alarm or warning An alarm or warning activates the

The output speed is higher than the speed set in 1-82 Min Speed for Function at Stop [Hz]. The motor is running and no warnings are present.

The motor is running within the programmed current ranges set in 4-50 Warning Current Low.

No warnings.

warnings.

output.

Positioning Control Application Guide

5-40 Function Relay

Option: Function:

[11] At torque limit

[12] Out of current range The motor current is outside the

[13] Below current, low The motor current is lower than set

[14] Above current, high The motor current is higher than set

[15] Out of frequency

range

[16] Below frequency,

low

[17] Above frequency,

high

[18] Out of feedb. range The feedback is outside the range

[19] Below feedback, low The feedback is below the limit set

[20] Above feedback,

high

[21] Thermal warning Thermal warning turns on when the

[22] Ready, no thermal

warning

[23] Remote,ready,no TW The frequency converter is ready for

[24] Ready, no over-/

under voltage

[25] Reverse The motor runs (or is ready to run)

[26] Bus OK Active communication (no time-out)

[27] Torque limit & stop Use for performing a coasted stop

The torque limit set in 4-16 Torque

Limit Motor Mode or 4-17 Torque Limit Generator Mode has been

exceeded.

range set in 4-18 Current Limit.

in 4-50 Warning Current Low.

in 4-51 Warning Current High.

The output speed/frequency exceed the set in 4-40 Warning Freq. Low and 4-41 Warning Freq. High.

The output frequency is lower than the setting in 4-40 Warning Freq. Low.

The frequency is higher than the setting in 4-41 Warning Freq. High.

set in 4-56 Warning Feedback Low and 4-57 Warning Feedback High.

in 4-56 Warning Feedback Low.

The feedback is above the limit set in 4-57 Warning Feedback High.

temperature exceeds the limit wither in motor, frequency converter, brake resistor or connected resistor.

The frequency converter is ready for operation and there is no overtemperature warning.

operation and is in Auto On mode. There is no overtemperature warning.

The frequency converter is ready for operation, and the mains voltage is within the specified voltage range.

clockwise when logic=0 and counterclockwise when logic=1. The output changes as soon as the reversing signal is applied.

via the serial communication port.

and frequency converter in torque

5-40 Function Relay

Option: Function:

limit condition. If the frequency converter has received a stop signal and is in torque limit, the signal is logic=0.

[28] Brake, no brake

warning

[29] Brake ready, no fault The brake is ready for operation and

[30] Brake fault (IGBT) The output is logic=1 when the

[31] Relay 123 Digital output/relay is activated

[32] Mech brake ctrl Selection of mechanical brake

[36] Control word bit 11 Activate relay 1 by a control word

[37] Control word bit 12 Activate relay 2 by a control word

[40] Out of ref range Active when the actual speed is

[41] Below reference, low Active when the actual speed is

The brake is active and there are no warnings.

there are no faults.

brake IGBT is short-circuited. Use this function to protect the frequency converter if there is a fault on the brake module. Use the digital output/relay to cut out the mains voltage from the frequency converter.

when [0] Control word is selected in parameter group 8-** Communi- cations.

control. When selected parameters in parameter group 2-2* Mechanical brake are active. The output must be reinforced to carry the current for the coil in the brake. Usually solved by connecting an external relay to the selected digital output.

from the fieldbus. No other functional impact on the frequency converter. Typical application: Controlling an auxillary device from a fieldbus. The function is valid when [0] FC Profile is selected in 8-10 Control Word Profile.

outside the settings in 4-55 Warning

Reference High and 4-56 Warning Feedback Low.

below the speed reference setting.

4 4

Positioning Control

VLT® AutomationDrive FC 360

5-40 Function Relay

Option: Function:

[42] Above ref, high Active when actual speed is above

the speed reference setting.

[45] Bus ctrl. Controls digital output/relay via bus.

The state of the output is set in 5-90 Digital & Relay Bus Control. The output state is retained in the event

[46] Bus control, timeout:OnControls output via bus. The state of

[47] Bus control, timeout:

Off

[56] Heat sink cleaning

warning, high

[60] Comparator 0

[61] Comparator 1

[62] Comparator 2

[63] Comparator 3

[64] Comparator 4

[65] Comparator 5

[70] Logic rule 0

[71] Logic rule 1

of a bus time-out.

the output is set in 5-90 Digital & Relay Bus Control. In the event of a bus time-out, the output state is set high (on).

Controls output via bus. The state of the output is set in 5-90 Digital & Relay Bus Control. In the event of a bus time-out, the output state is set low (off).

See parameter group 13-1* Smart Logic Control. If Comparator 0 in SLC is TRUE, the output goes high. Otherwise, it goes low.

See parameter group 13-1* Smart Logic Control. If Comparator 1 in SLC is TRUE, the output goes high. Otherwise, it goes low.

See parameter group 13-1* Smart Logic Control. If Comparator 2 in SLC is TRUE, the output goes high. Otherwise, it goes low.

See parameter group 13-1* Smart Logic Control. If Comparator 3 in SLC is TRUE, the output goes high. Otherwise, it goes low.

See parameter group 13-1* Smart Logic Control. If Comparator 4 in SLC is TRUE, the output goes high. Otherwise, it goes low.

See parameter group 13-1* Smart Logic Control. If Comparator 5 in SLC is TRUE, the output goes high. Otherwise, it goes low.

See parameter group 13-4* Logic Rules. If Logic Rule 0 in SLC is TRUE, the output goes high. Otherwise, it goes low.

See parameter group 13-4* Logic Rules. If Logic Rule 1 in SLC is TRUE,

5-40 Function Relay

Option: Function:

the output goes high. Otherwise, it goes low.

[72] Logic rule 2

[73] Logic rule 3

[74] Logic rule 4

[75] Logic rule 5

[80] SL digital output A

[81] SL digital output B

[82] SL digital output C

[83] SL digital output D

[160] No alarm [161] Running reverse [165] Local ref active [166] Remote ref active [167] Start command activ [168] Drive in hand mode [169] Drive in auto mode [170] Homing Completed [171] Target Position

Reached

[172] Position Control

Fault [173] Position Mech Brake [175] Running on tension [176] Ready to run [193] Sleep Mode [194] Broken Belt Function

See parameter group 13-4* Logic Rules. If Logic Rule 2 in SLC is TRUE, the output goes high. Otherwise, it goes low.

See parameter group 13-4* Logic Rules. If Logic Rule 3 in SLC is TRUE, the output goes high. Otherwise, it goes low.

See parameter group 13-4* Logic Rules. If Logic Rule 4 in SLC is TRUE, the output goes high. Otherwise, it goes low.

See parameter group 13-4* Logic Rules. If Logic Rule 5 in SLC is TRUE, the output goes high. Otherwise, it goes low.

See 13-52 SL Controller Action. Output A is low on [32] Smart Logic

Action. Output A is high on [38] Smart Logic Action.

See 13-52 SL Controller Action. Output B is low on [32] Smart Logic

Action. Output B is high on [38] Smart Logic Action.

See 13-52 SL Controller Action. Output C is low on [32] Smart Logic

Action. Output C is high on [38] Smart Logic Action.

See 13-52 SL Controller Action. Output D is low on [32] Smart Logic

Action. Output D is high on [38] Smart Logic Action.

Positioning Control Application Guide

6-72 Terminal 45 Digital Output

Option: Function:

Select the function of terminal 45 as a digital current output. See also 6-70 Terminal 45 Mode. See

parameter 5-40 Function Relay for descriptions of

the option.

[0] * No operation [1] Control Ready [2] Drive ready [3] Drive rdy/rem ctrl [4] Stand-by / no warning [5] Running [6] Running / no warning [7] Run in range/no warn [8] Run on ref/no warn [9] Alarm [10] Alarm or warning [11] At torque limit [12] Out of current range [13] Below current, low [14] Above current, high [15] Out of frequency range [16] Below frequency, low [17] Above frequency, high [18] Out of feedb. range [19] Below feedback, low [20] Above feedback, high [21] Thermal warning [22] Ready, no thermal warning [23] Remote,ready,no TW [24] Ready, no over-/ under voltage [25] Reverse [26] Bus OK [27] Torque limit & stop [28] Brake, no brake warning [29] Brake ready, no fault [30] Brake fault (IGBT) [31] Relay 123 [32] Mech brake ctrl [36] Control word bit 11 [37] Control word bit 12 [40] Out of ref range [41] Below reference, low [42] Above ref, high [45] Bus ctrl. [46] Bus control, timeout: On [47] Bus control, timeout: Off [56] Heat sink cleaning warning,

high

[60] Comparator 0

6-72 Terminal 45 Digital Output

Option: Function:

[61] Comparator 1 [62] Comparator 2 [63] Comparator 3 [64] Comparator 4 [65] Comparator 5 [70] Logic rule 0 [71] Logic rule 1 [72] Logic rule 2 [73] Logic rule 3 [74] Logic rule 4 [75] Logic rule 5 [80] SL digital output A [81] SL digital output B [82] SL digital output C [83] SL digital output D [160] No alarm [161] Running reverse [165] Local ref active [166] Remote ref active [167] Start command activ [168] Drive in hand mode [169] Drive in auto mode [170] Homing Completed [171] Target Position Reached [172] Position Control Fault [173] Position Mech Brake [174] TLD indicator [175] Running on tension [176] Ready to run [177] End of roll [193] Sleep Mode [194] Broken Belt Function [198] Drive Bypass

6-92 Terminal 42 Digital Output

Option: Function:

4 4

Positioning Control

VLT® AutomationDrive FC 360

6-92 Terminal 42 Digital Output

Option: Function:

[16] Below frequency, low [17] Above frequency, high [18] Out of feedb. range [19] Below feedback, low [20] Above feedback, high [21] Thermal warning

[22] Ready, no thermal warning [23] Remote,ready,no TW [24] Ready, no over-/ under voltage [25] Reverse [26] Bus OK [27] Torque limit & stop [28] Brake, no brake warning [29] Brake ready, no fault [30] Brake fault (IGBT) [31] Relay 123 [32] Mech brake ctrl [36] Control word bit 11 [37] Control word bit 12 [40] Out of ref range [41] Below reference, low [42] Above ref, high [45] Bus ctrl. [46] Bus control, timeout: On [47] Bus control, timeout: Off [56] Heat sink cleaning warning, high [60] Comparator 0 [61] Comparator 1 [62] Comparator 2 [63] Comparator 3 [64] Comparator 4 [65] Comparator 5 [70] Logic rule 0 [71] Logic rule 1 [72] Logic rule 2 [73] Logic rule 3 [74] Logic rule 4 [75] Logic rule 5 [80] SL digital output A [81] SL digital output B [82] SL digital output C [83] SL digital output D [160] No alarm [161] Running reverse [165] Local ref active [166] Remote ref active [167] Start command activ [168] Drive in hand mode [169] Drive in auto mode [170] Homing Completed [171] Target Position Reached [172] Position Control Fault

6-92 Terminal 42 Digital Output

Option: Function:

[173] Position Mech Brake [174] TLD indicator [175] Running on tension [176] Ready to run [177] End of roll [193] Sleep Mode [194] Broken Belt Function [198] Drive Bypass

4.7.2 Positioning Control Settings

37-01 Pos. Feedback Source

Option: Function:

[1] * MCB102 [2] MCB103

37-02 Pos. Target

Range: Function:

0* [-1073741824 - 1073741824 ]

37-03 Pos. Type

Option: Function:

[0] * Absolute [1] Relative

37-04 Pos. Velocity

Range: Function:

100 RPM* [1 - 30000 RPM]

37-05 Pos. Ramp Up Time

Range: Function:

5000 ms* [50 - 100000 ms]

37-06 Pos. Ramp Down Time

Range: Function:

5000 ms* [50 - 100000 ms]

37-07 Pos. Auto Brake Ctrl

Option: Function:

[0] Disable [1] * Enable

37-08 Pos. Hold Delay

Range: Function:

0 ms* [0 - 10000 ms]

37-09 Pos. Coast Delay

Range: Function:

200 ms* [0 - 1000 ms]

37-10 Pos. Brake Delay

Range: Function:

200 ms* [0 - 1000 ms]

Positioning Control Application Guide

37-11 Pos. Brake Wear Limit

Range: Function:

0* [0 - 1073741824 ]

37-12 Pos. PID Anti Windup

Option: Function:

[0] Disable [1] * Enable

37-13 Pos. PID Output Clamp

Range: Function:

1000* [1 - 10000 ]

37-14 Pos. Ctrl. Source

Option: Function:

[0] * DI [1] FieldBus

37-15 Pos. Direction Block

Option: Function:

[0] * No Blocking [1] Block Reverse [2] Block Forward

37-17 Pos. Ctrl Fault Behaviour

Option: Function:

[0] * Ramp Down&Brake [1] Brake Directly

37-18 Pos. Ctrl Fault Reason

Option: Function:

[0] * No Fault [1] Homing Needed [2] Pos. HW Limit [3] Neg. HW Limit [4] Pos. SW Limit [5] Neg. SW Limit [7] Brake Wear Limit [8] Quick Stop [9] PID Error Too Big [12] Rev. Operation [13] Fwd. Operation [20] Can not find home position

37-19 Pos. New Index

Range: Function:

0* [0 - 255 ]

4.7.3 32-** Motion Control Basic Settings

32-12 User Unit Numerator

Range: Function:

1* [1 - 65535 ]

32-67 Max. Tolerated Position Error

Range: Function:

2000000* [1 - 2147483648 ]

32-80 Maximum Allowed Velocity

Range: Function:

1500 RPM* [1 - 30000 RPM]

32-81 Motion Ctrl Quick Stop Ramp

Range: Function:

1000 ms* [50 - 3600000 ms]

4.7.4 33-** Motion Control Adv. Settings

33-00 Homing Mode

Select the homing mode.

Option: Function:

[0] * Not forced [1] Forced manual homing [2] Forced automated homing

33-01 Home Offset

Range: Function:

0* [-1073741824 - 1073741824 ]

33-02 Home Ramp Time

Range: Function:

10 ms* [1 - 1000 ms]

33-03 Homing Velocity

Range: Function:

100 RPM* [-1500 - 1500 RPM]

33-04 Homing Behaviour

Option: Function:

Define the behaviour when the home switch is found: Reversing without index (0 pulse) search, or forwarding without index search.

[1] * Reverse no index [3] Forward no index

33-41 Negative Software Limit

Range: Function:

-500000* [-1073741824 - 1073741824 ]

4 4

32-11 User Unit Denominator

Range: Function:

1* [1 - 65535 ]

33-42 Positive Software Limit

Range: Function:

500000* [-1073741824 - 1073741824 ]

Positioning Control

VLT® AutomationDrive FC 360

33-43 Negative Software Limit Active

When this parameter is set to active, the frequency converter continuously checks whether the target position is below the negative software limit. If it occurs, an error is issued and the frequency converter control is switched off.

Option: Function:

[0] * Inactive [1] Active

33-44 Positive Software Limit Active

When this parameter is set to active, the frequency converter continuously checks whether the target position is above the positive software limit. If it occurs, an error is issued and the frequency converter control is switched off.

Option: Function:

[0] * Inactive [1] Active

33-47 Target Position Window

Defines the size of the target window with user unit. A position is only viewed as reached when the actual position is within this window.

Range: Function:

0* [0 - 10000 ]

34-08 PCD 8 Write For Application

Range: Function:

0* [0 - 65535 ]

34-09 PCD 9 Write For Application

Range: Function:

0* [0 - 65535 ]

34-10 PCD 10 Write For Application

Range: Function:

0* [0 - 65535 ]

34-21 PCD 1 Read For Application

Range: Function:

0* [0 - 65535 ]

34-22 PCD 2 Read For Application

Range: Function:

0* [0 - 65535 ]

34-23 PCD 3 Read For Application

Range: Function:

0* [0 - 65535 ]

34-24 PCD 4 Read For Application

Range: Function:

4.7.5 34-** Motion Control Data Readouts

0* [0 - 65535 ]

34-01 PCD 1 Write For Application

Range: Function:

0* [0 - 65535 ]

34-02 PCD 2 Write For Application

Range: Function:

0* [0 - 65535 ]

34-03 PCD 3 Write For Application

Range: Function:

0* [0 - 65535 ]

34-04 PCD 4 Write For Application

Range: Function:

0* [0 - 65535 ]

34-05 PCD 5 Write For Application

Range: Function:

0* [0 - 65535 ]

34-06 PCD 6 Write For Application

Range: Function:

0* [0 - 65535 ]

34-07 PCD 7 Write For Application

Range: Function:

0* [0 - 65535 ]

34-25 PCD 5 Read For Application

Range: Function:

0* [0 - 65535 ]

34-26 PCD 6 Read For Application

Range: Function:

0* [0 - 65535 ]

34-27 PCD 7 Read For Application

Range: Function:

0* [0 - 65535 ]

34-28 PCD 8 Read For Application

Range: Function:

0* [0 - 65535 ]

34-29 PCD 9 Read For Application

Range: Function:

0* [0 - 65535 ]

34-30 PCD 10 Read For Application

Range: Function:

0* [0 - 65535 ]

34-50 Actual Position

The actual position in user unit.

Range: Function:

0* [-1073741824 - 1073741824 ]

Positioning Control Application Guide

34-56 Track Error

Range: Function:

0* [-2147483647 - 2147483647 ]

4 4

Positioning Control

VLT® AutomationDrive FC 360

Index Application Guide

Index

Abbreviations........................................................................................... 2

Convention................................................................................................ 2

Diameter measurement signal.......................................................... 8

Discharge time......................................................................................... 4

Document version.................................................................................. 2

High altitude............................................................................................. 5

High voltage............................................................................................. 4

Winder speed........................................................................................... 8

Winder speed match scale................................................................... 9

Initial diameter measurement............................................................ 8

Leakage current....................................................................................... 5

Line speed................................................................................................. 8

Load sharing............................................................................................. 4

Logic input................................................................................................ 8

Over-tension............................................................................................. 9

PELV............................................................................................................. 5

Qualified personnel................................................................................ 4

Safety........................................................................................................... 5

Software version...................................................................................... 2

Taper setpoint.......................................................................................... 8

Tension and taper setpoint................................................................. 8

Tension feedback............................................................................... 6, 8

Tension setpoint...................................................................................... 8

Unintended start..................................................................................... 4

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Danfoss A/S Ulsnaes 1 DK-6300 Graasten www.danfoss.com/drives

130R0629 MG06E102 11/2014

*MG06E102*

Danfoss VLT AutomationDrive FC 360 Application Manual

Specifications and Main Features

Frequently Asked Questions

User Manual