VLT® Center Winder MCO 352 Contents
Contents
1 How to Read these Operating Instructions
How to Read These Operating Instructions 3
Additional Literature for VLT AutomationDrive, MCO 305 and MCT 10 Motion Con-
trol Tool
Approvals 3
Symbols 3
Abbreviations 4
2 Safety Instructions and General Warnings
High Voltage Warning 5
Safety Instructions 5
Before commencing repair work 5
Avoid Unintended Start 5
Safe Stop of VLT AutomationDrive FC302 6
General Warning 6
3 Introduction to Center Winder Controller
MCO 352 Center Winder Controller 7
Additional Features 8
3
3
5
7
System Requirements 9
4 How to Install
VLT AutomationDrive Terminals 11
Center Winder Option Terminals 12
Digital and Analog I/Os 13
Read-only Application Parameters 25
5 Center Winder Calibration
Frequency Converter Checkout 27
Preset Winder Function Parameters 28
Winder Scaling Factor Calibration – Open loop Speed Adjustments 29
Check Inputs 30
Calibration of Diameter Measurement Signal 30
Check Tension Correction Direction 31
Winder Closed Loop Calibration 31
6 Troubleshooting
11
27
33
7 Appendix
Center Winder Settings 35
MCO Basic Settings 36
Index
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1 How to Read these Operating Instructions VLT® Center Winder MCO 352
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VLT® Center Winder MCO 352 1 How to Read these Operating Instructions
1 How to Read these Operating Instructions
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1.1.1 How to Read These Operating Instructions
These Operating Instructions will help you get started, program, and troubleshoot your Center Winder Option. Please read these operating instructions
in full and, in order to be able to work with the system safely and professionally, particularly observe t h e hi n t s and cautionary remarks.
Chapter How to Read these Operating Instructions introduces the manual and informs you about the approvals, symbols, and abbreviations used
in this literature.
Chapter Safety Instructions and General Warnings entails instructions on how to handle the Center Winder Controller correctly.
Chapter Introduction to Center Winder Controller informs you in general about center winders and different methods of rewinding and unwinding.
Chapter How to Ins tall informs you how to start up the Center Winder Option. This section includes the description of the terminals and the parameters.
Chapter Center Winder Calibration informs how to calibrate the wi nder. Detailed instructions on how to proceed can be found in this section.
Chapter Troubleshooting assists you in solving problems that may occur when installing and using the Cente r Winder Co ntrolle r.
Chapter Appendix provides information about para meters in clearl y arranged lists. P lease see t he Parame ter Ref erence in th e MCO 305 De sign Guide
for more details.
1.2.1 Additional Literature for VLT AutomationDrive, MCO 305 and MCT 10 Motion Control
Tool
The MCO 305 Operating Instructions provide the necessary information for build-in, set-up, and optimize the controller.
The VLT AutomationDrive FC 300 Operating Instructions provide the necessary information for getting the drive up and running.
The VLT AutomationDrive FC 300 Design Guide entails all technical information about the driv e and customer design and applications.
The VLT AutomationDrive FC 300 MCT 10 Operating Instructions provide information for installation and use of the software on a PC.
Danfoss Drives technical literature is also available online at www.danfoss.com/drives.
1.3.1 Approvals
1.4.1 Symbols
Symbols used in this Operating Instructions.
NB!
Indicates something to be noted by the reader.
Indicates a general warning.
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1 How to Read these Operating Instructions VLT® Center Winder MCO 352
Indicates a high-voltage warning.
∗
Indicates default setting
1.5.1 Abbreviations
Automatic Motor Adaptation AMA
Build-up Ratio BUR
Direct Current DC
Frequency Converter FC
Local Control Panel LCP
Milliampere mA
Millisecond ms
Minute min
Motion Control Option MCO
Motion Control Tool MCT
Parameter par.
Proportional Integral Derivative Control PID
Pulses per Revolution PPR
Revolutions per Minute RPM
Second s
Tension limit d etection TLD
Volts V
Quad Counts qc
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VLT® Center Winder MCO 352 2 Safety Instructions and General Warnings
2 Safety Instructions and General Warnings
VLT Center Winder MCO352
Operating Instructions
Software version: 1.xx
These Operating Instructions can be used for the VLT Center Winder MCO352 with all FC 300 frequency converters with software version 4.9x.
The software version of FC 300 can be read in parameter 15-43.
2.2.1 High Voltage Warning
The voltage of the VLT AutomationDrive is dangerous whenever the conver ter is connecte d to ma ins. Incorrect fitting of the motor or the VLT AutomationDrive may cause damage to the equipment, serious injury or death. Consequently, it is essential to comply with the instructions in this manual as well
as local and national rules and safety regulations.
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2.2.2 Safety Instructions
• Make sure the VLT AutomationDrive is properly connected to earth.
• Do not remove mains plugs or motor plugs while the VLT AutomationDrive is connected to mains.
• Protect users against supply voltage.
• Protect the motor against overloading according to national and local regulations.
Motor overload protection is not included in the default settings. To add this function, set par. 1-90
warning
.
For the North American market: ETR functions provide class 20 motor overload protection, in accordance with NEC.
The earth leakage current exceeds 3.5 mA.
The [OFF] key is not a safety switch. It does not disconnect the VLT AutomationDrive from mains.
Motor thermal protection
2.2.3 Before commencing repair work
1. Disconnect VLT AutomationDrive from mains.
2. Disconnect DC bus terminals 88 and 89.
3. Wait at least 4 minutes.
4. Remove motor plugs.
to value
ETR trip
or
ETR
2.2.4 Avoid Unintended Start
While VLT AutomationDrive is connected to mains, the motor can be started/stopped using digital commands, bus commands, references or via the LCP.
Disconnect the VLT AutomationDrive from mains whenever personal safety considerations make it necessary to avoid unintended start.
To avoid unintended start, always activate the [OFF] key before chan ging parameters. Un less terminal 37 is t urned off, an electronic f ault, temporary
overload, a fault in the mains supply, or lost motor connect i on may cause a stopped motor to start.
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2 Safety Instructions and General Warnings VLT® Center Winder MCO 352
2.2.5 Safe Stop of VLT AutomationDrive FC302
The VLT AutomationDrive FC 302 can perform the Designated Safety Function Uncontrolled Sto pping by removal of power (as defined by draft IEC
61800-5-2) or Stop Category 0 (as defined in EN 60204-1). I t is designed and approved suitable for the requirements of Safety Category 3 in EN 954-1.
This functionality is called Safe St op. In orde r to inst all an d use t he Saf e Sto p func tion in ac corda nc e with th e requ ire ments of Safety Ca tegory 3 in EN
954-1, the related information and instructions of the VLT AutomationDrive FC 300 Design Guide MG.33.BX.YY must be followed! The information and
instructions of the Operating Instructions are not sufficient for a correct and safe use of the Safe Stop functionality!
2.2.6 General Warning
WARNING:
Touching the electrical parts may be fatal – even after the equipment has been disconnected from mains.
Also make sure that all voltage inputs have been disconnected, such as load-sharing (linkage of DC intermediate circuit), as well as the motor
connection for kinetic back-up.
Using VLT AutomationDrive FC 300 wait at least 15 minutes.
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VLT® Center Winder MCO 352 3 Introduction to Center Winder Controller
3 Introduction to Center Winder Controller
3.1.1 MCO 352 Center Winder Controller
The MCO 352 Center Winder Controller uses the speed winder method with a diameter calculation and either a load cell or dancer feedback. Below is a
simplified block diagram of a tension controlled winder system. The system would be identical if a dancer were used except that the Taper Function block
would have a 0/4-20 mA output used to load the dancer air cylinder proportional to the tapered tension se t point. The drive is fed an open loop speed
reference based on the calculated diameter of the roll. This si gnal is summed wit h a signal gene rated by a PID a mplifier comp aring the actual tension
feedback with a tapered tension set point. The ta pered tension set point is actually the tension set point modified based on the roll diameter a nd the
taper set point. Taper generally reduces the tension set point hyperbolically with a change in diamete r. The PID ampli fier output is also reduced with
increasing diameter since the same change in reference will have a larger surface speed change as the roll increases in diameter . Ide a lly , th e op en l o op
reference signal is scaled at core so that the surface speed of the core matc hes line spe ed. The diamet er value is calcul ated by the ratio of line spee d
verse winder speed.
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Roll diameter
This calculation needs to be updated fairly quickly since the roll can change diameter very quickly when near the core. If the true diameter changes faster
than the diameter is calculated, the open loop reference speed will lag too far behind the re quired speed and the tension PID w il l ne ed to make u p to o
much of the difference.
=
core diameter
Line speed
(
Winder
speed
)
The Tension PID updates every 30 ms and should be updated at least 3 times faster than the diameter calculation. This is because the tension PID block
must be allowed to stabilize syst em tension before a new diameter is calculated, since the calculated diameter is used by both the open-loop ref ere nce
and as an input to the tension PID block.
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3 Introduction to Center Winder Controller VLT® Center Winder MCO 352
3.1.2 Additional Features
Several features have been included to increase the overall stability of the winder and to increase control and monitoring of the windi ng process.
• Acceleration Feed-Forward: The Winder block diagram includes an acceleration feed-forward function that allows a shift in the tension/taper set
point based on changes in line speed. This provides a tension boost during initial acceleration to help compensate for system inertia.
• Tension-Taper Set-Point Ramp: The tapered tension set point generator will integrate any changes to the tension or taper set points over multiple
program scans. A parameter is provided to increase or decrease response time.
• Diameter Calculator Limi ter: The diameter calculator incl udes a similar integration tech nique. A maximum rate of dia meter change can be
adjusted by parameter. In addition, the calculated diameter is restricted from moving in the wrong direction to only 20 % of the rate applied to
the expected change in diameter. For example, if the station is rewinding a roll, the diamet er is not expected to reduce in diameter.
• 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.
• Programmable Analog Inputs: The VLT AutomationDrive has two analog inputs. Inputs 53 and 54 are analog inputs with a voltage range of ±10
VDC or a current range of 0/4-20mA. Use DIP-switch S201/S202 to select configuration. The source of the tension and taper set-points can be
adjusted by either analog input or parameter setting. The tension feedback and initial diameter measurement can only use analog inputs.
Parameters are provided to select the source of each input. Care must be taken not to program a single input for more than one function.
• Initial Diameter Measurement: In many winding applications there are very few variations in starting core diameter or initial roll size. A choice
of three programmable starting diameters can be programme d and logically selected. For applications where the starting diameter can vary
regularly, the Winder will allow 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: An output is provided to indicate a diameter limit. For rewinding applications, the diameter limit occurs when the calculated
diameter exceeds a set limit. For unwinding applications, the diameter limit occurs when the calculated diameter is less than the set limit. The
station will continue to run after a diameter limit is detected. This output can be used to stop the line for a roll change.
• Tension Limit Detector: The Winder includes a tension limit detection (TLD) feature. This feature allows the Win der to trip if a lo w-tension or
high-tension feedback exists for a period of time. The trip delay includes a normal running delay as well as a secondary starting dela y.
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VLT® Center Winder MCO 352 3 Introduction to Center Winder Controller
3.2.1 System Requirements
The center winder system has some minimum requirements for proper operation.
• Frequency converter: VLT AutomationDrive with VLT Center Winder MCO 352. It is also recommended that the drive have dynamic braking
option capabilities to allow a quick stop of a large roll.
• Winder motor: The motor needs to be inverter duty with a wide speed range (>100:1). The motor should be geared or belted so tha t top m otor
speed at core does not exceed 4500 RPM. Generally, the motor maximum constant horsepower speed wil l be t he l imiting factor.
• Winder Encoder: The winder encoder needs to be mounted on the winder motor. The encoder must have a differential, quadrature TTL/5VDC
output. The encoder PPR should be selected such that the channel frequency is as close to 400 kHz at the winder motor top speed.
• Line Encoder: The line speed encoder output circu itry needs to be the same as the winde r encoder. Again, the encoder PPR should selecte d
such that the channel frequency is as close to 400 kHz at the maximum line speed.
• Tension Feedback: The tension feedback is required from either a load cell or dancer. If load cells are used they need to be calibrated for a
either a 0-20 mA or 0-10 V signal from zero to maximum tension. If a dancer is used the calibration should be 0-20mA/0-10V from bottom to
top of the dancer movement.
• Logic Inputs: The digital inputs for tension on, over/under etc. are 24 VDC, sinking inputs. The drive has a 24VDC/200mA supply available if dry
contacts are used. Logic commands can also be sent to the drive serial port. Note that a third party HMI/operator display such as EXOR or Red
Lion can be used in place of the digital inputs. It is possible to serially access logic parameters through the VLT AutomationDrive USB or RS485
port.
• Tension and Taper set-points: The tension and taper set-points are available on the display of the drive as parameters and can also be accessed
serially through the VLT AutomationDrive USB or RS485 port. These set points can also be set usin g any unused 0-20mA/0-10VDC drive input,
using an analog signal or potentiometer
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Maximum Winder Motor speed
Tension Loop Scan Time 30 ms
TLD Time Resolution 25 ms
Quick Stop Scan time 1 ms
Coast Scan Time <1 ms
Tension Loop Response Time 25 ms
Line encoder frequency 100 kHz - 410 kHz
Winder Encoder frequency 100 kHz – 410 kHz
Winder Speed resolution ±16384 qc counts @ 4500 RPM
Digital inputs 24 VDC, sinking
Digital outputs 24 VDC, sourcing
Analog Tension & taper set points 0-10 VDC, 0-20 mADC, 1000 count resolution
Load cell or dancer feedback 0-10 VDC, 0-20 mADC, 1000 count resolution
4500 RPM
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4 How to Install VLT® Center Winder MCO 352
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VLT® Center Winder MCO 352 4 How to Install
4How to Install
4.1.1 VLT AutomationDrive Terminals
The VLT AutomationDrive control card contains input and output logic terminals used by the Winder Option. The Winder Option does not assign a function
to all of the inputs and outputs on the control card. The terminals required for proper Winder operation are discussed in this manual. See the VLT
AutomationDrive Operating Instructions for further details.
Analog Inputs
53 Multifunction inpu t 1
54 Multifunction inpu t 2
55 A/I common
Inputs
27 Quick Stop
37 Safe Stop
Relay 1
Running on tension
4
Relay 2
Ready
Analog Outputs
42 Taper Tension Setpoint
Supply Voltage
50 10 V DC max. load 15 mA
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4 How to Install VLT® Center Winder MCO 352
4.1.2 Center Winder Option Terminals
The figure below shows the five green terminal str ips on the MC O 305 Op tion Card. The 24V supply on the digit al input and outp ut terminal strips are
internally connected to the VLT AutomationDrive +24V supply available at terminals 12 & 13. The COM is connected to VLT AutomationDrive terminal
39. An external 24 VDC power supply can be used. See the MCO 305 Instruction Manual for details on setting MCO Supplied by external 24 VDC (parameter
33-85). The isolated 5V/400mA and 8V/250mA encoder supply is generated on the MCO 305 Card from the 24 V power supply.
X55
is always used for winder/unwinder speed
X56
is always used for line speed
X57 Digital Inputs
I1 Over/under winding
I2 Winder jog reverse
I3 Winder jog forward
I4 Partial roll select
I5 Tension on/off (reset)
I6 Material select
I7 Core select
I8 Diameter reset
X59 Digital Outputs
O1 End of roll indicator
O2 TLD indicator
O3 Running on tension
O4 Ready
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