wp3000 rm001

WebPak 3000 DC Drive Application Workbook Version 1.
Instruction Manual D2-3446
The information in this manual is subject to change without notice. Throughout this manual, the following notes are used to alert you to safety considerations: ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.
Important: Identifies information that is critical for successful application and understanding of the product.
ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, operate, or service this equipment. Read and understand this manual in its entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.
Reliance, WebPak, and WebPakCS are trademarks of Rockwell Automation. 2000 Rockwell International Corporation
CONTENTS
Chapter 1 Getting Started 1.1 Where to Find Additional Information .............................................................. 1-1 1.2 Getting Assistance from Reliance Electric....................................................... 1-2 How to Use This Manual 2.1 If You Are Using WebPakCS Software to Configure the Drive........................ 2-1 2.2 If You Are Using the OIM to Configure the Drive............................................. 2-1 2.3 About Scaling .................................................................................................. 2-2 2.3.1 For Position Loops ................................................................................ 2-2 2.3.2 For Current and Tension Loops ............................................................ 2-2 Configuring the Speed Loop 3.1 The Speed Loop Reference ............................................................................ 3-2 3.1.1 Configuring Trim (Optional) ................................................................... 3-3 3.2 The Speed Reference Ramp........................................................................... 3-4 3.2.1 The LIMIT Block ..................................................................................... 3-5 3.2.2 The S-CURVE Block............................................................................... 3-8 3.3 Speed Mode Select ......................................................................................... 3-9 3.3.1 Configuring Jog ................................................................................... 3-10 3.3.2 Selecting the Outer Loop .................................................................... 3-10 3.3.3 Selecting the Outer Loop Type ........................................................... 3-12 3.3.4 Current Compounding ......................................................................... 3-12 3.4 Speed Loop Feedback .................................................................................. 3-13 3.5 Speed Loop Regulator With Gain Profiling .................................................... 3-14 3.5.1 The PI Block ........................................................................................ 3-15 3.5.2 The Current Memory Function ............................................................ 3-17 Configuring the Current Minor Loop 4.1 The Current Minor Loop Reference ................................................................. 4-1 4.1.1 Applications Requiring On-the-Fly Switching Between Current and Speed Regulation.................................................................................. 4-3 4.2 The Current Minor Loop Regulator .................................................................. 4-4 Configuring the Field Current Regulator 5.1 The Field Reference ........................................................................................ 5-1 5.2 The Field Feedback ......................................................................................... 5-5 5.3 Automatic Field Weakening (Spillover Control) ............................................... 5-5 5.4 The Field Regulator ......................................................................................... 5-6 Configuring the Diameter Calculator 6.1 The Diameter Calculator Update Threshold .................................................... 6-1 6.2 The Diameter Calculator.................................................................................. 6-2 6.2.1 Validating the Setup of the Diameter Calculator ................................... 6-4 Configuring Inertia Compensation 7.1 Instantaneous System Inertia .......................................................................... 7-1 7.2 Inertia-to-Current Scaling ................................................................................ 7-2 I Chapter 2
Chapter 3
Chapter 4
Chapter 5
Chapter 6
Chapter 7
Contents
Chapter 8 Chapter 9
Configuring Losses Compensation Configuring the Outer Control Loop Reference 9.1 The Tension Setpoint .......................................................................................9-1 9.1.1 Stall Tension Mode ................................................................................9-2 9.1.2 The Taper Function................................................................................9-3 9.1.3 The Taper Type ......................................................................................9-3 9.2 Dancer Loading................................................................................................9-4 Configuring the Current Major Outer Control Loop 10.1 Gain Profiler for the Current Major Outer Control Loop .................................10-1 10.2 Tension-to-Current Scaling ............................................................................10-2 10.3 The Tension PI Input ......................................................................................10-3 10.4 The Tension PI Output ...................................................................................10-3 10.5 The Slack Take-Up Function..........................................................................10-4 10.6 Validating the Settings of TEN PI PROP GAIN (P.841) and TEN PI LEAD FREQ (P.840).............................................................................10-5 Configuring the Position Outer Loop 11.1 The Position Gain Profiler ..............................................................................11-1 11.2 The Position PI Input ......................................................................................11-4 11.3 The Position PI Output ...................................................................................11-5 11.4 Type 3 Position Regulator..............................................................................11-6 Configuring the Tension Outer Control Loop 12.1 The Tension PI Input ......................................................................................12-1 12.1.1 The SCALE Block .................................................................................12-2 12.1.2 The LEAD/LAG Block ............................................................................12-3 12.1.3 The Tension Loop PI Block ..................................................................12-3 12.1.4 Dynamic Gain Profiling (Variable Diameter Applications)....................12-5 12.2 The Tension PI Output ...................................................................................12-5 12.3 The Slack Take-Up Function..........................................................................12-6 Configuring Other Parameters 13.1 Analog Outputs ..............................................................................................13-1 13.2 Digital Outputs................................................................................................13-2 13.3 Frequency I/O ................................................................................................13-2 13.4 Level Detectors ..............................................................................................13-3 13.5 AC Line ..........................................................................................................13-3 13.6 Armature Voltage Feedback ..........................................................................13-4 13.7 Underwind Operation .....................................................................................13-4
Chapter 10
Chapter 11
Chapter 12
Chapter 13
Appendix A Using the WebPak 3000 Drive for Web Applications: The Basics ........................... A-1 Glossary Index ..................................................................................................................... Glossary-1 ...........................................................................................................................Index-1
II
WebPak 3000 DC Drive Application Workbook, Version 1.1
List of Figures
Figure 3.1 Outer Control Loop Proportional Trim ................................................ 3-11
List of Tables
Table 2.1 Locating the Appropriate Chapters for Your Application........................ 2-1
Contents
III
IV
CHAPTER 1
Getting Started
ATTENTION: WebPak 3000 DC drive parameters must be configured by a qualified person who understands the significance of configuring them accurately. Failure to observe this precaution could result in severe bodily injury or loss of life.
This manual provides guidance in configuring the WebPak 3000 DC drive for web-handling applications. What You Need to Know
You must be qualified to program the drive and be familiar with web-handling
applications. If you are unfamiliar with web-handling applications, read Appendix A in this manual before proceeding.
You should be familiar with the WebPak Operator Interface Module (OIM) or the
WebPakCS Configuration Software. What You Need to Do
Complete all hardware installation as described in the WebPak 3000 drive hardware
reference manual (D2-3443).
Perform Quick Start as described in the OIM manual or configure the initialization
parameters using the WebPakCS software. Note that no entry fields will be provided in this Workbook for Quick Start parameters. Record these values in Appendix B of the software manual (D2-3444) during the Quick Start procedure.
Self-tune the current minor loop and the speed loop as described in the OIM
manual.
Determine your application type and locate the appropriate chapters in this manual
according to table 2.1 in chapter 2.
1.1
Where to Find Additional Information

To find information on:
Hardware, including installation, wiring, and troubleshooting information: See

D2-3443, WebPak 3000 DC Drive Hardware Reference.
Software, including parameter descriptions and block diagrams: See D2-3444,

WebPak 3000 DC Drive Software Reference.
The Operator Interface Module (OIM), including setting parameters, saving

parameters, and using Quick Start: See D2-3445, WebPak 3000 Drive Operator Interface Module (OIM) User Guide.
Configuration Software: See D2-3447, WebPakCS Configuration Software.

Getting Started
1-1
1.2
Getting Assistance from Reliance Electric

If you have any questions or problems with the products described in this instruction manual, contact your local Reliance Electric sales office. For technical assistance, call 1-800-726-8112.
1-2
CHAPTER 2
How to Use This Manual
This manual provides configuration guidance for users of the OIM and the WebPakCS Configuration Software.
2.1
If You Are Using WebPakCS Software to Configure the Drive

The chapter titles in this manual correspond to the screen selections available in the WebPakCS software. Each chapter guides you through the parameters as they appear on the screens.
2.2
If You Are Using the OIM to Configure the Drive

Use table 2.1 to locate the appropriate chapters in this manual for your application. Each chapter guides you through the parameters you need to configure. If you are unsure of which application type to select, read Appendix A in this manual before proceeding.
Table 2.1 Locating the Appropriate Chapters for Your Application
For This Application: Constant Diameter Speed Regulator Variable Diameter Speed Regulator Constant Diameter Current Regulator Variable Diameter Current Regulator Constant Diameter Position Regulator Variable Diameter Position Regulator Constant Diameter Tension Regulator Variable Diameter Tension Regulator Generic
Use These Chapters: 1, 2, 3, 4, 5, 8, 13 1, 2, 3, 4, 5, 6, 7, 8, 13 1, 2, 3, 4, 5, 8, 9 (9.1), 10, 13 1, 2, 3, 4, 5, 6, 7, 8, 9 (9.1), 10, 13 1, 2, 3, 4, 5, 9, 11, 13 1, 2, 3, 4, 5, 6, 7, 8, 9, 11, 13 1, 2, 3, 4, 5, 8, 9 (9.1), 12, 13 1, 2, 3, 4, 5, 6, 7, 8, 9 (9.1), 12, 13 All
Refer to Appendix A in the drive software manual (D2-3444) for block diagrams. Record parameter values in this book and then transfer the values to Appendix B of the software manual (D2-3444). This will enable you to verify that all the appropriate parameters have been set. Then configure the drive using the values you entered in Appendix B. Appendix B provides the OIM menu path for each parameter.
How to Use This Manual
2-1
2.3
About Scaling
The WebPak 3000 drive follows the scaling conventions described in sections 2.3.1 and 2.3.2.
2.3.1 For Position Loops

The dancer feedback should be scaled so that 0 to 4095 counts corresponds to 0 to full storage as defined by the parameter STORAGE (P.857). The midpoint of the dancer travel should correspond to 2048 counts.
2.3.2 For Current and Tension Loops

The current and tension outer loops are scaled so that 4095 counts corresponds to rated tension. Rated tension is defined as the tension in the line when the drive is operating with motor rated torque (motor rated current with rated field current) at full roll diameter. Rated tension is not necessarily the maximum line tension for a given process. If rated tension is greater than the maximum required line tension for your application, then the current/tension PI limits should be reduced accordingly.
2-2
CHAPTER 3
Configuring the Speed Loop
Use This Chapter for These Applications:
Constant Diameter Speed Regulator Variable Diameter Speed Regulator Constant Diameter Current Regulator Variable Diameter Current Regulator Constant Diameter Position Regulator Variable Diameter Position Regulator Constant Diameter Tension Regulator Variable Diameter Tension Regulator Generic
The WebPak 3000 drive can be configured as a speed regulator or as an armature voltage regulator, depending on the value of FEEDBACK SELECT (P.200). In this chapter, the phrase speed loop refers to either configuration unless otherwise noted. The speed loop reference sets the speed that the speed loop tries to maintain. The drive processes and scales the speed reference input for use by the speed loop. The speed loop uses the selected reference value and attempts to keep the speed feedback from the motor equal to the reference value. If the feedback is less than the reference, the speed loop increases the motor speed by commanding more current to the motor. If the reference is less than the feedback, the speed loop decreases the motor speed by commanding less current to the motor. The speed loop tries to minimize the amount of error between the speed reference and the speed feedback. The speed and accuracy with which the speed loop responds to reference or motor load changes is determined by the speed loop parameters. Configuring the speed loop includes setting up the following:
Speed loop reference Speed reference ramp Speed mode select Speed feedback Speed loop regulator with gain profiling
3-1
3.1
The Speed Loop Reference

Refer to figure A.4 in Appendix A of the software manual (D2-3444) as you set up the speed loop reference. The setup of the speed reference depends on the control source selected. The control source selections are:
KEYPAD
- The drive uses the reference from the OIM.
Important: If you select KEYPAD as the control source, the drive can be used to regulate speed only.
TERMBLK
- The drive uses the reference from the Regulator board terminal strip.
SERIAL - The drive uses the reference from a serial device (for example, a PC running WebPakCS software). NETWORK
- The drive uses the reference from the network.
To select the control source: v If you are using the WebPakCS software to program the drive, you configured
the control source during the initialization process by setting CONTROL SOURCE SELECT (P.000).
v If you are using the OIM to program the drive, select the control source
using
Range: KEYPAD, TERMBLK, SERIAL, NETWORK
P.000 =
If the CONTROL SOURCE (P.000) = TERMBLK:

v
Specify the line speed signal type in LINE SPEED REF SELECT (P.103). The choices are:
ANALOG FREQUENCY IN - The frequency input is typically used to daisy-chain multiple drives.
Range: ANALOG, FREQUENCY IN
P.103 =
If LINE SPEED REF SELECT (P.103) = ANALOG:

v
Verify that an analog line speed reference is connected to terminals 19(+) and 20(-) on the Regulator board. Set LINE SPEED SIG TYPE (P.100).
Range: 0 to 10V, +/-10V, 4 to 20mA, 10 to 50mA
P.100 =
Important: Jumpers J10 and J12 must be set for the type of line speed signal selected. See the drive hardware manual (D2-3443) for instructions.
v
Set LINE SPEED GAIN ADJ (P.101) to adjust the gain for the line speed input.
Range: 0.750 to 2.250
P.101 =
3-2
Set LINE SPEED ZERO ADJ (P.102) to adjust the zero point of the line speed reference input to remove any offset from the input signal.
Range: -200 to 200 COUNTS
P.102 =
COUNTS
Set TOP LINE SPEED (P.020).
ATTENTION: Do not allow the motor to exceed the maximum safe speed of the motor or driven equipment as determined by the equipment manufacturer. Failure to observe this precaution could result in bodily injury.
Range: 0 to 5000 FPM
P.020 =
FPM
LINE SPEED (P.188) is the analog output of the line speed reference after it has been scaled by the hardware and software.
If LINE SPEED REF SELECT (P.103) = FREQUENCY IN:

v
Verify that a frequency section speed reference is connected to terminals 39 (A), 40 (A Not), and 41 (common) on the I/O Expansion board. Set FREQ IN FULL SCALE (P.424).
Range: 2.0 to 250.0 kHz
P.424 =
KHZ
Set FREQ IN ZERO (P.423).

Range: 2.0 to P.424
P.423 =
KHZ
SOURCE SELECT OUT
The selected value of the speed loop reference is displayed in SPD (P.193) in user-defined units.
If the CONTROL SOURCE (P.000) = NETWORK:

v
Refer to the appropriate network manual for instructions on setting up the network parameters.
3.1.1 Configuring Trim (Optional)

If the drive is to be configured as a speed follower section, the speed loop reference function includes a trim reference capability. Trim is based on the signal from the source selected in TRIM REFERENCE SELECT (P.108). It is summed with the speed loop reference before being acted upon by the reference ramping function. Refer to figure A.4 in the software manual (D2-3444) as you configure trim.
To configure trim: v Set TRIM REFERENCE SELECT (P.108) to specify the trim reference source. The
choices are:
REGISTER REGISTER
- The trim reference signal is based on the value set in TRIM REF (P.107).
ANALOG - The trim reference signal is based on the analog input (diameter/input range) at terminals 17(+), 18(-), and 16(10V) on the Regulator board.
3-3
1, 2, 3 - The trim reference signal is based on network input register 1, 2, or 3 if the control source (P.000) = NETWORK. (Available only if a communication option board is installed.)
NETW IN REG
Range: REGISTER, ANALOG, NETW IN REG 1, 2, 3
P.108 =
If TRIM REFERENCE SELECT (P.108) = REGISTER:

v
Set TRIM REF REGISTER (P.107).

Range: +/-100.0%
P.107 =
If TRIM REFERENCE SELECT (P.108) = ANALOG

v
If necessary, adjust the gain using DIAMETER/TAPER GAIN (P.104).

Range: 0.750 to 2.250
P.104 =
If necessary, remove any offset using DIAMETER/TAPER ZERO (P.105).

Range: -3000 to 3000
P.105 =
ANALOG TRIM REF
(P.195) displays the scaled output of the analog input.
v Set TRIM RANGE (P.109) to specify the percentage of the selected trim
reference signal that is to be used to modify the line speed reference. For example, the trim reference maximum value from any one of the three sources (REGISTER, ANALOG, or NETWORK 1, 2, 3) would be 4095 counts. At 100%, TOP LINE SPEED (P.020) is also 4095 counts. Therefore, the % adjustment of P.109 will determine how many counts are added to modify the speed reference at any line speed operating point. Note that the composite value of the trim reference and the line speed reference cannot exceed 4504 counts.
Range: 0.0 to 100.0%
P.109 =
The product of the selected trim and reference value and trim range value is displayed in DRAW PERCENTAGE OUT (P.196).
3.2
The Speed Reference Ramp

Refer to figure A.5 in Appendix A of the software manual (D2-3444) as you configure the speed reference ramp. The speed reference ramp task provides additional conditioning of the speed reference task output parameters, SPD SOURCE SELECT OUT (P.193) and DRAW PERCENTAGE OUT (P.196). Two functions define this additional conditioning: Limiting and S-CURVE ramping. Since both of these functions are impacted by the setting of TRIM MODE SELECT (P.110), this is the first step in configuring the speed ramp task.
3-4
To configure the speed reference ramp: v Set TRIM MODE SELECT (P.110). The choices are:
NO TRIM
- Used when the drive is configured as:
a stand-alone speed-regulated section a lead or master section of a process an inner speed loop as part of major outer control loop design.
- Depending on the polarity of the trim reference, adds or subtracts from the speed reference a constant value that is derived from TOP LINE SPEED (P.020).
INCREMENTAL PROPORTIONAL - Depending on the polarity of the trim reference, adds or subtracts from the speed reference a value that varies based on the speed reference value, as determined by SPD SOURCE SELECT OUT (P.193).
Range: NO TRIM, INCREMENTAL, PROPORTIONAL
P.110 =
The actual value of the signal used to trim the selected speed loop signal, after it is set by a multiplier block, is defined as TRIM OUTPUT (P.197). This is summed with SPD SOURCE SELECT OUT (P.193) to become the input to the LIMIT block.
3.2.1 The LIMIT Block

The LIMIT block limits the amplitude of the line speed reference. The input to this block is the sum of TRIM OUTPUT (P.197) and SPD SOURCE SELECT OUT (P.193). For variable diameter applications, the minimum and maximum line speed limits are determined from NORM ROLL DIAMETER (P.131) and the motor minimum and maximum limits (MINIMUM SPEED (P.003) and MAXIMUM SPEED (P.004)). Refer to figure A.5 in Appendix A of the software manual (D2-3444) as you set up the LIMIT block.
To set up the LIMIT block: v Set MINIMUM SPEED BYPASS (P.111). The choices are:
ON
- Allows the drive to operate down to zero speed.
OFF - (Default) Establishes the low end of the LIMIT block to a value determined by the section diameter.
Range: ON, OFF
P.111 =
ATTENTION: The drive can operate at and maintain zero speed when MINIMUM SPEED BYPASS (P.111) is set to ON. The user is responsible for assuring safe conditions for operating personnel by providing suitable guards, audible or visual alarms, or other devices to indicate that the drive is operating at or near zero speed. Failure to observe this precaution could result in severe bodily injury or loss of life. If this is a constant diameter application:
v
Set DIAMETER CALC ENABLE (P.826) to DISABLE.

Range: ENABLE, DISABLE
P.826 =
3-5
Leave DIAMETER REGISTER (P.874) at its default value of 1.000.

Range: 1.000 to 20.000
P.874 =
To modify the results of the LIMIT block using REVERSE DISABLE (P.015). v Set REVERSE DISABLE (P.015). The choices are:
ON
- Prevents the speed reference from going below zero (prohibits the drive from operating in the opposite direction).
OFF
- (Default) Allows the speed reference to go below zero (allows the drive to operate in the opposite direction).
Range: ON, OFF
P.015 =
If the speed reference is an analog signal, there may be an injection of a ripple on the reference input. This may cause unwanted changes at the output of the S-CURVE block. LINE SPEED HYSTERESIS (P.136) sets a minimum signal change threshold below which the input to the S-CURVE block will not change. This also smoothes the line speed reference so that the S-CURVE block calculates the reference rate that is used by inertia compensation.
v Set LINE SPEED HYSTERESIS (P.136).

Range: 0 to 10 COUNTS
P.136 =
COUNTS
3-6
ABOUT SPEED PARAMETERS It is important to understand the relationship of the following speed-defined parameters:
TOP LINE SPEED
(P.020) is the maximum speed of the drive in length per time; for example,
feet per minute.

GEAR IN SPEED (P.011) is the motor speed in RPM that results in TOP LINE SPEED (P.020). If the section is a center-driven unwind or winder (variable diameter), GEAR IN SPEED is the motor RPM that results in TOP LINE SPEED at EMPTY CORE DIAMETER (P.830). MAXIMUM SPEED
(P.004) is the maximum motor speed in RPM that can be supported by the Example 1
connected load. Typically, TOP LINE SPEED (P.020), GEAR IN SPEED (P.011), and MAXIMUM SPEED (P.004) correspond to the same operating speed. However, due to mechanical or process limits, MAXIMUM SPEED (P.004) may be less than GEAR IN SPEED (P.011). Assume the following machine specifications: Line speed = 2000 FPM Motor = 10 HP, 500/2000 RPM Empty Core = 4 inches Full Roll = 24 inches Motor is direct-coupled to roll (1:1 gear ratio) Under these drive conditions, the speed parameters would use the following settings: (P.020) = 2000 FPM (P.011) = 1910 RPM P.011 = 2000 FPM x 12 inches = 1910 RPM (4 x )inches/rev MAXIMUM SPEED (P.004) = 1910 RPM
TOP LINE SPEED GEAR IN SPEED
Example 2 Assume the following machine specifications: Line Speed = 2000 FPM Motor = 10 HP, 500/2000 RPM Empty Core = 3 inches Full Roll = 24 inches Motor is direct-coupled to roll (1:1 gear ratio). Since the 3-inch core will be required to operate at 2546 RPM when the line speed is set at 2000 FPM, it will be necessary to limit maximum line speed to 1571 FPM at the 3-inch core diameter so that the maximum motor speed of 2000 RPM is not exceeded. This is an inherent feature of the drive reference design. The maximum line speed of 2000 FPM will be attainable when the roll diameter builds up to 3.82 inches. Under these drive conditions, the speed parameters would use the following settings: (P.020) = 2000 FPM (P.004) = 2000 RPM GEAR IN SPEED (P.011) = 2546 RPM
TOP LINE SPEED MAXIMUM SPEED
ATTENTION: The drives overspeed protection is based on GEAR IN SPEED
!
(P.011). GEAR IN SPEED is typically set at or below the motors rated base speed or field weakened speed. If the application requires GEAR IN SPEED to be set above motor base speed (fixed field) or above the motors nameplate field weakened speed, the drives internal motor overspeed fault protection is not valid. In this case, the user is responsible for providing external overspeed protection, such as a motor overspeed switch. Failure to observe this precaution could result in severe bodily injury or loss of life.
3-7
3.2.2 The S-CURVE Block

The output of the LIMIT block is the input to the S-CURVE block. SPEED RAMP BYPASS (P.112) controls the output of the S-CURVE block. Refer to figure A.5 in Appendix A of the software manual (D2-3444).
To set up the S-CURVE block: v Set SPEED RAMP BYPASS (P.112). The choices are:
- Bypasses the S-CURVE block, and the output of the LIMIT block is used as the value of SPEED RAMP OUTPUT (P.199). (This value can also be read as SPEED RAMP INPUT TP (P.198)).
ON
Note that setting SPEED RAMP BYPASS to ON will negate the use of inertia compensation when INERTIA COMP SELECT (P.221) is set to CALCULATOR. To use the drives on-board programmed inertia compensation function, P.112 must be set to OFF.
OFF OUTPUT
- The output of the S-CURVE block is used as the value of SPEED RAMP (P.199). P.112 =
Range: ON, OFF
If SPEED RAMP BYPASS (P.112) = OFF:

v
Set S-CURVE ROUNDING (P.014) to specify the smoothing of the S-CURVE block output. The range is 0 to 50%. A 0% setting results in a linear ramp function. A 50% setting results in the entire ramp being smoothed 50% at the beginning and 50% at the end, which extends the ramp time.
Range: 0 to 50%
P.014 =
v Set STOP MODE SELECT (P.114). The choices are:

RAMP - RAMP STOP DECEL TIME (P.018) or DECELERATION TIME (P.002) is used. Note that if the trim mode previously selected in TRIM MODE SELECT (P.110) is PROPORTIONAL, under a ramp stop configuration the ramp time will be modified in the same way as the acceleration ramp time. COAST/DB
- If a coast stop or a dynamic braking stop is initiated, the main contactor will open immediately, and the drive will coast or dynamically brake to zero speed. - All deceleration ramps are bypassed. P.114 =
CURRENT LIMIT
Range: RAMP, COAST/DB, CURRENT LIMIT
If STOP MODE SELECT (P.114) = RAMP, then STOP DECEL SELECT (P.122) must be set to P.002 or P.018:
v
Set STOP DECEL SELECT (P.122) to specify which deceleration time will be used for a ramp stop sequence. The ramp deceleration time for stopping can be set independent of the normal running deceleration ramp. Note that if an external ramped reference is used, the deceleration rate for the internal speed ramp (S-CURVE block) should be set so that it is faster than the deceleration rate of the external speed reference ramp.
3-8
The choices for STOP DECEL SELECT (P.122) are:

DECELERATION TIME
(P.002) - The ramp stop deceleration time is controlled by P.002, which was set during Quick Start.
(P.018) - The ramp stop deceleration time is controlled by P.018. Note that the S-CURVE function is disabled if P.108 is selected.
RAMP STOP DECEL TIME
Range: P.002, P.018
P.122 =
If STOP DECEL SELECT (P.122) = P.018:

v
Set RAMP STOP DECEL TIME (P.018). P.018 =

SECONDS
Range: 0.1 to 300.0 SECONDS
v Set STOP SPEED THRESHOLD (P.113) to specify the speed below which the main
contactor will open after a ramp stop or current limit stop is asserted.
Range: 0 to MAXIMUM SPEED (RPM OR USER-DEFINED UNITS)
P.113 =
REFERENCE RATE (P.866) is the rate of change of the speed loop reference (also scaled as GEAR IN SPEED (P.011) per 1 second = 4095 counts). P.866 is used as one of the
inputs to the inertia compensation calculator function block. A LAG block modifies the S-CURVE rate signal to provide filtering to the reference rate to minimize noise that may be present on the reference signal.
v Set REF RATE LAG FREQ (P.864).

Range: 0.01 to 139.62 RAD/S
ACCELERATION TIME
P.864 =
RAD/S
(P.001), set during Quick Start, specifies the minimum time that the selected speed reference can change from zero to GEAR IN SPEED (P.011).
If NO TRIM or INCREMENTAL trim was selected in TRIM MODE SELECT (P.110), the drive uses the value in ACCELERATION TIME (P.001). If PROPORTIONAL trim was selected in P.110, the drive uses the value in ACCELERATION TIME (P.001) divided by the result of the following equation:
(1+ (DRAW PERCENTAGE OUT (P.196)) / 100
For example, if P.196 was set at 10, the acceleration time would be the value of P.001 divided by 1.1. Note that if an external ramped reference is used, the acceleration rate for the internal speed ramp (S-CURVE block) should be set so that it is faster than the acceleration rate of the external speed reference ramp.
3.3
Speed Mode Select

Configuring the speed loops mode of operation involves:
Configuring jog Selecting the outer loop
3-9
Selecting the outer loop type

Refer to figure A.6 in Appendix A of the software manual (D2-3444).
3.3.1 Configuring Jog

ATTENTION: This drive can operate at and maintain zero speed when JOG SPEED (P.012) is set to zero. A voltage-regulated drive can produce zero speed at low minimum speed values. The user is responsible for assuring safe conditions for operating personnel by providing suitable guards, audible or visual alarms, or other devices to indicate that the drive is operating at or near zero speed. Failure to observe this precaution could result in severe bodily injury or loss of life.
Two of the three parameters used to configure jog were set during Quick Start:
JOG SPEED
(P.012) specifies the speed level for jogging in either the forward or reverse direction. This value is the input to a RATELIM block. The output of the RATELIM block is defined as JOG RAMP OUTPUT (P.294). (P.013) sets a common acceleration and deceleration time.
JOG ACCEL/DECEL TIME
To configure jog: v Set JOG OFF DELAY TIME (P.121) to specify the minimum delay between
removing the jog reference to the drive and the opening of the main contactor. This delay reduces contactor wear if the drive is jogged repeatedly for a short period of time.
Range: 0 to 10 SECONDS
P.121 =
SECONDS
3.3.2 Selecting the Outer Loop To select the outer control loop: v Set OCL SELECT (P.817) to select which outer control loop will be configured.
The choices are:
NONE
- Sets the drive as a speed regulator.
TENSION, CURRENT, or POSITION - Operates with the speed loop in either a CASCADE or PARALLEL configuration as selected by OCL TYPE (P.818). Set OCL SELECT (P.817) to POSITION when OCL TYPE 3 POSN REG (P.814) is set to ENABLED.
Range: NONE, TENSION, CURRENT, POSITION
P.817 =
ATTENTION: The user must read and understand the drive sequencing description and state diagram (figure 3.3 in the software manual, D2-3444) before using the TENSION ON input. Setting OCL SELECt to any value but NONE permits the TENSION ON input to start the drive. Once the TENSION ON input is permitted to start the drive, negating the TENSION ON input while in any state other than the stall tension state will not stop the drive. Failure to observe this precaution could result in severe bodily injury or loss of life.
3-10
To select the outer control loop proportional trim operation:

The value of the outer control loop PI limits is set proportional to the absolute value of SPEED RAMP OUTPUT (P.199). This keeps the gain of the outer control loop constant at all line speed operating levels. A SCALE block is used to establish the range of the outer control loop percent control. The output of the SCALE block will be a number that will change linearly from the value of OCL PROP TRIM GAIN (P.812) to 1.0 as SPEED RAMP OUTPUT (P.199) changes from its minimum value of zero to TOP LINE SPEED (P.020). When P.812 is set at its default value of 1.0, the outer control loop PI limit will be a fixed percentage of TOP LINE SPEED (P.020); but as line speed is decreased, the limit will increase proportionately as shown in figure 3.1.
Maximum PI Limit
2 Outer Loop PI Limit 3
Speed
Top Line Speed
Curve 1 Curve 2 Curve 3
O C L P R O P TRIM G A I N O C L P R O P TRIM G A I N O C L P R O P TRIM G A I N
(P.812) = 1.0 (P.812) >0.0<1.0 (P.812) = 0.0
Figure 3.1 Outer Control Loop Proportional Trim
v Set OCL PROP TRIM GAIN (P.812). The minimum value of P.812 should be set at
0.05 so that a minimum speed loop reference is available for stall tension operation.
Range: 0 to 1.000
P.812 =
v Set OCL INVERT ENABLE (P.815) to specify the polarity of the outer control loop.
The location of a drives outer loop control zone in a process line may be upstream or downstream of the lead section; therefore, the polarity of the outer control loop needs to be set accordingly.
ENABLE: DISABLE:
The OCL signal is subtracted from the speed loop reference. The OCL signal is added to the speed loop reference. P.815 =
3-11
3.3.3 Selecting the Outer Loop Type To select the outer loop type: v Set OCL TYPE (P.818). The choices are:
CASCADE
- The outer control loop trim signal is added to the speed loop reference. The dynamics of the outer control loop and the inner speed loop are interactive in the cascade mode.
PARALLEL - The outer control loop trim signal is used as the input level for both the high and low current limits of the speed loop PI block. The speed loop operates in a limit mode, and the limited output of speed loop PI block is set by the dynamics of the outer control loop.
Certain processes and electro-mechanical systems may favor the parallel type of outer control loop operation because of its apparent simpler design. However, the cascade design, when used with dynamic gain profiling, will typically provide better overall dynamic response and stability over a greater range of machine and process characteristics.
Range: CASCADE, PARALLEL
P.818 =
If OCL TYPE (P.818) = PARALLEL, an offset to drive the speed regulation loop into limit is required.
v
Set OCL PARALLEL OFFSET (P.810). This is typically set to 10% of TOP LINE SPEED, which would infer a setting for P.810 of 409 counts.
Range: -4095 to 4095 COUNTS (4095 = TOP LINE SPEED)
P.810 =
COUNTS
3.3.4 Current Compounding

Some drives, when operating as speed regulators, may have application requirements for a softening or a drooping of speed with motor load. The current compounding function uses a scaled percentage of CML FEEDBACK (P.397), which is subtracted from the SPEED RAMP OUTPUT (P.199). Current compounding should be used only when no outer control loop has been selected.
To use current compounding: v Set CURRENT COMPOUNDING (P.209) to specify the trim that is subtracted from
the speed reference based on motor load.
Current Compounding Example Requirement: Change the motor speed by 5% when the motor is operating at 50% full load and at TOP LINE SPEED.
5% motor speed x 100 = 10% = setting of CURRENT COMPOUNDING (P.209) 50% motor load
Range: -50% to 50% OF THE MOTOR LOAD
P.209 =
CURRENT COMPOUND TP (P.293) reads the percentage of CML FEEDBACK (P.397) that is subtracted from the speed reference.
3-12
(P.295) is the composite signal configured by the various modes listed in this section. The final value of P.295 is clamped at + or 110% of TOP LINE SPEED (P.020). If REVERSE DISABLE (P.015) = ON, SPD LOOP REFERENCE (P.295) is prevented from setting a reverse reference by clamping this reference to zero.
SPD LOOP REFERENCE
3.4
Speed Loop Feedback

Refer to figure A.10 in Appendix A of the software manual (D2-3444) as you configure the speed loop feedback.
To configure the speed loop feedback: v FEEDBACK SELECT (P.200) was set during Quick Start to select the type of
feedback signal to be used for the speed/voltage loop. Since the WebPak 3000 drive standard design is a regenerative power bridge, a DC tach or a dual-channel differential-output encoder is required. ATTENTION: The incorrect configuration of FEEDBACK SELECT (P.200), ANALOG TACH GAIN ADJ (P.201), and ANALOG TACH ZERO ADJ (P.202) can cause an overspeed condition. This parameter must be configured by a qualified person who understands the significance of configuring it accurately. Failure to observe this precaution could result in bodily injury.
If FEEDBACK SELECT (P.200) = DC TACH:

v
If required, set ANALOG TACH ZERO ADJ (P.202) to remove any offset from the analog tachometer feedback signal.
Range:-200 to 200 COUNTS
P.202 =
COUNTS
If required, set ANALOG TACH GAIN ADJ (P.201) to scale the analog tachometer feedback signal.
Range: 0.750 to 1.250
P.201 =
J11 ANLG TACH VLT SCL
(P.792) displays the position in which to set the J11 hardware jumper based on the values of GEAR IN SPEED (P.011) and ANLG TACH VOLTS/1000 (P.203).
J14 ANLG TACH VLT RNG (P.793) displays the position in which to set the J14 hardware jumper based on the values of GEAR IN SPEED (P.011) and ANLG TACH VOLTS/1000 (P.203).
See the drive hardware manual (D2-3443) for information on setting the J11 and J14 jumpers
ANALOG TACH FEEDBACK
(P.291) is the digital value of the analog tachometer feedback input after all hardware and software scaling.
If FEEDBACK SELECT (P.200) = ENCODER: The drive uses the values set during Quick Start for ENCODER PPR (P.207) and GEAR IN SPEED (P.011).
ENCODER KIT (P.798) indicates whether or not the Pulse Encoder (Tachometer) kit is installed in the drive and if it has passed diagnostics. ENCODER FEEDBACK (P.292) is the digital value of the encoder after hardware and software scaling.
3-13
v Set SPD LEADLAG SELECT (P.216) to compensate for backlash in the drive-train
gears and couplings. The choices are:
LEAD/LAG
- SPD LEADLAG LOW FREQ (P.214) specifies the lag break frequency.
BYPASS - The lead/lag block is bypassed and the feedback signal is used directly by the speed loop summing junction. LAG/LEAD
- SPD LEADLAG LOW FREQ (P.214) specifies the lead break frequency. P.216 =
Range: LEAD/LAG, BYPASS, LAG/LEAD
If SPD LEADLAG SELECT (P.216) = LEAD/LAG or LAG/LEAD:

v
Set SPD LEADLAG LOW FREQ (P.214).

Range: 0.01 to 34.90 RAD/S or 0.01 to 69.81 RAD/S
P.214 =
RAD/S
Set SPD LEADLAG RATIO (P.213) to specify the ratio between the low and high break frequencies. The selection of the high and low break frequencies is dependent on the mechanical characteristics of the drive train.
Range: 2 to 20
P.213 =
3.5
Speed Loop Regulator With Gain Profiling

Refer to figure A.7 in Appendix A of the software manual (D2-3444) as you configure the speed loop regulator with gain profiling. Output parameters FIELD REFERENCE (P.590) and INSTANTANEOUS INERTIA (P.230) are inputs to the gain profiler block. They both have dynamic values that are calculated by the field shaping and inertia calculator tasks, respectively. The gain profiler calculates and outputs to the speed loop PI amplifier values for the proportional gain (KP) and the integral gain (WLD). The third gain profiler output is SPEED CROSS OVER (P.133), which is used as an input to the position and current major outer control loop gain profilers. The last gain profiler output is SPD LOOP LAG FREQ (P.215), which provides a low pass frequency filter at the output of the speed loop PI block. A positive or negative step input to the LAG block drives the output to increase or decrease its value with respect to the input. A lower lag frequency will exhibit a slower step response than a higher one.
To configure gain profiling: v Set SPEED PROFILER ENABLE (P.127). The choices are:
ENABLE - Use for all variable diameter applications. The profiler block uses equations that are based on the dynamic physical properties of connected load; therefore, a robust speed regulator that maximizes system response and stability can be expected. DISABLE
- Use for all constant diameter applications. P.127 =
3-14
If SPEED PROFILER ENABLE (P.127) = ENABLE:

v
Set SPD LOOP PI PROP GAIN (P.211). This value is determined during speed loop self-tuning.
Range: 0.10 to 128.00
P.211 =
Set SPD LOOP PI LEAD FREQ (P.212). This value is determined during speed loop self-tuning.
P.212 =
RAD/S
Set SYSTEM INERTIA (P.222). System inertia (called JBAR in the gain profiler block) is the time, in seconds, to accelerate an empty core to the motor base speed parameter, BASE SPEED (P.017), which is the speed of the DC motor when full field strength and full rated armature voltage are applied. System inertia can be determined by running self-tuning with an empty core load. Note that self-tuning will overwrite any values entered manually.
P.222 =
SECONDS
If SPEED PROFILER ENABLE (P.127) = DISABLE:

GAIN
The values calculated during self tuning are used for SPD LOOP PI PROP (P.211) and SPD LOOP PI LEAD FREQ (P.212).
The calculated values for proportional gain (KP) and integral gain (WLD) output from the profiler will remain SPD LOOP PI PROP GAIN (P.211) and SPD LOOP PI LEAD FREQ (P.212), and will use the values determined by the speed loop self-tuning test.
3.5.1 The PI Block

SPD LOOP ERROR (P.297) is the signal input to the PI amplifier and is the difference between speed reference and speed feedback. SPD LOOP REFERENCE (P.295) is converted to a rotational speed using a multiplier block before it is compared to the speed loop feedback signal.
To configure the PI block: v Set POS CURRENT LIMIT SEL (P.223). The choices are:
REGISTER
- POSITIVE CURRENT LIM (P.005) is used as the positive current limit.
PARALLEL OCL - Sets the limits to the value of OCL PARALLEL OUT (P.816) which is the vernier signal of the selected outer control loop. NETW IN REG
1, 2, 3 - Sets the limit values in network registers if a network card is installed and the control source is NETWORK (P.000 = NETWORK).
Range: REGISTER, PARALLEL OCL, NETW IN REG 1, 2, 3
P.223 =
If POS CURRENT LIMIT SEL (P.223) = REGISTER:

v
Set POSITIVE CURRENT LIM (P.005).

Range: 0 to MAXIMUM CURRENT (%FLA)
P.005 =
%FLA
3-15
v Set NEG CURRENT LIMIT SEL (P.224). The choices are:

REGISTER
- NEGATIVE CURRENT LIM (P.006) is used as the negative current limit.
PARALLEL OCL - Sets the limits to the value of OCL PARALLEL OUT (P.816) which is the vernier signal of the selected outer control loop. NETW IN REG
1, 2, 3 - Sets the limit values in network registers if a network card is installed and the control source is NETWORK (P.000 = NETWORK).
Range: REGISTER, PARALLEL OCL, NETW IN REG 1, 2, 3
P.224 =
If NEG CURRENT LIMIT SEL (P.224) = REGISTER:

v
Set NEGATIVE CURRENT LIM (P.006).

Range: 0 to P.007 or -P.007 to 0
P.006 =
%FLA
v Set NEG CUR LIM INV EN (P.226).

Note that the default setting for NEG CUR LIM INV EN (P.226) is ENABLED which restricts P.005 and P.006 to positive values. The signal at the LO input of the PI block should always be negative (-). Therefore, the setting of P.226 should be consistent with the polarity of the negative current limit. If the negative current limit is positive, then P.226 should be ENABLED. If the negative current limit is negative, then P.226 should be DISABLED.
Range: DISABLED, ENABLED
P.226 =
v Set SPD LOOP LAG BYPASS (P.217). The choices are:

ON
- The LAG block is bypassed and does not affect the speed loop forward path signal.
OFF
- The LAG block will filter the output of the speed loop PI block. The value of the filtered signal is SPD LOOP LAG OUTPUT (P.298).
Range: ON, OFF
P.217 =
If SPD LOOP LAG BYPASS (P.217) = OFF:

v
Set SPD LOOP LAG FREQ (P.215) using the following calculation:
WLG
= 1.5 X (KPS X LIMBAR X BASE SPEED/JBAR X GEAR IN SPEED) RAD/S
Where:
KPS
= SPD LOOP PI PROP GAIN (P.211) = MAXIMUM CURRENT (P.007) / 100 = BASE SPEED (P.017) = GEAR IN SPEED (P.011)
LIMBAR
BASE SPEED JBAR
= SYSTEM INERTIA (P.222)
GEAR IN SPEED
Note: The results of speed loop self-tuning should yield a value for JBAR, or it can be calculated as:
JBAR
(seconds) = Total Inertia (lb-ft2) x Motor Base Speed (RPM) 308 x Motor Full Load Torque (lb-ft)
P.215 =
RAD/S
3-16
3.5.2 The Current Memory Function

The transfer dynamics of some unwind and winder designs will require an operating mode change from the primary outer control loop regulator to an interim current loop regulator. This regulator transition is necessary when the primary loop regulator feedback device (load cell or dancer) becomes mechanically isolated at some point in the transfer sequence. The current memory function places the drive in a current regulator mode with a fixed reference. The state of the current memory command is displayed in CURRENT MEM COMMAND (P.319).
To enable the current memory function: v Set CURRENT MEMORY ENABLE (P.314) to ENABLE.
The output of the speed loop PI block, SPD LOOP OUTPUT (P.299) is captured and held when the digital input CURRENT MEMORY DIN TP (P.499) is asserted. The value for current memory will equal the last value of P.299, prior to the assertion of P.499. However, the value can be modified by CURRENT MEMORY BOOST (P.313) over a range of 75% to 150%. ATTENTION: The current memory funciton places the drive in a current regulator mode with a fixed reference. The user must ensure that the motor is properly loaded or provide external overspeed protection to avoid an unsafe speed condition. It is also recommended that an external timer limit the kength of time the drive may be held in current memory to prevent damage to the motor. Failure to observe this precaution could result in severe bodily injury or loss of life.
P.314 =
(1$%/(
To modify the current memory value in SPD LOOP OUTPUT (P.299): v Set CURRENT MEMORY BOOST (P.313).
Range: 75% to 150%
P.313 =
3-17
3-18
CHAPTER 4
Configuring the Current Minor Loop
The current minor loop (CML) regulates the amount of current flowing through the motor armature. The CML is a simple control loop composed of a reference and a feedback. Refer to figure A.9 in Appendix A of the software manual (D2-3444). The input to the PI block, known as CML ERROR (P.398), is the difference between the reference and feedback. The output of the PI block determines the level of current flowing through the motor armature. When a reference change occurs, the error becomes non-zero, causing the PI block output to change. This results in a higher or lower level of current flowing through the armature until the feedback again becomes equal to the reference. Configuring the CML consists of setting up the following:
Current minor loop reference Current minor loop regulator
4.1
The Current Minor Loop Reference

Refer to figure A.8 in Appendix A of the software manual (D2-3444) as you configure the current minor loop reference. Three signals compose the CML speed reference signal CML SPEED REFERENCE (P.391) when J15 REGULATOR TYPE (P.799) is set to SPEED/VOLTAGE:
SPD LOOP OUTPUT
(P.299), which is the output of the speed loop PI block. (P.221) (P.315)
INERTIA COMP SELECT LOSSES COMP SELECT
4-1
The composite CML reference signal, read as CML RAMP INPUT TP (P.390), passes through an amplitude limit block and a rate limit block. The amplitude limit block prevents the reference signal from becoming greater than or less than the limits selected by CML REF LIMIT SELECT (P.311). The rate limit block limits the rate of change of the selected CML reference based on the value you input for CML REF RATE LIMIT (P.303). The amplitude- and rate-limited CML reference appears as the output parameter CML REFERENCE (P.396).
To configure the current minor loop reference: v Set INERTIA COMP SELECT (P.221) to select the source of the inertia
compensation signal. The choices are:
NONE - No inertia compensation signal is added to the current minor loop reference. CALCULATOR - The drive uses the output of the inertia compensation calculator (INERTIA COMPENSATION (P.244)). NETW IN REG
1, 2, 3 - The drive uses a network value. P.221 =
Range: NONE, CALCULATOR, NETW IN REG 1, 2, 3
v Set LOSSES COMP SELECT (P.315) to select the source of the losses
compensation signal. The choices are:
NONE - No losses compensation signal is added to the current minor loop reference. CALCULATOR - The drive uses the output of the losses compensation calculator (LOSSES COMPENSATION (P.316)). NETW IN REG
1, 2, 3 - The drive uses a network value. P.315 =
Range: NONE, CALCULATOR, NETW IN REG 1, 2, 3
v Set OCL TYPE 3 POSN REG EN (P.814) to select the source of the current minor
loop reference. The choices are:
DISABLED ENABLED
- TORQUE REFERENCE (P.189) is used as the CML reference.
- OCL OUTPUT (P.848) is used as the CML reference. This enables you to configure the outer control loop as a type 3 position loop. This design bypasses the speed loop. The position loop vernier signal is connected directly to the current minor loop. This design eliminates the need to provide a motor speed feedback device. However, the trade-off is that it may be difficult or, in some system configurations, impossible to achieve stable operation. Note that OCL SELECT (P.817) must be set to POSITION to use this feature. ATTENTION: The J15 jumper must be set to the torque/current position when using the WebPak 3000 drives type 3 position loop feature (P.814 = ENABLED). Applying a drive as a direct current regulator has safety issues that must be considered. Failure to observe this precaution could result in severe bodily injury or loss of life.
!
.
P.814 =
4-2
v Set CML REF LIMIT SELECT (P.311) to select the source for the CML HI (positive)
and LO (negative) current limits. The choices are:
SPD LOOP PI LIMITS - The CML loop reference limits are the same as those used by the speed loop PI block. REGISTER
CURRENT LIM
- The CML loop limits are POSITIVE CURRENT LIM (P.005) and NEGATIVE (P.006). P.311 =
Range: SPD LOOP PI LIMITS, REGISTER
If CML REF LIMIT SELECT (P.311) = REGISTER and you want NEGATIVE CURRENT LIMIT (P.006) and POSITIVE CURRENT LIMIT (P.005) to be restricted to positive values:
v
Set NEG CUR LIM INV EN (P.226) to ENABLE. (Note that if P.006 is a negative value, set P.226 to DISABLE.)
P.226 =
v If necessary, adjust CML REF RATE LIMIT (P.303) to set the accel/decel time of
the RATELIM block. This sets the minimum time for CML REFERENCE (P.396) to change from zero to MAXIMUM CURRENT (P.007). This parameter is set by the CML self-tuning procedure. Self-tuning will overwrite values entered manually.
Range: 1 to 1000 ms
P.303 =
ms
4.1.1 Applications Requiring On-the-Fly Switching Between Current and Speed Regulation
If an application requires that the drive dynamically switch between current and speed regulation, the function must be implemented via a network logic sequence since the drive uses the hardware jumper J15 to select the regulator function. ATTENTION: When operating in a current/torque mode, there is no regulation of motor speed in the drive. Motor speed is determined by other equipment and/or operating conditions of the application and can become uncontrolled under some circumstances such as a web break. The user is responsible to assure that the system level design has appropriate detection and interlock protection to prevent the motor from reaching unsafe speeds under all operating conditions. Failure to observe this precaution could result in severe bodily injury or loss of life.
To implement dynamic switching between current and speed regulation:

Install a network kit and connect the J15 jumper to current/torque. (Refer to the WebPak 3000 hardware manual, D3-3443.)
v Set the control source to NETWORK (P.000 = NETWORK).

Range: KEYPAD, SERIAL, TERMBLK, NETWORK
P.000 =
1(7:25.
v Set CURRENT/SPEED SWITCH (P.811) to ENABLE.

P.811 =
(1$%/(
4-3
Note the following design features:
Network logic will switch between current and speed regulation by activating bit 11
of the network command word.
If a network kit is installed, the control source is NETWORK, and P.811 is set to
DISABLE,
the drive will operate according to the status of jumper J15.
If a network kit is not installed, drive operation will revert back to the status of jumper
J15, ignoring the status of P.811. NETWORK KIT (P.796) indicates if a network kit is INSTALLED or NOT INSTALLED.
Speed loop and current minor loop self-tuning can only be performed when the
control source is TERMBLK. Jumper J15 must be set to the speed/voltage position to perform speed loop self-tuning.
Section jog cannot be used when current/torque is active. The current/speed

network bit must be set to speed to permit section jog. If a jog-to-run transition occurs, the drive will run in the mode specified by the current/speed network bit. This will permit switching on the fly from a speed-regulated jog mode to a current/torque regulator.
The S-CURVE block and the speed loop PI block are conditioned to permit a smooth
transition from torque to speed by network bit switching.
In the current/torque mode, a stop command will initiate a coast/DB stop. In the speed/voltage mode, a stop command will initiate a stop as defined by STOP
MODE SELECT
(P.114).
Important: The WebPak 3000 drive does not accommodate bumpless dynamic switching of other types of outer control loop designs.
4.2
The Current Minor Loop Regulator

Refer to figure A.9 in Appendix A of the software manual (D2-3444) as you configure the current minor loop (CML) regulator. The proportional-integral (PI) controller adjusts the armature power bridge firing angle, ARMATURE DELTA (P.399), to compensate for any difference between the reference CML REFERENCE (P.396) and the feedback CML FEEDBACK (P.397).
ARMATURE BRIDGE POL (P.394) indicates which armature power bridge is active. OFF indicates the forward bridge. ON indicates the reverse bridge. CML FEEDBACK (P.397) is scaled by CML FEEDBACK GAIN ADJ (P.300), J18 ARM I FB RESISTOR (P.395), MOTOR RATED ARM AMPS (P.008), and CT TURNS RATIO (P.010). These
parameters can be validated for the connected motor by using information found in the WebPak 3000 software manual (D2-3444).
To configure the current minor loop regulator: v Set or verify CML FEEDBACK GAIN ADJ (P.300).
Range: 0.900 to 1.100
P.300 =
4-4
v Set or verify CT TURNS RATIO (P.010).

ATTENTION: The CT TURNS RATIO (P.010) parameter is used in the calculation of the burden resistor value. Do not change this parameter from its factory default value unless you are replacing the Regulator board. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
Range: FACTORY SET; SEE SOFTWARE MANUAL (D2-3444)
P.010 =
J18 ARM I FB RESISTOR (P.395) indicates the burden resistor position required to properly scale armature current feedback.
v Set INV FAULT AVOID SEL (P.312) to specify how the drive responds to an
inverting fault. Refer to the WebPak 3000 software manual (D2-3444) before setting this parameter.
Range: DISABLED, FAULT IMMEDIATELY, DELAY BEFORE FAULT
P.312 =
ATTENTION: When activated, inverting fault avoidance takes control of the current minor loop by either forcing the current reference to zero (if the drive is regenerating) or by disabling the regenerative bridge (if the drive is not regenerating). It is the users responsibility to analyze the application to determine whether or not inverting avoidance should be used. Failure to observe this precaution could result in bodily injury.
The following parameters are set by the current minor loop self-tuning function. Self-tuning will overwrite values entered manually.
v Set CML PI PROP GAIN (P.301).

Range: 0.000 to 4.000
P.301 =
v Set CML PI LEAD FREQUENCY (P.302).

Range: 10 to 500 RAD/S
P.302 =
RAD/S
4-5
4-6
CHAPTER 5
Configuring the Field Current Regulator
Configuring the field current regulator consists of setting up the following:
Field reference Field feedback Automatic field weakening (spillover control) Field regulator
The output parameter FLD CURRENT REGULATOR (P.586) indicates that the Field Current Regulator kit has been installed. Refer to figure A.12 in Appendix A of the software manual (D2-3444) as you configure the field current regulator.
5.1
The Field Reference

FIELD REFERENCE (P.590) is the value of the conditioned signal that represents the reference to the field regulator PI block as a percentage of MOTOR HOT FLD AMPS (P.510). (Note that if factory defaults are restored, or if a valid value has not been entered for P.510, the DC field voltage is fixed at 150 V for a 230 VAC line or at 300 V for a 460 VAC line.)
Field economy reduces the field voltage when the motor is at zero speed and the contactor is open. This reduces standby power consumption and prolongs the insulation life of the motor field windings. The status of the field economy function is displayed in FIELD ECONOMY ACTIVE (P.599).
5-1
If FIELD ECONOMY ACTIVE (P.599) = ON, the field economy function is enabled. The value of the reduced field voltage is a percentage of MOTOR HOT FLD AMPS (P.510) as determined by the output of a multiplier block that multiplies P.510 by FIELD ECONOMY REF (P.511). FIELD ECONOMY DELAY (P.501) will, after the motor stops, hold the field voltage at its normal operating level for the time set by P.501, before entering field economy. If FIELD ECONOMY ACTIVE = OFF, the field economy function is bypassed.
To configure the field reference: v Set FIELD ECONOMY REF (P.511).

Range: 0 to 100%
P.511 =
v Set FIELD ECONOMY DELAY (P.501).

Range: 0 to 27 MINUTES
P.501 =
MINUTES
v Set FIELD REF SELECT (P.521) to select the source of the primary field
reference.The choices are:
REGISTER
- Uses the value set by FIELD REF REGISTER (P.513).
FULL FIELD - Sets the value to the maximum MOTOR HOT FIELD AMPS (P.510). This selection is recommended if field auto weakening (spillover control) is used. FIELD SHAPING - Sets the value to the output of the field shaping function.The output of the field shaping function is based on a TABLE LOOKUP block.
Range: REGISTER, FULL FIELD, FIELD SHAPING
P.521 =
If FIELD REF SELECT (P.521) = REGISTER:

v
Set FIELD REF REGISTER (P.513).

Range: 0 to MOTOR HOT FLD AMPS (P.510)
P.513 =
If FIELD REF SELECT (P.521) = FIELD SHAPING, the output of the field shaping function is based on a TABLE LOOKUP block. Refer to figure A.11 in Appendix A of the software manual (D2-3444). The TABLE LOOKUP block is set up so that its output is indexed by the eight points set by FIELD INPUT 1-8 (P.530-P.537) whose values are based on the choice made by FIELD SHAPING TYPE P.539. The shaped field reference is generated by the values of the table set by the eight points of FIELD CURRENT 1-8 (P.522-P.529). These eight field current reference points are determined from the motor field speed curve. If this curve is not available, the field auto weaken function can be used to determine the curve.1 If factory defaults are restored or if a valid value has not yet been entered for P.510, the DC field voltage is fixed at 150 V for a 230 VAC line or at 300 V for a 460 VAC line.
To use the field auto weaken function to determine the curve, set FIELD AUTO WEAKEN (P.517) to ENABLE and run the motor from BASE SPEED (P.017) to GEAR IN SPEED (P.011). Record eight values of FIELD FEEDBACK (P.589) over this range, and use these values to set FIELD CURRENT 1-8. When finished, set P.517 to disable.
5-2
Set FIELD SHAPING TYPE (P.539). The choices are:

SPEED - The index values are tabled to follow the absolute value of motor rotational speed by multiplying the absolute value of SPD SOURCE SELECT OUT (P.193) with NORM ROLL DIAMETER (P.131). The product is limited to a high value of GEAR IN SPEED (P.011) and a low value of MOTOR SPD AT MAX FLD (P.540), which typically is the motor speed with the motor field excitation set at MOTOR HOT FLD AMPS (P.510). That is, full field and with the armature voltage set at MOTOR RATED ARM VOLTS (P.009). DIAMETER - The index values are tabled to follow the output of the diameter calculator, ROLL DIAMETER (P.865) and limited by FULL FIELD DIAMETER (P.124) and WEAKENED FIELD DIA (P.126).
Range: SPEED, DIAMETER
P.539 =
If FIELD SHAPING TYPE (P.439) = SPEED:

v
Set MOTOR SPD AT MAX FLD (P.540).

Range: 10 RPM to P.017
P.540 =
RPM
Set FULL FIELD DIAMETER (P.124).

Range: P.126 to P.125
P.124 =
INCHES
Set WEAKENED FIELD DIA (P.126).

Range: P.830 to P.124
P.126 =
INCHES
Set FIELD INPUT 1 (P.530).

Range: 0 to 5000 RPM
P.530 =
RPM

P.531 =
RPM

P.532 =
RPM

P.533 =
RPM

P.534 =
RPM

P.535 =
RPM

P.536 =
RPM
5-3

P.537 =
RPM
Set FIELD CURRENT 1 (P.522).

Range: 0.00 to MOTOR HOT FLD AMPS (P.510)
P.522 =
AMPS

P.523 =
AMPS

P.524 =
AMPS

P.525 =
AMPS

P.526 =
AMPS

P.527 =
AMPS

P.528 =
AMPS

P.529 =
AMPS
Set FIELD SHAPING LAG (P.538) to specify a lag frequency for the field shaping output.
Range: .01 to 13.96 RAD/S
P.538 =
RAD/S
v Set FIELD LOSS THRESHOLD (P.512). This is the value of motor field current that
is compared with FIELD FEEDBACK (P.589), and is set as a percentage of MOTOR HOT FLD AMPS (P.510). It is usually set for 85% of the motor nameplate field weakened current to check for field loss. The choices are: 50 to 100% of MOTOR HOT FLD AMPS (P.510) when FEEDBACK SELECT (P.200) is set to ARMATURE VOLT. 0 to 100% of MOTOR HOT FLD AMPS (P.510) when FEEDBACK SELECT (P.200) is set to DC TACH or ENCODER. ATTENTION: Setting FIELD LOSS THRESHOLD (P.512) too low can eliminate field loss protection. Set P.512 such that field loss protection will shut the drive down before it reaches unsafe speed. Failure to observe this precaution could result in severe bodily injury or loss of life.
Range: 50 to 100% of P.510 or 0 to 100% of P.510
!
.
P.512 =
5-4
5.2
The Field Feedback

FIELD FEEDBACK (P.589) is derived from field current being fed into an analog input and scaled by MOTOR HOT FLD AMPS (P.510) and FLD FEEDBACK GAIN ADJ (P.516). Refer to
figure A.12 in Appendix A of the software manual (D2-3444).
To configure field feedback: v Set FLD FEEDBACK GAIN ADJ (P.516).

Range: 0.900 to 1.100
P.516 =
5.3
Automatic Field Weakening (Spillover Control)

For a typical constant diameter application designed to operate in both a constant torque and a constant horsepower mode, automatic field weakening (spillover control) will transition motor operation from constant torque to constant horsepower. Refer to figure A.12 in Appendix A of the software manual (D2-3444).
To configure automatic field weakening: v Set FIELD AUTO WEAKEN (P.517): The choices are:
DISABLED - The HI LIM (P.587).
limit of the field regulator PI block is set to FIELD DELTA HIGH
ENABLED - A spillover field regulator is provided which uses a PI block with inputs from FLD WEAKEN THRESHOLD (P.518) and ARMATURE VOLTAGE (P.289). When P.289 exceeds P.518, the field begins to weaken and the field control loop begins regulating armature voltage.
The output of the spillover regulator PI block is the input to the HI limit of the field current regulator PI block. If armature voltage increases, the HI limit decreases which lowers the field current and, subsequently, lowers armature voltage back to its threshold value. Important: When FEEDBACK SELECT (P.200) is set to ARMATURE VOLT, P.517 is automatically set to DISABLED and cannot be changed.
P.517 =
v Set FIELD DELTA HIGH LIM (P.587). It is recommended that this parameter
remain at its default value of 130 degrees.
Range: 0 to 180 DEGREES
P.587 =
DEGREES
If FIELD AUTO WEAKEN (P.517) = ENABLED:

v
Set FIELD REF SELECT (P.521) to FULL FIELD to fix the starting point of the spillover design.
Range: REGISTER, FULL FIELD, FIELD SHAPING
P.521 =
)8// ),(/'
5-5
Refer to the WebPak 3000 software manual (D2-3444) for the descriptions of the following parameters and adjust them to tune the field control loop if necessary.
FLD WEAKEN THRESHOLD
(P.518). P.518 = %
Range: 0 to 120% of P.009

FLD WEAKEN LEAD FREQ
(P.520). P.520 = (P.519). P.519 =

RAD/S

FLD WEAKEN PROP GAIN
Range: 0.01 to 128.00
5.4
The Field Regulator

The field current regulator operates closed loop with a PI amplifier block. FIELD DELTA (P.588) is the output of the PI block and sets the firing angle of the field phase firing logic which, in turn, sets the voltage output level of the field power bridge.
To modify the lead frequency and gain of the FIELD AUTO WEAKEN PI block
(recommended for stable operation of the field current regulator PI block):
v Set FIELD PI PROP GAIN (P.514) to tune for stable operation of the spillover
regulator PI block.
Range: 0.10 to 128.00
P.514 =
v Set FIELD PI LEAD FREQ (P.515) to tune for stable operation of the spillover
regulator PI block.
Range: 0 to 282.70 RAD/S
P.515 =
RAD/S
5-6
CHAPTER 6
Configuring the Diameter Calculator
Variable Diameter Speed Regulator Variable Diameter Current Regulator Variable Diameter Position Regulator Variable Diameter Tension Regulator Generic
For variable diameter applications, typically unwinds and winders, the diameter calculator supports diameter-sensitive drive tasks such as stability, inertia compensation, motor field profiling and taper tension. This drive task uses two function blocks:
Diameter calculator update threshold Calculator

The diameter calculator output is determined by using the ratio of line speed to motor speed. As motor speed changes with roll diameter change, the calculator outputs a value proportional to this change, and this value is NORM ROLL DIAMETER (P.131). The interval between diameter updates is set by the update threshold function. The number of roll revolutions between updates should be based on the rate at which the diameter is changing. Typically, thick webs would use less revolutions between updates than thin webs. The diameter calculator uses speed loop feedback from a motor shaft feedback device, such as an encoder or analog tach. Refer to figure A.13 in Appendix A of the software manual (D2-3444).
6.1
The Diameter Calculator Update Threshold

The output of the diameter calculator update threshold block is used as a threshold input by the diameter calculator function block.
To configure the diameter calculator update threshold: v Set GEARING (P.019) to specify the ratio of motor revolutions to one driven roll
revolution.
Range: 1.00 to 50.00
P.019 =
6-1
v Set DIAMETER UPDATE RATE (P.867) to specify the number of roll revolutions
between diameter updates. This is based on web thickness. Typically, thinner webs use a higher update number.
Range: 1 to 10 REVOLUTIONS
P.867 =
REV
For variable diameter applications (unwinds or winders), GEAR IN SPEED (P.011) is the motor speed at TOP LINE SPEED (P.020) and EMPTY CORE DIAMETER (P.830):
v
Set EMPTY CORE DIAMETER (P.830).

Range: 1.00 to 30.00 INCHES
P.830 =
INCHES
6.2
The Diameter Calculator

Six of the inputs to the diameter calculator function block are calculated by the system:
The absolute value of SPEED RAMP OUTPUT (P.199). The absolute value of SPD LOOP FEEDBACK (P.296). The output of the threshold function block. A reset diameter value determined by the status of digital input DIAMETER SELECT A
59 on the I/O Expansion board) and digital input DIAMETER (terminal 60 on the I/O Expansion board) as shown in the following table. P.495 and P.496 can also be asserted over the network when a network card is installed. Status Input A (P.495)
ON OFF ON OFF TP (P.495) (terminal SELECT B TP (P.496)
Status Input B (P.496)

OFF ON ON OFF WINDER CORE DIA WINDER CORE DIA WINDER CORE DIA
Reset Diameter Value 1 (P.822) 2 (P.824) 3 (P.825)
UNWIND DIAMETER IN
(P.828) which is the analog signal of the analog input diameter/taper (terminals 16, 17, and 18 on the Regulator board) when DIAMETER/TAPER SELECT (P.870) is set to DIAMETER.
Important: Note that the analog signal will be maximum at core diameter and minimum at full roll diameter. This is consistent with the output characteristics of a sonic roll diameter detector. When a potentiometer is used to set diameter, the connections should reflect maximum volts at core and minimum volts at full roll.
DIAMETER/TAPER IN TP (P.192), which is the value in counts of the input after gain and zero have been applied. DIAMETER RESET TP (P.829) will reset the diameter calculator to a diameter based on the status of DIAMETER SELECT A TP (P.495) and DIAMETER SELECT B TP (P.496). P.829 is on when digital input 62 on the I/O Expansion board is on provided that DIAMETER RST DIN TP (P.497) is asserted.
6-2
The remaining inputs are user configurable.
To configure the diameter calculator function: v Set WINDER CORE DIA 1 (P.822).
P.822 =
INCHES
v Set WINDER CORE DIA 2 (P.824).

Range:1.00 to 120.00 INCHES
P.824 =
INCHES
v Set WINDER CORE DIA 3 (P.825).

P.825 =
INCHES
v Set EMPTY CORE DIAMETER (P.830).

P.830 =
INCHES
v Set FULL ROLL DIAMETER (P.125).

Range: P.830 to 120.00 INCHES
P.125 =
INCHES
v Set DIAMETER ACCEL RATE (P.823). DIAMETER ACCEL RATE (P.823) sets the
maximum rate of change to ramp the diameter calculator output for a winder application from EMPTY CORE DIAMETER (P.830) to FULL ROLL DIAMETER (P.125).
Range: 0.000 to 1.000 INCHES/SECOND
P.823 =
IN/SEC
v Set DIAMETER DECEL RATE (P.827). DIAMETER DECEL RATE (P.827) sets the rate
of change to ramp the diameter calculator output from FULL ROLL DIAMETER (P.125) to EMPTY CORE DIAMETER (P.830) for an unwind application.
Range: 0.000 to 1.000 INCHES/SECOND
P.827 =
IN/SEC
v Set DIAMETER CALC ENABLE (P.826) to ENABLE to activate the diameter

calculator function.
P.826 =
When P.826 is set to DISABLE, the calculated value of NORM ROLL DIAMETER (P.131) reverts to a value determined by the parameter DIAMETER REGISTER (P.874). This supports two functions:
When the WebPak 3000 internal diameter calculator is used, the diameter register
can be used to validate the setup of the diameter calculator (see section 6.2.1).
When a network card is installed, the user has the option of providing an external
diameter calculator and use the diameter register as the diameter input over the network. The diameter calculator has three outputs:
ROLL DIAMETER (P.865) is a read-only parameter that is the value of the calculated roll diameter in inches. DIAMETER ANALOG
(P.821) is the analog output of the diameter calculator scaled from 0 to 4095. At empty core, the parameter value is 0. At full roll diameter, it is 4095. 6-3
NORM ROLL DIAMETER (P.131) is the calculated roll diameter normalized to 1.000 at EMPTY CORE DIAMETER (P.830). A limit block and a rate block condition the final value of NORM ROLL DIAMETER (P.131), which is used as an input parameter in other drive
tasks.
6.2.1 Validating the Setup of the Diameter Calculator To validate the setup and operation of the diameter calculator without an
actual buildup of a variable diameter roll:
v Set DIAMETER CALC ENABLE (P.826) to DISABLE.

This will activate the use of DIAMETER REGISTER (P.874) as an alternative input to the CONVERT TO ROTATIONAL SPEED multiplier block located in the speed regulator block diagram. With the drive running at a speed set by SPD LOOP REFERENCE (P.295), and with DIAMETER REGISTER (P.874) set for various simulated diameters from core to a maximum of 20 inches, the diameter calculator will respond by changing the value of DIAMETER CALC OUTPUT (P.132).
P.826 =
',6$%/(
v Set DIAMETER REGISTER (P.874).

Range: 1.000 to 20.000
P.874 =
INCHES
Note that P.874 is a volatile parameter that will reset to its default value at power up.
6-4
CHAPTER 7
Configuring Inertia Compensation
Variable Diameter Speed Regulator Variable Diameter Current Regulator Variable Diameter Position Regulator Variable Diameter Tension Regulator Generic
Inertia compensation provides the change in motor torque required during acceleration and deceleration to minimize transient error of the controlled process variable. The inertia compensation drive task uses two function blocks:
Instantaneous system inertia Inertia-to-current scaling

Refer to figure A.14 in Appendix A of the software manual (D2-3444).
7.1
Instantaneous System Inertia

The instantaneous system inertia function block calculates and outputs the parameter INSTANTANEOUS INERTIA (P.230). One of the inputs to the function block, NORM ROLL DIAMETER (P.131), is the output of the diameter calculator. The remaining inputs are user-configurable.
To configure the instantaneous system inertia function block: v Set BUILDUP CONSTANT (P.871), which is a per-normal value of product density,
using the following calculation:
N
= BUILDUP CONSTANT = (JBARI/JBAR)-1 /(DBARi4-1)WDBARl
Where:
JBARI = time to accelerate a roll, whose diameter I can be anywhere between core and full roll, to base speed with full shunt field excitation. Note that speed loop self-tuning can be used to determine JBARI; however, once the value is extracted, the speed loop self-tuning should be set to a final value for JBAR, which is identified as SYSTEM INERTIA (P.222).
7-1
JBAR = time to accelerate an empty core to base speed with full shunt field excitation. The results of speed loop self tuning should yield a value for JBAR in SYSTEM INERTIA (P.222) or it can be calculated as:
JBAR
(seconds) = Total Inertia (lb-ft2) X Motor Base Speed (RPM) 308 X Motor Full Load Torque (lb-ft)
DI
= the diameter of the roll used to calculate JBARI = empty core diameter = normalized instantaneous diameter = DI/ Dec
DEC
DBARI WI =
width of product on roll when JBARI is measured = maximum product width = normalized product width = WI /WMAX P.871 =
WMAX
WDBARI
Range: 0.000 to 1.000
v Set WIDTH/BUILDUP FACTOR (P.872), which is configured as a ratio of maximum

material width. The parameter is normalized so that maximum width = 1.000. P.872 can be arbitrarily set to provide additional accuracy for BUILDUP CONSTANT (P.871). For example: If the buildup constant resulted in a value of 0.00154, change the buildup constant to 0.154 and assume a value of 0.01 for P.872. Then:
0.01 x 0.154 = 0.00154 (the desired value of P.871) Range: 0.001 to 1.000
P.872 =
7.2
Inertia-to-Current Scaling
The output of the inertia-to-current scaling function block is multiplied by NORM FIELD REF (P.130). This sets the motor armature current required to accelerate the calculated inertia at the desired rate, and is defined as output parameter INERTIA COMPENSATION (P.244). Refer to figure A.15 in Appendix A of the software manual (D2-3444). Three of the inputs to the inertia-to-current scaling function block are calculated by the system:
INSTANTANEOUS INERTIA (P.230) which is the output of the instantaneous system inertia function block (refer to figure A.14 in Appendix A of the software manual, D2-3444).
The output of a multiply block which uses inputs from BASE SPEED (P.017) and NORM
ROLL DIAMETER
(P.131) to calibrate to rotational speed.
REFERENCE RATE
(P.866), which is the line speed rate of change. The maximum value is 4095 when TOP LINE SPEED (P.020) is reached in 1 second.
The remaining inputs are user-configurable.
To set up the inertia-to-current scaling block: v Set SYSTEM INERTIA (P.222), which is the value of JBAR as defined in section
7.1.
P.222 =
SECONDS
7-2
v Set INERTIA GAIN ACCEL (P.245). Typically, this is left at its default value of 1 but
may need to be adjusted if inertia is not equal in both directions.
Range: 0.10 to 10.00
P.245 =
v Set INERTIA GAIN DECEL (P.229). Typically, this is left at its default value of 1 but
may need to be adjusted if inertia is not equal in both directions.
Range: 0.10 to 10.00
INERTIA GAIN ACCEL
P.229 =
(P.245) and INERTIA GAIN DECEL (P.229) support the setting of separate levels of inertia compensation for acceleration and deceleration. Typically, the level of deceleration compensation is less than the level of acceleration compensation because the friction load components assist the stopping torque profile.
7-3
7-4
CHAPTER 8
Configuring Losses Compensation
Constant Diameter Speed Regulator Variable Diameter Speed Regulator Constant Diameter Current Regulator Variable Diameter Current Regulator Variable Diameter Position Regulator Constant Diameter Tension Regulator Variable Diameter Tension Regulator Generic
When a current regulator is used to control tension or to support load share profiling, its performance will be enhanced by the application of friction and windage loss compensation. These losses vary with line speed/motor speed; therefore, FRICTION LOSS (P.123) and WINDAGE LOSS (P.243), which are set based on machine dynamics such as bearing loads and gearbox loads, will be modified as a function of speed. Line speed is normalized by applying SPD SOURCE SELECT OUT (P.193) and TOP LINE SPEED (P.020) to a multiplier block. The block output is multiplied by NORM ROLL DIA (P.131) to convert it to a rotational speed. The speed-modified values of P.123 and P.243 are scaled, summed and set proportional to motor field amps based on the value of NORM FIELD REF (P.130). This composite signal is identified as LOSSES COMPENSATION (P.316). Refer to figure A.15 in Appendix A of the software manual (D2-3444) as you configure losses compensation.
To configure the losses compensation function: v Set FRICTION LOSS (P.123).

Range: 0.0 to 50.0%
P.123 =
v Set WINDAGE LOSS (P.243).

Range: 0.0 to 50.0%
P.243 =
To calibrate the losses compensation function: v Tune the speed loop with its connected load. If the load is variable diameter,
use empty core diameter.
Configuring Losses Compensation
8-1
v Run the drive as a speed regulator long enough to stabilize the mechanical
characteristics of the load (bearings, couplings, etc.).
v Set the speed reference to 10% of TOP LINE SPEED (P.020). v Run the drive and adjust FRICTION LOSS (P.123) until the speed loop PI output
SPD LOOP OUTPUT
(P.299) is zero. P.123 =

%
Range: 0.0 to 50.0%
v Set the speed reference to 100% of TOP LINE SPEED (P.020). v Run the drive and adjust WINDAGE LOSS (P.243) until SPD LOOP OUTPUT (P.299)
is zero.
Range: 0.0 to 50.0%
P.243 =
8-2
CHAPTER 9
Configuring the Outer Control Loop Reference
Constant Diameter Current Regulator (Section 9.1) Variable Diameter Current Regulator (Section 9.1) Constant Diameter Position Regulator Variable Diameter Position Regulator Constant Diameter Tension Regulator (Section 9.1) Variable Diameter Tension Regulator (Section 9.1) Generic
The outer control loop (OCL) is typically used to provide dancer position or tension control in a web processing system. Configuring the outer control loop reference includes setting up the following:
Tension setpoint Dancer loading

Refer to figure A.17 in Appendix A of the software manual (D2-3444) as you configure the outer control loop reference.
9.1
The Tension Setpoint

To configure the tension setpoint when OCL SELECT (P.817) is set to CURRENT
or TENSION:
v Set TENSION SETPOINT SEL (P.855) to select the source of the tension
reference. The choices are:
REGISTER - Provides a tension TENSION SETPOINT (P.854).
reference based on the register value of
ANALOG - The tension reference is developed by the analog input signal at terminals 50 and 51 on the Regulator board and is scaled by parameters TENSION SETPT SIG TYPE (P.413), TENSION SETPOINT ZERO (P.414), and TENSION SETPOINT GAIN (P.415).
Range: REGISTER, ANALOG
P.855 =
9-1
If TENSION SETPOINT SEL (P.855) = REGISTER:

v
Set TENSION SETPOINT (P.854).

Range: 0 to 4095 COUNTS (4095 COUNTS = RATED TENSION)
P.854 =
COUNTS
If TENSION SETPOINT SEL (P.855) = ANALOG:

v
Set TENSION SETPT SIG TYPE (P.413).

Range: 0 to 10 V, +/-10 V, 4 to 20 mA, 10 to 50 mA
P.413 =
Set TENSION SETPOINT ZERO (P.414).

P.414 =
COUNTS
Set TENSION SETPOINT GAIN (P.415).

Range: 0.750 to 2.250
P.415 =
TENSION SETPOINT IN
(P.492) is the digital value of the analog reference.
9.1.1 Stall Tension Mode

Stall tension can be configured as a percentage of the tension setpoint or as a fixed value independent of the tension setpoint. For example, if stall tension is set at 25% of the tension setpoint, the value of the stall tension reference would be 1024 counts when the tension setpoint is at its maximum count value of 4095. Setting the stall tension at a fixed value of 1024 counts will produce the same level of stall tension; however, the value will not change as the tension setpoint is changed.
To operate the drive in stall tension mode:

The tension on input (terminal 63 on the I/O Expansion board) must be asserted (input status is displayed in TENSION ON DIN TP (P.498)). The section run input must not be asserted.
v Set STALL TENSION PERCENT (P.135) to set the stall tension reference as a
percentage of the tension setpoint as established in section 9.1.
Range: 0.0 to 100.0%
P.135 =
If STALL TENSION PERCENT (P.135) = 0, the stall tension reference is the value of STALL TENSION FIX (P.134), which is an incremental reference adjustable from zero to maximum tension.
v
Set STALL TENSION FIX (P.134). Note that P.134 should be used only when P.135 is set to zero, and conversely, P.135 should be used only when P.134 is set to zero.
Range: 0 to 4095 COUNTS (4095 COUNTS = RATED TENSION)
P.134 =
COUNTS
9-2
WebPak 3000 DC Drive Application Workbook, Verson 1.1
9.1.2 The Taper Function To implement a taper function for winder tension profiling with roll buildup:
The section run input and the tension on input must be asserted.
v Set TAPER ENABLE (P.858) to ENABLE. This will modify the tension reference
based on the dynamic value of TAPER PERCENT (P.859) which is the product of (P.862) and TAPER TYPE (P.863). (See section 9.1.3, Taper Type.)
TAPER SET SELECT
P.858 =
(1$%/(
v Set TAPER SET SELECT (P.862) to configure the source of the value used to
calculate the percent reduction of the tension reference from core to full roll winder diameters. The choices are:
REGISTER REGISTER
- Provides a taper percentage based on the value of TAPER SET (P.861).
ANALOG - Provides a taper percentage based on the value of the dual function diameter/taper range analog input signal at terminals 16, 17, and 18 on the Regulator board.
P.862 =
If TAPER SET SELECT (P.862) = REGISTER:

v
Set TAPER SET REGISTER (P.861).

Range: 0.0 to 100.0%
P.861 =
If TAPER SET SELECT (P.862) = ANALOG:

v
Set DIAMETER/TAPER SELECT (P.870) to TAPER RANGE to configure the analog input function.
Range: DIAMETER, TAPER RANGE
P.870 =
7$3(5 5$1*(
Set DIAMETER/TAPER ZERO (P.105) to adjust the zero point of the diameter/taper range input (terminals 16, 17, and 18 on the Regulator board).
Range: -3000 to 3000
P.105 =
Set DIAMETER/TAPER GAIN (P.104) to adjust the gain for the diameter/taper range input.
Range: 0.750 to 2.250
P.104 =
DIAMETER/TAPER IN TP
(P.192) is the digital value of the analog input.
9.1.3 The Taper Type To configure the taper type: v Set TAPER TYPE (P.863) to select the diameter-sensitive curve that the taper
signal will follow. The choices are:
LINEAR
- Provides a linear change in tension, decreasing from core to full roll as determined by the output of the diameter calculator NORM ROLL DIAMETER (P.131). 9-3
The linear function is based on the equation:

Taper Percent = (Instantaneous Roll Dia. Empty Core Dia.) / (Full Roll Dia. Empty Core Dia.) HYPERBOLIC - Provides a taper profile decreasing from core to full roll based on the equation: Taper Percent = (1- Empty Core Dia. / Instantaneous Roll Dia.) / (1 Empty Core Dia. / Full Roll Dia.) TAPER REGISTER - Provides the capability to generate the taper curve external to the WebPak 3000 drive and input the curve over the network interface.
Range: LINEAR, HYPERBOLIC, TAPER REGISTER

TENSION DEMAND
P.863 =
(P.844) is the composite outer control loop reference as modified by the taper function.
9.2
Dancer Loading
When the outer control loop is configured for position control, the pneumatic loading of the dancer can be electrically programmed by a voltage/current-to-pneumatic transducer. See Appendix A in this manual for more information.
DANCER LOADING
(P.820) is the rate-limited and scaled value of TENSION DEMAND
(P.844).
To configure dancer loading: v Set DANCER ACCEL TIME (P.873) to specify the minimum time in which the
MAX DANCER LOAD
dancer loading output (P.820) can change from MIN DANCER LOAD (P.832) to (P.831).
P.873 =
SECONDS
v Set DANCER DECEL TIME (P.819) to specify the maximum time in which the
MIN DANCER LOAD
dancer loading output (P.820) can change from MAX DANCER LOAD (P.831) to (P.832).
P.819 =
SECONDS
v Set MAX DANCER LOAD (P.831) and MIN DANCER LOAD (P.832) to specify the
operating range of the dancer consistent with maximum and minimum tension and with the electro-pneumatic characteristics of the transducer. Note that MAX DANCER LOAD (P.831) must be greater than MIN DANCER LOAD (P.832).
Range: -4095 to 4095 COUNTS Range: -4095 to 4095 COUNTS
P.831 = P.832 =
COUNTS COUNTS
v Set ANLG OUT 3 SELECT (P.418) to DANCER LOADING (P.820).

Range: SEE SOFTWARE MANUAL (D2-3444)
P.418 =
'$1&(5 /2$',1*
9-4
v Set ANLG OUT 3 SIG TYPE (P.419) to 0 to 10 volts or 4 to 20 mA, depending on

the type of input signal the dancer transducer requires.
Range: 0 to 10 V, +/-10V, 4 to 20 mA, 10 to 50 mA
P.419 =
v Set ANLG OUT 3 GAIN ADJ (P.420) to specify the maximum value of the analog output when the dancer loading input is at its maximum.
Range: .500 to 1.300
P.420 =
DANCER LOADING SETUP EXAMPLE Assumptions:
When TENSION SETPOINT (P.854) is set to MAXIMUM, TENSION DEMAND (P.844) is at

4095 counts.
When TENSION SETPOINT (P.854) is set to MINIMUM, TENSION DEMAND (P.844) is at 0

counts.
The pneumatic transducer uses a 4 to 20 mA input, zero loading (tension) is

equivalent to 4 mA, and maximum loading (tension) is equivalent to 20 mA. Under these conditions:
Set MAX DANCER LOAD (P.831) to 4095 counts, where 4095 equals maximum web
tension.
Set MIN DANCER LOAD (P.832) to 0 counts, where 0 counts equals zero web
tension at 4 mA.
9-5
9-6
CHAPTER 10
Configuring the Current Major Outer Control Loop
Constant Diameter Current Regulator Variable Diameter Current Regulator Generic
The current major outer control loop uses the same RATELIM and PI control blocks as the tension outer control loop. The current major outer control loop includes the following sections:
Gain profiler Tension-to-current scaling Tension PI input Tension PI limits Tension PI output To select the current major outer control loop (OCL): v Set OCL SELECT (P.817) to CURRENT.
P.817 =
&855(17
10.1 Gain Profiler for the Current Major Outer Control Loop
The profiler block uses equations that are based on the dynamic physical properties of the connected load to maximize system response and stability. Refer to figure A.19 in Appendix A of the software manual (D2-3444). Four inputs to the profiler block are calculated internally:
NORM FIELD REF
(P.130) is the output of the field current regulator task. (P.131) is the output of the diameter calculator task.
NORM ROLL DIAMETER
INSTANTANEOUS INERTIA
(P.230) is the calculated value of the dynamic load inertia as provided by the inertia compensation task.
10-1
SPEED CROSS OVER (P.133), which is the bandwidth of the speed loop. This parameter is one of the outputs calculated by the speed loop gain profiler block.
The remaining inputs are user configurable.
To configure the gain profiler block: v Set TEN PROFILER ENABLE (P.878). The choices are:
ENABLE
- The value of TEN PI KP OUT (P.879) is the output of the gain profiler block. (TEN PI KP OUT (P.879) is the value of the proportional gain applied to the current major loop regulator PI block.) Set P.878 to ENABLE for all variable diameter applications. - The value of TEN PI KP OUT (P.879) is TEN PI PROP GAIN (P.841). P.878 =
DISABLE
v Set OCL TYPE (P.818) to CASCADE. (Setting P.818 to PARALLEL is not

recommended for most variable diameter applications.)
P.818 =
&$6&$'(
v Set TEN PI PROP GAIN (P.841) using the following calculation:

P.841 = LIMBAR / (2 X JBAR X FBAR)
where:
LIMBAR JBAR FBAR
= MAXIMUM CURRENT (P.007) / 100
= SYSTEM INERTIA (P.222) = GEAR IN SPEED (P.011) / BASE SPEED (P.017)
For a variable diameter application, the results of speed loop self-tuning with a core diameter connected load should yield a value for JBAR, or it can be calculated as:
JBAR (seconds) = (Total Inertia (lb-ft2) X Motor Base Speed (RPM)) / (308 X Motor Full Load Torque (lb-ft)) Total Inertia = Motor Inertia + (Core Inertia / Gear Ratio2)
Note that self-tuning will overwrite any manual entry for JBAR.
Range: 0.001 to 32.767
P.841 =
10.2 Tension-to-Current Scaling

TEN TO CURRENT OUT
(P.876) is the calculated output of the tension-to-current scaling block, which correlates rated tension in engineering units to motor current. Refer to figure A.18 in Appendix A of the software manual (D2-3444). P.876 modifies the value of the setpoint TENSION DEMAND (P.844).
Rated Tension (lb) = Motor HP x 33000 / Line Speed in FPM
However, the relationship between rated tension and motor full load current is impacted by motor design and machine design characteristics. Current regulated applications, especially variable diameter applications, that use a motor with both armature and field control require proper armature current scaling to maximize drive control.
10-2
Three of the inputs to the tension-to-current scaling block are calculated by the system:
NORM FIELD REF
(P.130) is the normalized field reference input to the field shaping (P.131) is the normalized roll diameter output of the diameter
task.
NORM ROLL DIAMETER
calculator table.
Normalized full roll diameter, which is the calculated value of roll buildup.
The remaining input is user configurable:
v Set MAXIMUM CURRENT (P.007) to specify the value of the drive current limit
setting in % of motor full load amps. This parameter was set during Quick Start.
Range: 25 to 200%FLA
P.007 =
%FLA
10.3 The Tension PI Input

The reference to the tension PI block is the rate-limited value of TENSION DEMAND (P.844). The output of this block is TEN RAMP OUTPUT (P.842). Refer to figure A.19 in Appendix A of the software manual (D2-3444). The PI block feedback is the value of SPD LOOP OUTPUT (P.299), which is the reference to the current minor loop; therefore, it is directly proportional to motor current. The PI block proportional gain is set by the value of TEN PI KP OUT (P.879) as described in section 10.1.
TEN LOOP ERROR TEN PI LEAD FREQ
(P.834) reads the difference between P.842 and P.299. (P.840) is the PI block integral gain.
To configure the tension PI input: v Set TEN RAMP TIME (P.833) to set the reference rate of change.
P.833 =
SECONDS
v Set TEN PI LEAD FREQ (P.840) initially to 40 rad/s.

P.840 =
5$'6
10.4 The Tension PI Output

The output of the PI block is TENSION VERNIER (P.856), which is used as a trim signal on the speed loop. Refer to figure A.19 in Appendix A of the software manual (D2-3444). The amount of speed loop trim is set by the HI and LO limits of the PI block, which would nominally be configured at 10%. However, product characteristics, such as modulus of elasticity, can require more or less than 10% trim.
10-3
Note that TENSION VERNIER (P.856) will be a proportional or incremental trim of line speed dependent on the configuration of OCL PROP TRIM SELECT (P.813). Refer to section 3.3 and figure 3.1.
To set the PI block HI and LO limits: v Set TENSION PI LIMIT (P.853). For example, if 10% tension vernier is to be used,
set the PI block HI and LO limits to 409 counts. The output of the tension PI block provides a vernier signal that is used to trim the speed loop reference when OCL TYPE (P.818) is set to CASCADE and to trim the speed loop PI limits when OCL TYPE (P.818) is set to PARALLEL. In cascade, 4095 counts equals top line speed. In parallel, 4095 counts equals maximum current.
P.853 =
COUNTS
If the outer control loop is configured as a current regulator

(P.817 = CURRENT):
v Set TEN LEADLAG SELECT (P.837) to BYPASS.

P.837 =
10.5 The Slack Take-Up Function

The slack take-up function initiates a smooth removal of loose web, when drive tension is on, by limiting the amount of motor torque applied until the slack is removed. When slack take-up is released, the drive operates at the tension set by TEN RAMP OUTPUT (P.842). Refer to figure A.19 in Appendix A of the software manual (D2-3444).
To use the slack take-up function: v Set SLACK TENSION PI LIM (P.318).
Range: 0.0 to 100.0%
P.318 =
v Assert the slack take-up digital input (terminal 12 on the Regulator board).
(SLACK TAKE UP DIN TP (P.494) should be ON.) The drive uses the value of SLACK TENSION PI LIM (P.318), which is a percentage of the running limit value as set by TENSION PI LIMIT (P.853).
To turn off the slack take-up function: v De-assert the slack take-up digital input (terminal 12 on the Regulator board).
(SLACK TAKE UP DIN TP (P.494) should be OFF.)
10-4
10.6 Validating the Settings of TEN PI PROP GAIN (P.841) and TEN PI LEAD FREQ (P.840)
This section describes how to verify the dynamic performance of the drive with web in the machine. Important: The parameters listed in the procedure below are adjusted specifically for this procedure and then are reset to their previous values. Use the blanks to record the values of the parameters before the validation procedure is performed.
To validate the settings of the PI proportional gain (P.841) and PI lead

frequency (P.840):
v Set the gain profiler TEN PROFILER ENABLE (P.878) to DISABLE.

P.878 =
v Set OCL TYPE (P.818) to CASCADE.

P.818 =
v Set OCL SELECT (P.817) to CURRENT.
ATTENTION: The user must read and understand the drive sequencing description and state diagram (figure 3.3 in the WebPak 3000 software manual, D2-3444) before using the TENSION ON input. Setting OCL SELECT (P.817) to any option but NONE permits the TENSION ON input to start the drive. Once the TENSION ON input is permitted to start the drive, negating the TENSION ON input while in any state other than the stall tension state will not stop the drive. Failure to observe this precaution could result in severe bodily injury or loss of life.
P.817 =
v Verify that TEN LEADLAG SELECT (P.837) is set to BYPASS.

P.837 =
v Set TEN RAMP TIME (P.833) to the minimum value (0.1 seconds).
P.833 =
v Set the speed reference at 20% of maximum. v With the load connected to the motor (core, if variable diameter), start the
drive with the section run input. The TENSION ON digital input (terminal 63 on the I/O Expansion board) must be de-asserted. This will run the drive as a speed regulator.
v Set TENSION SETPOINT SEL (P.855) to REGISTER and set the register value at
200 (approximately 5% of maximum).
P.855 =
10-5
ATTENTION: Depending on machine losses, the 5% current step required in the next step may accelerate the motor above 20% line speed. The user must be ready to shut the drive down in case of overspeed. Failure to observe this precaution could result in severe bodily injury or loss of life.
v Assert the TENSION ON digital input to step the current reference 5%. v Set ANLG OUT 1 SELECT (P.404) to CML FEEDBACK, and connect the analog
output signal to a oscilloscope or strip chart recorder.
Range: SEE SOFTWARE MANUAL (D2-3444)
P.404 =
v Verify that a 5% step in the current reference will result in a rise time to peak
of 150 ms.
v If necessary, tune TEN PI PROP GAIN (P.841) for the desired 150 ms rise time. v Reset all parameters except P.841 to their previous values as recorded in the
blanks provided.
10-6
CHAPTER 11
Configuring the Position Outer Loop

The position outer control loop includes:
Constant Diameter Position Regulator Variable Diameter Position Regulator Generic
Position gain profiler Position PI input Position PI output Type 3 position regulator To select the position outer loop: v Set OCL SELECT (P.817) to POSITION.
P.817 =
326,7,21
Refer to figure A.16 in Appendix A of the software manual (D2-3444) as you configure the position outer loop.
11.1 The Position Gain Profiler

The position gain profiler block uses equations that are based on the dynamic physical properties of the connected load to maximize system response and stability. Gain profiling should not be used when a type 3 position loop (no speed loop) is selected (OCL TYPE 3 POSN REG EN (P.814) is set to ENABLED; see section 11.4). The position gain profiler block has six inputs. SPEED CROSS OVER (P.133) is calculated by the speed loop gain profiler block (see section 3.5). The remaining five inputs are user-configurable. Variable Diameter Applications
To configure the gain profiler block inputs for variable diameter

applications:
v Set POS PROFILER ENABLE (P.253) to ENABLE.

Range: DISABLE, ENABLE
P.253 =
(1$%/(
11-1
v Set STORAGE (P.857) to equal the amount of material in feet that can be stored
in the dancer over which the position feedback varies from 0 to maximum.
Range: 0.0 to 10.0 FEET
P.857 =
FEET
v Set TOP LINE SPEED (P.020) to specify the maximum machine speed in feet per
STORAGE
minute. Note that the units of length must be the same as the units used for (P.857).
Range: 0 to 5000 FPM
P.020 =
FPM
v Set POSITION CROSS OVER (P.239) to specify the crossover frequency of the
position loop. This should be set to 5 radians/second. Any higher setting should be tested so that the proportional gain of the position loop (KP) does not exceed 60. ATTENTION: If POSITION CROSS OVER (P.239) is set to a value higher than 5 radians/second, instability could occur. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
P.239 =
RAD/S
If P.239 > 5 radians/second:

v
See the formula and example at the end of section 11.1.
v Set POSITION ZETA (P.242) to 1.0. This is the position loop damping coefficient.
Range: 0.10 to 10.00
P.242 =


P.818 =
&$6&$'(
The position gain profiling block outputs the calculated values of four parameters:
POS PI KP OUT
(P.248) - the position loop PI block proportional gain. (P.249) - the position loop PI block lead frequency. (P.246) - the low frequency setting of the position feedback LEAD/LAG
POS PI WLD OUT POS LL WLO OUT
block.
POS LL RATIO OUT (P.247) - the ratio of the lag-to-lead frequencies of the position feedback LEAD/LAG block.
Constant Diameter Applications For constant diameter applications, the gain profiler is bypassed.
To configure the drive for constant diameter applications: v Set POS PROFILER ENABLE (P.253) to DISABLE.
Range: DISABLE, ENABLE
P.253 =
',6$%/(
11-2
v Set POS PI PROP GAIN (P.236) using the same test formula as for KP as shown
at the end of this section. P.236 becomes the value for P.248.
Range: 0.10 to 128.00
P.236 =
v Set POS PI LEAD FREQ (P.234) to 0.2 radians/seconds. P.234 becomes the
value for P.249.
P.234 =
5$'6
v Set POS LEADLAG LOW FREQ (P.231) to the same value as SPEED CROSS OVER
(P.133). P.231 becomes the value for P.246.
P.231 =
RAD/S
v Set POS LEADLAG RATIO (P.232) to 7.5. P.232 becomes the value for P.247.
Range: 2 to 20
P.232 =

v If required, tune the position loop performance by increasing POS PI PROP GAIN
(P.236). However, since raising the value of P.236 also increases POSITION CROSS OVER (P.239), the value of POS PI LEAD FREQ (P.234) may also need to be increased.
Range: 0.10 to 128.00
P.236 =
v Set POS LEADLAG BYPASS (P.255). The use of the lead/lag function for the
position feedback is recommended for applications with or without position gain profiling. Bypass of this function can be accomplished using POS LEADLAG BYPASS (P.255).
Range: ON, OFF
P.255 =
Testing the Value of Position Cross Over (P.239) Use the following formula if the value of P.239 exceeds 5 radians/second.
KP = (PCO x S) / (LS x (PV% / 100))
Where:
= POSITION CROSS OVER (P.239) KP = POS PI PROP GAIN (P.236) PV% = POS VERNIER PERCENT (P.238) S = STORAGE (P.857) LS = TOP LINE SPEED (P.020)
PCO
Example: If POSITION CROSS OVER (P.239) is nominally set to 5.0 radians/seconds:
PV% S
(P.238) is set to 10 = 5 feet LS = 20 feet/second
Then: KP = (5 x 5) / (20 x (10 / 100)) = 12.5 In this example, since KP did not exceed 60, PCO could be increased to raise the value of KP to maximize position loop performance.
11-3
11.2 The Position PI Input

The input to the position PI block is the rate-limited value of POSITION REFERENCE (P.240). The input to the RATELIM block is P.240, the output is POS RAMP OUTPUT (P.237).
To configure the position PI block input: v Set POSITION REFERENCE (P.240) to specify the dancer position reference in
counts. The value in P.240 defines the dancer loop position during steady state operation, which would normally be the midpoint of the dancer storage (typically 2048 counts).
Range: -4095 to 4095 COUNTS (4095 = FREE STORAGE)
P.240 =
COUNTS
v Set POS RAMP TIME (P.233) to specify the reference rate of change to minimize
position loop transients during the adjustment of P.240.
P.233 =
SECONDS
v The analog position feedback signal must be connected to terminals 52(+)

and 53(-) on the I/O Expansion board. The standard type of PI block feedback is an analog signal proportional to dancer position; therefore, it is assumed that the dancer position transducer is either a potentiometer or some other type of linear or rotary transducer whose output has been converted to an analog signal and conditioned to provide a 0 to 10 volt DC signal linear from 0 to maximum position (free storage).
v Set TENSION/DANCER GAIN (P.417) to adjust the gain of the analog input signal.
Range: 0.750 to 2.250
P.417 =
v If necessary, set TENSION/DANCER ZERO (P.416) to adjust the zero point of the
analog input signal.
TENSION/DANCER FDBK
P.416 =
COUNTS
(P.493) is the scaled value of the analog signal used for position feedback to the PI block. The position feedback signal is conditioned by a SCALE block and a LEAD/LAG block which is set to approximately cancel the lag attributable to the speed loop bandwidth. The LEAD/LAG block values are set using the procedures detailed in section 11.1.
To set up the SCALE block: v Set TENSION FDBK MIN (P.852) to set the lower limit.
P.852 =
COUNTS
v Set TENSION FDBK MAX (P.851) to set the upper limit.

P.851 =
COUNTS
11-4
The output of the SCALE block is TEN/DANCER FDBK SCALED (P.489). See the following examples for more information on setting up the SCALE block. Setting Up the Scale Block The setting for TENSION FDBK MIN (P.852) and TENSION FDBK MAX (P.851) depend on the characteristics of the dancer feedback signal. The output of the SCALE block will go from 0 to 4095 counts as the dancer goes from zero storage to maximum storage. Typically, the dancer feedback signal will be zero at zero storage and maximum at maximum storage. Example 1 If the dancer feedback signal can be set, by external calibration and/or analog input calibration, so that TENSION/DANCER FDBK (P.493) is 0 to 10 volts as the dancer moves from minimum to maximum position, then TENSION FDBK MIN (P.852) would be set to 0, and TENSION FDBK MAX (P.851) would be set to 4095. Example 2 The dancer feedback signal (analog input) goes from 1.0 volts to 8.0 volts as the dancer moves from minimum to maximum position, and TENSION/DANCER FDBK (P.493), which is the digitized equivalent, goes from 409 to 3276. In this example, TENSION FDBK MIN (P.852) would be set to 409 and TENSION FDBK MAX (P.851) would be set to 3276.
11.3 The Position PI Output

Refer to figure A.16 in appendix A of the software manual (D2-3444) as you configure the position PI output. The output of the PI block is POSITION VERNIER (P.241), which is used as a trim signal on the speed loop when CASCADE is selected, or as the input to the speed loop limits when PARALLEL is selected as configured by OCL TYPE (P.818). The amount of speed loop trim is set by the HI and LO limits of the PI block, which would nominally be configured at 10% by setting POS PI LIMIT (P.235) to 409.5. However, product characteristics, such as modulus of elasticity, can require more or less than 10% trim. Note that POSITION VERNIER (P.241) will be a proportional or incremental trim of line speed, dependent on the configuration of OCL PROP TRIM GAIN (P.812). Refer to section 3.3, Speed Mode Select.
To configure the position PI output: v Set POS PI LIMIT (P.235) to set the HI and LO output limits of the PI block.
Range: 0 to 4095 COUNTS (4095 = TOP LINE SPEED)
P.235 =
COUNTS
11-5
11.4 Type 3 Position Regulator
ATTENTION: The J15 jumper must be set to the torque/current position when using the WebPak 3000 drives type 3 position loop feature. Applying a drive as a direct current regulator has safety issues that must be considered. Failure to observe this precaution could result in severe bodily injury or loss of life.
The drives type 3 position regulator feature bypasses the speed loop, which eliminates the need to provide a motor speed feedback device. However, the trade-off is that it may be difficult or, in some system configurations, impossible to achieve stable operation. The decision to use this feature was previously established during the configuration of the current minor loop reference in section 4.1 ((OCL TYPE 3 POSN REG EN (P.814) is set to ENABLED). Note that OCL SELECT (P.817) must be set to POSITION to use this feature. Gain profiling should not be used when a type 3 position loop is selected Important: The J15 jumper must be set to current/torque when OCL TYPE 3 POSN REG EN (P.814) is set to ENABLED.
11-6
CHAPTER 12
Configuring the Tension Outer Control Loop
Constant Diameter Tension Regulator Variable Diameter Tension Regulator Generic
The tension outer control loop regulator uses the same RATELIM and PI control blocks as the current major outer control loop. The tension output control loop includes:
Tension PI input Tension PI limits Tension PI output To select the tension outer control loop:
v Set OCL SELECT (P.817) to TENSION.
P.817 =
7(16,21
12.1 The Tension PI Input

Refer to figure A.18 in Appendix A of the software manual (D2-3444) as you configure the tension PI input. The input to the PI block is the rate-limited value of TENSION DEMAND (P.844), which is the input to RATELIM block. The output is TEN RAMP OUTPUT (P.842).
To configure the PI block input:

v Set TEN RAMP TIME (P.833) to specify the reference rate of change.
P.833 =
SECONDS
v Connect the analog tension feedback signal to terminals 52(+) and 53(-) on
the I/O Expansion board. The standard PI block feedback is an analog signal proportional to tension; therefore, it is assumed that the tension transducer output has been amplified (if necessary) and conditioned to provide a 0 to 10 volt DC signal linear from 0 to maximum tension.
12-1
v Set TENSION/DANCER GAIN (P.417) to adjust the gain of the analog input signal
if necessary.
Range: 0.750 to 2.250
P.417 =
v If necessary, set TENSION/DANCER ZERO (P.416) to adjust the zero point of the
analog input signal.
Range: -3000 to 3000
TENSION/DANCER FDBK (P.493) feedback to the PI block. Note
P.416 =
is the value of the analog signal used for tension that this is the same analog input that would have been used for a position feedback signal, if the drive had been configured with a position outer control loop.
12.1.1 The SCALE Block

The tension feedback signal is conditioned by a SCALE block. Refer to figure A.18 in Appendix A of the software manual.
To set up the SCALE Block:

v Set TENSION FDBK MIN (P.852) to set IN_MIN.
P.852 =
COUNTS
v Set TENSION FDBK MAX (P.851) to set IN_MAX.

P.851 =
COUNTS
The output of the SCALE block is TEN/DANCER FDBK SCALED (P.489). See the following examples for more information on setting up the SCALE block. Setting Up the Scale Block The setting for TENSION FDBK MIN (P.852) and TENSION FDBK MAX (P.851) depend on the characteristics of the tension feedback signal. The output of the SCALE block will go from 0 to 4095 counts as the load cell goes from zero tension to maximum tension. Typically, the tension feedback signal will be zero at zero tension and maximum at maximum tension. Example 1 If the tension feedback signal can be set, by external calibration and/or analog input calibration, so that TENSION/DANCER FDBK (P.493) is 0 to 10 volts as the tension goes from minimum to maximum tension, then TENSION FDBK MIN (P.852) would be set to 0, and TENSION FDBK MAX (P.851) would be set to 4095. Example 2 The tension feedback signal (analog input) goes from 1.0 volts to 8.0 volts as the tension goes from minimum to maximum, and TENSION/DANCER FDBK (P.493), which is the digitized equivalent, goes from 409 to 3276. In this example, TENSION FDBK MIN (P.852) would be set to 409 and TENSION FDBK MAX (P.851) would be set to 3276.
12-2
12.1.2 The LEAD/LAG Block

The tension feedback signal is also conditioned by a LEAD/LAG block, which is set to approximately cancel the lag attributable to the speed loop bandwidth. Refer to figure A.18 in Appendix A of the software manual (D2-3444).
To set up the LEAD/LAG block:

v Set TEN FDBK LL BYPASS (P.845) to OFF.
Range: OFF, ON
P.845 =
2))
v Set TEN FDBK LL LOW FREQ (P.835) to the same value as SPEED CROSS OVER
(P.133).
P.835 =
RAD/S
v Set TEN FDBK LL RATIO (P.836) to 7.5.

Range: 2 to 20
P.836 =

To bypass the LEAD/LAG block:

v Set TEN FDBK LL BYPASS (P.845) to ON.
Range: OFF, ON
P.845 =
21
12.1.3 The Tension Loop PI Block

Refer to figure A.19 in Appendix A of the software manual (D2-3444) as you configure the tension loop PI block. The input to the tension loop PI block is TEN LOOP ERROR (P.834), which is a read-only parameter.
To set the PI block integral gain:

v Set TEN PI LEAD FREQ (P.840) to 0.2 radians/second.
P.840 =
5$'6
If the drive is a variable diameter section:

v Tune the proportional gain at empty core diameter.
To set the PI block proportional gain, TEN PI PROP GAIN (P.841):

v Set TEN PROFILER ENABLE (P.878) to DISABLE.
P.878 =
',6$%/(

P.818 =
&$6&$'(
v Set OCL SELECT (P.817) to TENSION.

P.817 =
7(16,21
12-3
ATTENTION: The user must read and understand the drive sequencing description and state diagram (figure 3.3 in the WebPak 3000 software manual, D2-3444) before using the TENSION ON input. Setting OCL SELECT (P.817) to any option but NONE permits the TENSION ON input to start the drive. Once the TENSION ON input is permitted to start the drive, negating the TENSION ON input while in any state other than the stall tension state will not stop the drive. Failure to observe this precaution could result in severe bodily injury or loss of life.
v Verify that TEN LEADLAG SELECT (P.837) is set to LAG/LEAD, and the values are
set in accordance with section 12.2.
P.837 =
v Set TEN RAMP TIME (P.833) to its minimum value (0.1 seconds).
P.833 =
SECONDS
v Set the line speed reference at 20% of maximum. v Set TENSION SETPOINT SEL (P.855) to REGISTER, and set the register value to
200, which is approximately 5% of maximum.
P.855 =
5(*,67(5
v Set TEN PI PROP GAIN (P.841) to 2.0.

Range: 0.001 to 32.767
P.841 =

ATTENTION: Depending on machine losses, the 5% tension step required in the following steps may accelerate the motor above 20% line speed. The user must be ready to shut the drive down in case of overspeed. Failure to observe this precaution could result in severe bodily injury or loss of life.
TENSION ON
v With material in the machine, start the drive by asserting the SECTION RUN and
digital inputs.
v Change the register value to 400, which will step the tension reference 5%. v Connect the tension feedback signal to a strip chart recorder or oscilloscope. v Verify that a 5% step in tension reference will result in a rise time to peak in
1.0 seconds.
v If necessary, tune the proportional gain (P.841) and lead frequency (P.840) for
the desired 1.0 second rise time.
v Reset all parameters except P.841 to their normal settings.
12-4
12.1.4 Dynamic Gain Profiling (Variable Diameter Applications)

It is recommended that all variable diameter tension applications use dynamic gain profiling.The gain profiler calculates the dynamic value for the PI block proportional gain parameter TEN PI KP OUT (P.879). Refer to figure A.19 in Appendix A of the software manual (D2-3444).
To configure dynamic gain profiling:

v Set TEN PROFILER ENABLE (P.878) to ENABLE.
P.878 =
(1$%/(
v Set OCL TYPE (P.818) to select the profiling block for cascade or parallel
operation. The choices are:
CASCADE
- The inputs to the profiling block are: (P.841) as determined in the step response test.
TEN PI PROP GAIN NORM FIELD REF
(P.130) (P.131)
NORM ROLL DIAMETER SPEED PI KP OUT
(P.251) (P.840) as determined in the step response test.
TEN PI LEAD FREQ
PARALLEL
- The inputs to the profiling block are: (P.841) as determined in the step response test.
TEN PI PROP GAIN NORM FIELD REF
(P.130) (P.131) P.818 =
NORM ROLL DIAMETER
12.2 The Tension PI Output

Refer to figure A.19 in Appendix A of the software manual (D2-3444) as you configure the tension PI output. The output of the PI block is TENSION VERNIER (P.856), which is used as a trim signal on the speed loop when CASCADE is selected or as the input to the speed loop current limits when PARALLEL is selected as configured by OCL TYPE (P.818). The amount of speed loop trim is set by the HI and LO limits of the PI block, TENSION PI LIMIT (P.853), which would nominally be configured at 409 counts (10%). However, product characteristics, such as modulus of elasticity, can require more or less than 10% trim. Note that TENSION VERNIER (P.856) will be a proportional or incremental trim of line speed dependent on the configuration of OCL PROP TRIM GAIN (P.812). Refer to section 3.3 and figure 3.1.
12-5
To set the PI block HI and LO limits:

v Set TENSION PI LIMIT (P.853). For example, if 10% tension vernier is to be used,
set the PI block HI and LO limits to 409 counts. The output of the tension PI block provides a vernier signal that is used to trim the speed loop reference when OCL TYPE (P.818) is set to CASCADE and to trim the speed loop PI limits when OCL TYPE (P.818) is set to PARALLEL. In cascade, 4095 counts equals top line speed. In parallel, 4095 counts equals maximum current.
P.853 =
COUNTS
If the outer control loop is configured as a tension regulator

(P.817 = TENSION):
v Set TEN LEADLAG SELECT (P.837) to LAG/LEAD.

P.837 =
/$*/($'
v Set SPD LOOP PI LEAD FREQ (P.212). Note that this value was set during
self-tuning.
P.212 =
RAD/S
v Set TEN OUT LL LOW FREQ (P.838) to twice the value of SPD LOOP PI LEAD FREQ
(P.212).
P.838 =
RAD/S
v Set TEN OUT LL RATIO (P.839) to 8.0.

Range: 2 to 20
P.839 =

12.3 The Slack Take-Up Function

The slack take-up function initiates a smooth removal of loose web when drive tension is on by limiting the amount of motor torque applied until the slack is removed. When slack take-up is released, the drive operates at the tension set by TEN RAMP OUTPUT (P.842). Refer to figure A.19 in Appendix A of the software manual (D2-3444) as you configure the tension PI limits for the slack take-up function.
To use the slack take-up function:

v Set SLACK TENSION PI LIM (P.318).
Range: 0.0 to 100.0%
P.318 =
v Assert the slack take-up digital input (terminal 12 on the Regulator board).
(SLACK TAKE UP DIN TP (P.494) should be ON). The drive uses the value of SLACK TENSION PI LIM (P.318), which is a percentage of the running limit value as set by TENSION PI LIMIT (P.853).
To turn off the slack take-up function:

v De-assert the slack take-up digital input (terminal 12 on the Regulator board).
(SLACK TAKE UP DIN TP (P.494) should be OFF). 12-6
CHAPTER 13
Configuring Other Parameters
The parameters listed in this section may or may not apply to your application. Refer to the WebPak 3000 software manual (D2-3444) for more information about each of these parameters.
13.1 Analog Outputs

The Regulator board provides two analog outputs that are unfiltered or filtered. The I/O Expansion board has two unfiltered analog outputs, ANLG OUT 3 and 4. One can generate a bipolar DC voltage only. The other can be configured to generate a DC voltage from a 0 to +/-10 VDC, 4 to 20 mA, or 10 to 50 mA signal. These outputs can be scaled to generate DC voltage signals as low as 5 V, but maximum resolution (0.025%) is obtained when the full scale output signal is used. The full scale value (FSV) is determined based on the selected parameter group: load, speed, voltage, power, field, or other. Analog outputs are read every 10 ms.
13-1
Refer to figure A.21 in Appendix A of the software manual (D2-3444) for a block diagram of the analog outputs. The following parameters are used to configure the analog outputs:
ANLG OUT ANLG OUT ANLG OUT ANLG OUT ANLG OUT ANLG OUT ANLG OUT ANLG OUT ANLG OUT ANLG OUT ANLG OUT ANLG OUT
1 GAIN ADJ (P.400) 1 ZERO ADJ (P.402) 1 FILTER EN (P.406) 2 GAIN ADJ (P.401) 2 ZERO ADJ (P.403) 2 SELECT (P.405) 2 FILTER EN (P.407) 3 SELECT (P.418) 3 SIG TYPE (P.419) 3 GAIN ADJ (P.420) 4 SELECT (P.421) 4 GAIN ADJ (P.422)
P.400 = P.402 = P.406 = P.401 = P.403 = P.405 = P.407 = P.418 = P.419 = P.420 = P.421 = P.422 =
13.2 Digital Outputs

The I/O Expansion board provides two user-selectable digital outputs. If you use these outputs, you need to set parameters that select the source that drives the output and whether the output is normally open or normally closed. Refer to figure A.24 in Appendix A of the software manual for a block diagram of the digital outputs. The following parameters are used to configure the digital outputs:
DIG OUT DIG OUT DIG OUT DIG OUT
1 CONTACT TYP (P.410) 1 SELECT (P.409) 2 CONTACT TYP (P.412) 2 SELECT (P.411)
P.410 = P.409 = P.412 = P.411 =
13.3 Frequency I/O

The I/O Expansion board provides one unipolar frequency output. The output is unfiltered. The full scale value (FSV) is based on the selected parameter group: load, speed, voltage, power, field, or other. The frequency output is read every 10 ms.
13-2
Refer to figure A.21 in the software manual (D2-3444) for a block diagram of the frequency output. Refer to figure A.20 in the software manual for a block diagram of the frequency input. The following parameters are used to configure the frequency I/O:
FREQ IN
(P.491) (P.427)
P.491 = P.427 = P.425 = P.426 =
FREQ OUT FULL SCALE FREQ OUT SELECT FREQ OUT ZERO
(P.425)
(P.426)
13.4 Level Detectors

The level detectors detect when the absolute value of a signal becomes greater than or equal to a specified threshold for longer than a specified period. They can be used as zero-speed detectors, at-speed detectors, or limit switches. They are used to drive I/O Expansion board digital output 1 or 2. To use the level detectors, DIG OUT 1 SELECT (P.409) or DIG OUT 2 SELECT (P.411) must be set to LEVEL DETECTOR OUT 1 or LEVEL DETECTOR OUT 2. Level detector outputs can also be monitored over the AutoMax or ControlNet network. Refer to figure A.22 in the software manual (D2-3444) for a block diagram of the level detectors. The following parameters are used to configure the level detectors:
LEVEL DETECT LEVEL DETECT LEVEL DETECT LEVEL DETECT LEVEL DETECT LEVEL DETECT
1 DELAY (P.604) 1A SEL (P.602) 1B SEL (P.610) 2 DELAY (P.607) 2A SEL (P.605) 2B SEL (P.611) 1(P.603) 2 (P.606)
P.604 = P.602 = P.610 = P.607 = P.605 = P.611 = P.603 = P.606 =
LEVEL REGISTER LEVEL REGISTER
13.5 AC Line
In addition to performing Quick Start, you might need to configure the AC line parameters for your application. Generally, you only need to configure these parameters if the default values are incorrect for your application. These parameters should be configured before completing Quick Start.
NOMINAL AC LINE FREQ
(P.306) (P.307)
P.306 = P.307 =
NOMINAL AC LINE VOLTS
13-3
13.6 Armature Voltage Feedback

Use the following parameters if necessary to configure the armature voltage feedback. Refer to figure A.10 in the software manual (D2-3444).
ARM VOLTAGE GAIN ADJ ARM VOLTAGE ZERO ADJ
(P.204) (P.205)
P.204 = P.205 =
13.7 Underwind Operation

Unwind and winder applications can require over-under operation, which is simply a way to implement reversing operation as different products are used.
Digital input at terminal 6 of the Regulator board initiates underwind mode.

UNDERWIND COMMAND
(P.877) indicates the state of the underwind enable command.
13-4
APPENDIX A
Using the WebPak 3000 Drive for Web Applications: The Basics
Drive system requirements for web-handling process lines cover applications which require both simple speed regulators for pull rolls and complex tension regulators for unwinds and winders with wide ranges of diameter change and tensions. The WebPak 3000 DC drive provides a common drive platform to be used for all sections of the process line without the need for an external controller. A web transport line can be divided into three section groupings:
Entry zone Process zone Exit zone

In its most basic configuration, the total line could be comprised of three sections:
An unwind in the entry zone A pull roll in the process zone A winder in the exit zone
Contrasting this basic line with a more complex process, section count in each of the three zones could be three or more. A sample section line is shown in Table A.1.
Table A.1 Sample Section Line
Entry Zone Unwind Spindle A Unwind Spindle B Unwind Turret Index Unwind Pull Roll
Process Zone Coater Applicator Coater Backer Coater Metering Vacuum Pull Roll Dryer Exit Roll Aux. Unwind Spindle A Aux. Unwind Spindle B Aux. Unwind Turret Index Laminator Top Roll Laminator Bottom Roll Laminator Exit Pull Roll
Exit Zone Winder Pull Roll Winder Spindle A Winder Spindle B Winder Turret Index
The unwind and winder spindle drives on both the basic three-section line and the complex 19-section line are typically variable diameter sections. All other sections are constant diameter.
A-1
The digital drives applied to these sections are configured as closed-loop speed, current, position, or tension regulators. The section regulator designs have varying levels of complexity dependent on process dynamics and mechanical design. The WebPak 3000 drive is capable of supporting these regulator requirements within the specified design limits.
A.1 WebPak 3000 Drive Design Features

The design features of the WebPak 3000 drive provide the capability to configure closed-loop regulator solutions for most web-handling drive applications. Preconfigured regulator software blocks with accessible tuning parameters simplify the configuration and setup process.
A.1.1 Features Supporting Constant Diameter Sections

For a process line section with fixed diameter-driven rolls, such as pull rolls, laminators, coaters, and extruders, the WebPak 3000 drives closed-loop regulator capabilities are supported by the following attributes:
High performance self-tuning current minor loop High performance self-tuning speed loop Configurable current regulator Configurable position regulator Configurable tension regulator Friction and windage loss compensation Constant torque and/or constant horsepower operation Analog or digital speed feedback Regenerative armature power bridge A.1.2 Features Supporting Variable Diameter Sections
For a process line with variable diameter driven rolls, such as unwinds and winders, the WebPak 3000 drives closed-loop regulator capabilities are supported by the same attributes listed for constant diameter sections (section A.1.1) plus the following:
Diameter calculator (ratio detector) Inertia compensation Motor field current regulator Gain profiling Taper tension
A-2
WebPak 3000 Drive Application Workbook, Version 1.1
A.2 Application Guidelines

Guidelines for the following applications are described in section A.2.1 through A.2.8:
Speed regulators Current regulators Position regulators Tension regulators Voltage and field control Diameter calculator Flying splice unwinds Flying transfer winders A.2.1 Speed Regulators
Most WebPak 3000 drives will be applied using speed loop control. The speed loop operates with either analog tachometer or digital encoder feedback with a 10 ms update rate. A self-tuning algorithm is used to tune the WebPak 3000 speed loop and to calculate the system inertia. The reflected load that is used in self-tuning a variable diameter section unwind or winder is the empty core inertia. The system inertia can also be entered through the OIM or WebPakCS software if this has already been manually calculated. Otherwise, the system inertia calculated by the self-tuning algorithm will be used by the drive. Sections that use tension, position or current major loops are designed to operate in cascade with the inner speed loop. The speed loop control algorithm includes adaptive gain, which maximizes speed loop performance on a variable diameter application. The adaptive gain profiler can be enabled or disabled via the OIM or WebPakCS software. Tension major loops are also designed to operate in a parallel operation. In parallel operation, the tension loop error signal is used as an input to the high and low limits of the speed loop regulator, and the speed loop runs in limit.
A.2.2 Current Regulators

Web transport systems have two types of applications that cover the majority of drives configured as current regulators. The primary application uses DC armature current closed loop control to profile motor shaft torque and thereby establish web tension in a web process zone. This zone could be a constant diameter section, such as a pull roll, or a variable diameter drive section, such as an unwind or winder. This control concept can be described as open loop tension control, since web tension is indirectly controlled by feedback of motor torque.
A-3
The WebPak 3000 drive operating in open loop tension control provides an update rate of 20 ms and compensates for other machine conditions, such as friction, windage, and inertia. Motor torque demand includes these loads, as well as, the torque demand required to establish the tension reference set point. Profiling these load conditions in the current regulator design improves the accuracy of the open loop tension control system. Friction and windage values are part of the start-up process. Inertia compensation is based upon drive calculated values. A variable diameter section has its values updated by the diameter calculator function. An unwind or winder using current regulation to control web tension will operate with an inherent taper tension if the current reference is held constant as the diameter changes. This means that the tension decrease is directly proportional to roll buildup on a winder, and the tension increase is directly proportional to roll builddown on an unwind. This taper pattern may be unacceptable in certain winding applications, but unwinding typically requires constant tension over builddown. When inherent taper is not acceptable, taper profiling with diameter can be used. Because the characteristics of machine load profiles can impact the range of open loop tension control, recommended limits for both fixed and variable diameter systems are listed in section A.5.2. A second use for the current regulator is a helper or load share drive section. A typical web process line application is a two-roll laminator with each roll powered by a separate drive. One roll is the lead section and could be speed, tension, or position controlled. The second roll would be current-regulated using the load current of the lead roll as the reference for its load share profile. All of the current regulator functions described in the open loop tension mode can be applied as required to the load share mode. Under the current regulator design, the current loop, acting as the primary control loop, is cascaded with an inner speed loop. This control scheme provides a more stable design as well as an inherent speed limit function. The current major loop includes a gain profiling function to maximize both steady state and dynamic performance.
A.2.3 Position Regulators

In web processing machines, position regulation assumes that a dancer roll, float roll, or Z roll is used to provide a loop of storage in the web line. A linear or rotary transducer is coupled to the roll assembly, and the transducer DC voltage signal is used as position feedback to the drive position loop. Although, from a drive system perspective, this machine design is true position feedback, it is applied as a web tension controller. By applying a load (typically via a pneumatic cylinder), which is opposite to the force developed by web tension, the drive position regulator will maintain the desired web tension as long as the position loop stays within its active storage limits, both in dynamic and steady-state line operation. The amount of web in the loop, maximum line speed, and maximum line speed rate of change are machine operating parameters that will impact viable position regulator design. Design limits for these parameters, for both fixed and variable diameter systems are listed in section A.5.2.
A-4
Changing the load by mechanically adjusting the air supply to the pneumatic cylinder will change web tension. However, a voltage-to-pneumatic (E-to-P) controller applied to the pneumatic cylinder air supply will allow web tension to be set remotely by an operators device. This electrical setpoint can be programmed to provide a tension profile, such as taper tension for a center winder. Under position regulation, the operating tension range is not limited by the electrical drive system. The mechanical characteristics of the dancer roll structure will establish both the high and low tension boundaries. Variable position loop control assumes that the dancer roll assembly tracks the web during all normal steady-state and dynamic machine conditions. Thus, the high tension limit is set by the mechanical maximum load of the dancer assembly, and the low tension limit is set by the friction and the mass of the dancer assembly. The mass effect can be compensated for by counter-loading the assembly. Friction can be minimized but not realistically to zero. Since the dancer must move to regulate loop position, the differential tension developed across the dancer assembly to move it establishes the minimum web tension value. The position loop is configured to operate in cascade with an inner speed loop with a 20 ms update rate. By calibrating the speed loop to follow the master line speed, the output of the position loop can be programmed to operate as a percent trim of the speed loop. The amount of trim used is based upon machine requirements, but is typically set at 10%. For variable diameter sections, the inner speed loop is programmed to be compensated as the roll diameter changes. The diameter calculator provides this speed loop compensation, which dynamically adjusts the speed loop to operate as an accurate surface speed regulator at all diameters. The position loop includes a gain profiling function to maximize both steady state and dynamic performance.
A.2.4 Tension Regulators

The WebPak 3000 tension regulator operates as a direct web tension control system. The tension loop feedback voltage signal is derived from a load cell on the web line. The load cell couples the drive directly to the web line parameters of modulus of elasticity, cross-sectional area, and length of material in the control zone span. The dynamics of these parameters impact the tuning of the tension loop stability and dynamic response. Web lines that are designed to run products that exhibit wide ranges of moduli of elasticity and cross-sectional areas may not support maximized drive performance with one set of tuning values. Multiple product web lines may further complicate tension loop tuning if alternate web paths are used and the web length in the tension control zone changes. Tension operating ranges recommended for fixed and variable diameter systems are listed in section A.5.2. The tension regulator supports both parallel and cascade loop design with separate gain profiling for each. Tension setpoint generation includes roll diameter profiled taper function. The profile is selectable for linear or hyperbolic taper.
A-5
A.2.5 Voltage and Field Control

A DC drive that can operate in both the constant torque and constant horsepower range of its associated DC motor can provide performance and economic advantages over a voltage-only drive. Once the motor shaft torque requirements of a driven load have been determined, the motor design parameters are based on the mechanical requirements of the load and the performance requirements of the application. Driven load profiles that exhibit a need for high torque at low speeds and less torque at higher speeds are usually optimized in both cost and performance by using a drive with both armature voltage and field voltage control capabilities. Extruders and center driven unwinds and winders are prime examples of this type of load profile. The physical size (frame size) of a motor is directly related to the maximum shaft torque it must deliver. The base speed at which the torque is developed determines the motor nameplate horsepower. For example, a 10 HP 500/2000 RPM motor will deliver approximately the same maximum relative shaft torque as a 40 HP 1750 RPM. Both designs will use the same frame size and cost basis. Although the motor cost is similar, power module size and cost would favor the 10 HP design. Cost savings may be reason enough to justify the choice of a voltage and field system, but drive performance enhancement may be even more of a justification. Center-driven unwinds and winders are often performance limited by diameter change and tension range requirements. The judicious use of a voltage and field design can expand drive system operating capabilities. System design criteria are listed in section A.5.2. A drive with voltage and field control requires a field current regulator. The field current regulator requires two types of field reference shaping:
Type 1 supports a spillover design which maintains full field current from zero to
base speed until the motor approaches its maximum armature voltage. Then, as the motor speed demand increases, the field current is regulated to a lower value proportional to the new speed. This is the type often used for an extruder.
Type 2 supports a reference determined by a field shaping table generated by a

diameter calculator. The input to the table is a field current reference value proportional to the instantaneous diameter or motor RPM. See figure A.1 for a typical curve generated by the field reference function. This is the type used for unwind and winders. The WebPak 3000 drive is designed to support a motor field regulator with both Type 1 and Type 2 capabilities. The WebPak 3000 motor field regulator provides a 6:1 maximum field control range.
A-6
Field Current
1 2
FIELD CURRENT n
3 4 5 6 7
FIELD INPUT n
GEAR IN SPEED
Motor RPM or Roll Diameter
Figure A.1 Typical Type 2 Field Reference Curve
A.2.6 Diameter Calculator

The need for a diameter calculator function was established under the Type 2 field current regulator design. However, the unwind and winder variable diameter applications require instantaneous diameter information for the additional functions of inertia compensation, taper tension, and control loop gain profiling. The diameter calculator requires two signal inputs to perform its task. Web speed, which is typically approximated by line speed reference, and motor speed are used to calculate the running diameter as a software value, which is applied to modify the drive system functions that have been programmed to be diameter sensitive. The diameter calculator is capable of covering a maximum diameter range of 20:1. Full roll diameter can be a maximum of 20 x core diameter up to a maximum of 120 inches.
A.2.7 Flying Splice Unwinds

The entry zone of a web process line can be either a single-position unwind drive or, when the process is continuous, a two-position unwind drive with flying splice operation. A flying splice two-position unwind is more complex then a single-position winder due to the performance issues related to the splice sequence. The individual unwind spindle drives have to support the steady state operation of unwinding the web into the process under the primary tension control mode in addition to accurately maintaining tension during the dynamics of the splice. In some unwind flying splice machines, the need for a control function called current memory may exist. This function changes the drive on the outgoing roll from its primary tension regulator to a current regulator whose current reference is the memorized value of its armature current just prior to being switched out of tension operation.
A-7
Not all flying splice unwinds will require current memory. On unwinds where the mechanical sequence isolates the outgoing roll from its tension feedback device, current memory would be needed. Current memory may also be used to minimize tension upsets during turret indexing and would be switched into the outgoing roll just before the start of the index. A representative splice sequence follows:
Incoming roll is prepared for splicing with glue pattern or tape. Incoming roll diameter is determined and inputted to the appropriate unwind drive
diameter calculator.
Outgoing roll is indexed to the splice position. Incoming roll is started and accelerates to web speed. Outgoing roll is sequenced into current memory, if necessary. Bump roll and knife assembly engage the incoming roll. Knife cuts the web. Outgoing roll is stopped and incoming roll is switched from speed regulation to
tension regulation.
New roll is indexed to unwinding position.

All WebPak 3000 drives have the necessary digital input logic to switch to the required regulator modes during the splice sequence. All of the splice sequence logic is done external to the WebPak 3000 drives by a separate controller. Communication between the devices is by discrete I/O or by logic commands over a network connection.
A.2.8 Flying Transfer Winders

The exit zone of a web process line, in most designs, duplicates the entry zone associated with the same line. If the entry zone uses a single-position unwind, the exit zone will use a single-position winder. A two-position unwind with flying splice operation will be complemented with a two-position winder with a flying transfer design. The individual winder spindle drives have to support the steady operation of winding the web out of the process under the primary tension control mode in addition to accurately maintaining tension during the dynamics of flying transfer. Two basic types of flying transfer mechanical designs are in use. They are identified as bump and cut and enveloper arm. The bump and cut type does not contact the incoming core until just before the knife operates. The enveloper arm design will isolate the outgoing roll from its feedback device during some part of transfer sequence, which generates the need for current memory for the outgoing roll regulator design. In fact, all of the regulator functions provided at unwinds are required at the winders.
A-8
A representative transfer sequence follows:
The outgoing full roll is indexed to the transfer position, which also places the
incoming empty core in position. Current memory could be applied to the outgoing roll during indexing to minimize tension transients.
The incoming core is started and accelerates to surface speed match the web
speed. The correct core diameter had been entered as a one of the spindle drives setup parameters.
The enveloper arm and transfer knife mechanism are positioned around the
incoming core. If the design was bump and cut, the bump roll would be positioned at the core.
Knife operates. Outgoing roll is stopped and incoming core is switched from speed regulation to
tension regulation.
New roll is indexed to winding position. The individual spindle drives have the necessary digital input logic to switch to their
required regulator modes during the transfer sequence. All of the splice sequence logic is done external to the WebPak 3000 drives by a separate controller. Communication between the devices is by discrete I/O or by logic commands over a network connection.
A.3 I/O Functions

The WebPak 3000 drive provides following I/O functions:
Digital inputs Digital outputs Analog inputs Analog outputs Frequency I/O
Each function is described in sections A.3.1 to A.3.5.
A.3.1 Digital Inputs

The following digital inputs are programmed to support the described functions. All inputs are rated at 24 volts.
Coast Stop - Provides a hardwired critical stop removing the motor from its power
source. If dynamic braking is provided, it can be implemented by this input.
Section Run - Starts the drive in speed regulation mode if tension is off. If tension
has been turned on prior to initiation of section run, the drive will accelerate to run speed, and regulation will switch from stall tension to run tension.
Section Off - Stops the drive under controlled deceleration. Over/Under - Establishes the motor direction of rotation.
A-9
Jog Fwd - Speed-regulated preset low speed. Used for roll positioning or slack
removal.
Jog Rev - Speed-regulated preset low speed. Used for roll positioning or slack
removal.
Customer Interlock - Can be used as an external permissive run contact in drive

sequence.
Fault Reset - Resets the drive after fault or alarm has occurred. Tension On - Puts the drive in stall tension if the line is not running. Puts the drive in
run tension if the line is running.
Diameter A On, Diameter B Off - Selects winder core diameter #1 value. Diameter B On, Diameter A Off - Selects winder core diameter #2 value. Diameter A and B Both On - Selects winder core diameter #3 value. Diameter A and B Both Off - Selects analog input for unwind diameter. Diameter Reset - Resets the diameter calculator to a preset value. Current Memory - Enables current memory function. Slack Take Up - Initiates a low speed. Functional in the current and tension major
loop operating mode.
A.3.2 Digital Outputs

The two digital outputs can be programmed to support 19 dedicated functions. The outputs can be selected as N.O. or N.C. contacts.
A.3.3 Analog Inputs

The five analog inputs are programmed to support the following functions:
Diameter/Taper Range - Sets the diameter of an unwind incoming roll or sets the
tension taper range for a winder.
Line Speed - External line speed reference. Analog Tach - Analog tach feedback signal. Tension Setpoint - Tension reference signal. Tension/Dancer Feedback - Load cell signal for tension control or dancer signal for
position control.
A.3.4 Analog Outputs

The four analog outputs can be programmed to support 31 dedicated functions.
A-10
A.3.5 Frequency I/O

The following frequency input and output are programmed to support the following functions:
Frequency In - Configurable as the line speed reference. 250 kHz maximum

frequency.
Frequency Out - Programmed to support the same 31 functions supplied for the
analog input.
A.4 Setup Procedures

Setting up the drive includes:
Selecting the drive attributes Configuring the parameters Entering the parameter values
The Application Workbook (D2-3446) provides the user with a parameter roadmapping tool that, when completed, simplifies the input of parameter values to the software database of the WebPak 3000.
A.4.1 Selecting Drive Attributes

The configuration of a section will require the user to select the following drive functional attributes:
Constant or variable diameter Field regulator type Fixed or shaped by spillover or motor field curve Major loop type Speed, current, position, tension Diameter calculator Unwind or winder Inertia compensation Tapered or constant tension Losses compensation Current memory on Digital, analog or frequency I/O A.4.2 Configuring the Parameters
After the drive functions listed in section A.4.1 have been selected, you will need to configure two types of parameters to complete the drive section setup procedure:
Machine section parameters, such as, line speed, roll diameter, winder core
diameter, gear ratio, roll inertia, etc.
A-11
Drive regulator parameters used to setup and tune the selected control loops, such
as, proportional gain, integral gain, current limit, tension on, current memory on, etc. All of these parameters are listed in the Application Workbook.
A.4.3 Entering the Parameter Values

Parameter values can be entered using either the OIM or the WebPakCS configuration software. The OIM enables you to:
Enter parameter values Monitor drive status Monitor and change drive parameters Read and reset the drive fault and error log Control the drive (start, stop, etc.)
In addition to the above, the WebPakCS software enables you to:
Create, store, upload, download and print drive configurations Display trace signals in the drive
Refer to the WebPak 3000 OIM User Guide (D2-3445) or the WebPakCS Software Manual (D2-3447) for more information.
A.5 Operating Capabilities

The use of a closed loop regulator and drive to solve web handling application presumes that the system design capabilities will support both steady-state and dynamic operation within the defined machine parameters. The WebPak 3000 drive, being a high response digital drive, expands the acceptable range of machine parameters without compromising viable electromechanical drive system performance. However, expanded boundaries must be constrained by limits that reflect attainable machine operation. Therefore, it becomes necessary to define these parameter limits so the user is capable of maximizing drive system performance expectations. It is recommended that the parameter limits as defined be used when setting expectations for steady-state and dynamic drive performance. It is assumed that the drive section sizing (horsepower rating, torque rating, and speed range) is consistent with the requirements of the machine parameters.
A.5.1 Machine Parameter Limits

Limits on machine parameters may be set by either machine capabilities or drive capabilities. Satisfying the limits of the machine does not necessarily satisfy the limits of the drive, and vice versa.
A-12
Machine limits can be mechanical or process related. For example, maximum line speed could be limited by maximum roll RPM or by the maximum speed at which a dryer can operate. Drive limits are set based on optimizing drive steady-state and dynamic performance. Refer to table A.2.
Table A.2 Drive Limits
Function Maximum Line Speed Minimum Line Speed Unwind Core Diameter Unwind Max Roll Diameter Unwind Max Roll Diameter Unwind Max Roll Diameter Winder Core Diameter Winder Max Roll Diameter Winder Max Roll Diameter Winder Max Roll Diameter Ratio of Core to Full Roll Inertia Ratio of Core to Full Roll Inertia Ratio of Core to Full Roll Inertia Maximum Tension - Constant Diameter Minimum Tension - Constant Diameter Minimum Tension - Constant Diameter Minimum Tension - Constant Diameter Maximum Tension - Variable Diameter Minimum Tension - Variable Diameter Minimum Tension - Variable Diameter Minimum Tension - Variable Diameter Maximum Motor Field Range Dancer Loop Storage
Mode All All All Current Position Tension All Current Position Tension Current Position Tension All Current Position Tension All Current Position Tension All Position
Limit Undefined 5% of max. 1.0 in min. 6 x core 20 x core 15 x core 1.0 in min. 6 x core 20 x core 15 x core 15 25 25 Undefined 100% of max. Undefined 5% of max Undefined 10% of max. Undefined 5% of max. 6:1 Undefined
Limited By Machine Drive Machine Drive Drive Drive Machine Drive Drive Drive Drive Drive Drive Machine/Drive Drive Machine Drive Machine/Drive Drive Machine Drive Drive Machine/Drive
A-13
A.5.2 Steady-State and Dynamic Performance

A WebPak 3000 drive section, when applied within the machine parameter limits and set up with the necessary regulator parameters as listed in the Application Workbook, will operate with the following steady-state performance specifications:
Speed regulator with digital encoder feedback
0.01% of top speed over 20:1 speed range 1.0% of top speed over 20:1 speed range 0.5% of rated current over 20:1 current range 0.1% of position range 0.1% of maximum tension over 20:1 tension range
Speed regulator with analog tach feedback
Current regulator
Position regulator
Tension regulator
These steady-state performance values assume machine conditions that do not exhibit cyclic drive speed or load profiles. Drive response to step or ramp inputs would characterize the dynamic performance specifications. Nominal results based on defined machine parameter limits can be expected. However, predicting the actual values is difficult because variable machine conditions will impact results. The WebPak 3000 drive is capable of maintaining process continuity during machine transient conditions as long as the machine parameters fall within their defined boundaries. Any operating requirements that fall outside of the parameter limit will require specific system analysis. Contact Reliance Electric for assistance.
A-14
GLOSSARY
automatic field weakening (spillover control) - A speed control method that allows the motor to operate throughout the entire constant-torque and constant-horsepower ranges with only one speed control. The field current regulator is controlled by armature voltage. When armature voltage is between zero and 85% of rated voltage, field current is maximum. As armature voltage increases from 85 to 100%, field current is automatically reduced to provide maximum motor speed. Small speed changes can be made quickly because field strength is varied as a function of armature voltage. base speed - The manufacturers nameplate rating where the motor will develop rated horsepower at rated load and voltage. It is commonly the point where full armature voltage is applied with full rated field excitation. cascade control - A control strategy in which the output of one loop is the input for another loop. Synonymous with series control. closed-loop system - A regulator circuit in which the actual value of the controlled variable (e.g., speed) is sensed and a signal proportional to this value (feedback signal) is compared with a signal proportional to the desired value (reference signal). The difference between these signals (error signal) causes the actual value to change in the direction that will reduce the difference in signals to zero. CML - Current minor loop. See loop. constant horsepower - A designation for variable speed motors used for loads requiring the same amount of horsepower regardless of their motor speed during a normal operation. constant horsepower range - A range of motor operation where motor speed is controlled by field weakening. In this range, motor torque decreases as speed increases. Since horsepower is speed times torque (divided by a constant), the value of horsepower developed by the motor in this range is constant. constant torque - Refers to loads with horsepower requirements that change linearly at different speeds. Horsepower varies with the speed, i.e., 2/1 HP at 1800/900 RPM (seen on some two-speed motors). constant torque range - A speed range in which the motor is capable of delivering a constant torque, subject to cooling limitations of the motor. control types:
position control - Position control is used to coordinate speed and/or tension

between adjacent sections of a process line. The position feedback can be a potentiometer or transducer connected to a position-sensing roll. Web tension is established by loading the position-sensing roll.
Glossary
Glossary-1
speed control - Velocity feedback is used when an absolute value of motor shaft
speed is required. Shaft speed is measured by a tachometer whose signal is compared to the speed reference signal.
tension control - Tension control systems are used where direct tension
measurement is required. The feedback device is a force transducer mounted on each end of a tension-sensing roll.
voltage control - A voltage signal is obtained directly from the output terminals of
the drive and compared to the reference signal from the speed-setting potentiometer. counts - The internal units used by the drive. Most parameters that are entered in engineering units are usually converted to a value in counts for use by the drive. By converting to counts, the drive is better able to maintain consistency and accuracy when making calculations. When parameters expressed in units of RPM are entered into the drive, the value is converted to counts and normalized so that 4095 counts corresponds to the gear-in speed in engineering units. For example: If the gear-in speed is 1000 RPM, then a reference of 250 RPM is converted to 1023 counts, or 25% of 4095 counts. The value 4095 is used because this corresponds to the maximum value produced by the drives 12-bit A/D and D/A converters. cross over frequency - Also known as the cut-off frequency and indicates bandwidth. In the case of the speed loop or outer loop, only input frequencies between zero and the corresponding cross over frequency will be passed through the loop. Frequencies outside this range will be attenuated. current memory - A function that changes the drive on the outgoing roll from its primary tension regulator to a current regulator whose current reference is the memorized value of its armature current just prior to being switched out of tension operation. engineering units - Units of measurement (such as pounds, pounds per square inch, degrees Celsius) relative to the process. An input signal is often a percentage of the full-scale range (such as 5 volts or 4-20 mA) of direct measurement that must then be converted, through scaling, into engineering units. See scaling. field economy - A circuit design feature of a DC motor shunt field supply that reduces the supply voltage output after a predetermined period of time after the motor is stopped. On many field supplies, this means a 50% reduction in output voltage 2 to 3 minutes after machine shutdown (idle). A field economy circuit serves to reduce standby power consumption and prolong the insulation life of the motor field windings. field shaping - A function that enables center-driven winders to meet wide speed range requirements by operating in the field weakening range of the motor. field weakening - The action of reducing the current applied to a DC motor shunt field. This action weakens the strength of the magnetic field and thereby increases the motor speed while decreasing the available motor torque. gain - The ratio of the magnitude of the output signal with respect to that of the input signal.
Glossary-2
gain profiling - A function that dynamically adjusts the gains of the speed loop, the tension loop, the current major loop, and the position loop as the response of the system changes due to roll inertia, system losses, and motor torque. geared-in speed - The instantaneous motor speed, taking into account any gearing between the motor shaft and spindle, required to produce the top line speed with an empty core diameter. inertia - A measure of a bodys resistance to changes in velocity, whether the body is at rest or moving at a constant velocity. The velocity can be either linear or rotational. The moment of inertia (WK2) is the product of the weight (W) of an object and the square of the radius of gyration (K2). The radius of gyration is measure of how the mass of the object is distributed about the axis of rotation. WK2 is usually expressed in units of lb-ft2. inertia compensation - Provides the change in motor torque required during acceleration and deceleration to minimize transient error of the controlled process variable. JBAR - Defines the time in sections to accelerate the total connected load of a drive from zero speed to motor base speed with full shunt field excitation. Also identified as system inertia. jog - A control function which provides for the momentary operation of a drive for the purpose of accomplishing a small movement of the driven machine. KPS - Abbreviation for the proportional gain of an amplifier. lag - A lag block is a low-pass filter. The frequency components of the input signal that are higher than the lag or cut-off frequency are attenuated or reduced. Lag blocks are often used to suppress unwanted noise or high frequency (short duration) disturbances caused by such phenomenon as backlash in gearboxes. Lag blocks are so named because they introduce a delay or phase lag between the input and output signals. lag/lead - A type of filter that incorporates both a low-pass (lag) and a high-pass (lead) filter. In the control blocks where the type of filter can be selected (either lag/lead or lead/lag), the low frequency input corresponds to the break frequency of the first element in the filter name. In a lag/lead filter, the lag frequency or the low-pass filter break frequency is lower than the lead frequency. This results in a low-pass filter with an improved phase margin at higher frequencies. A lead/lag filter is similar except the lead frequency is lower than the lag frequency and results in a type of high-pass filter. The ratio input specifies the ratio between the lead and lag frequency (lag and lead frequencies for a lead/lag filter). For a lag/lead filter with a lag frequency of 10 rad/s and a ratio of 4, the lead frequency will be 40 rad/s. lead/lag - See lag/lead lead - See lag/lead LIMBAR - The per normal value of maximum motor current. It is maximum current in percent of full load amps / 100.
Glossary
Glossary-3
loop - A control scheme in which a reference input to a device is compared to a feedback signal from the device for purpose of regulation. Any error is amplified to affect the input to the device to reduce the error. All other functions in the loop can be viewed as gain functions.
inner loop - Also known as a minor loop. outer loop - Also known as a major loop.
losses - A motor converts electrical energy into mechanical energy, and in doing so, encounters losses. These losses are all the energy that is put into a motor and not transformed into usable power, but are converted into heat causing the temperature of the windings and other motor parts to rise. losses compensation - Provides the additional motor torque required to compensate for the friction and windage losses of the motor and connected load. motor full load torque - Torque developed when the motor is operating with full load current and full field excitation. open-loop system - A control system that lacks feedback. overwind (or underwind) - Defines the direction of rotation of a center-drive winder. Also referred to as face in or face out winding. parallel control - A control strategy in which the output of two outer loops are used to provide the input to an inner loop. parameter - A value used to represent a drive or motor characteristic. There are three types of parameters:
configurable - Parameters that can be adjusted or changed only when the drive
is stopped.
tunable - Parameters that can be adjusted or changed when the drive is running
or stopped.
read only - Parameters that cannot be adjusted.

PI - Proportional-integral; when the transient response of a feedback control system is considered satisfactory, but the steady-state error is too large, it is possible to eliminate the error by increasing the system type. The system type can be increased by operating on the actuating signal to produce one that is proportional to both the magnitude and the integral of this signal resulting in improved system performance. rated tension - The tension in the line when the drive is operating with motor rated torque (motor rated current with rated field current) at full roll diameter. reference rate - The rate of velocity change for the speed reference. regulator - A piece of hardware or software that regulates a quantity such as voltage, power, speed, etc., at a set value or between certain close limits. scaling - The process of changing a quantity from one level to another level. self-tuning - The adjustment of otherwise fixed parameters by an automatic procedure (initiated manually) that calculates parameters based on data acquired empirically and a pre-defined regulator-tuning algorithm. Glossary-4
sequencing - Logic that controls the state of the drive (running, stopped, etc.). See chapter 3 in the drive software manual (D2-3444) for more information. slack - Lacking in usual or normal firmness and steadiness; not tight or taut. speed loop - An outer control loop using a speed-sensing device to provide speed feedback for comparison to the speed reference. stall tension - A function that is used to hold a reduced level of tension on the web during a stall condition. system inertia - See JBAR top line speed - The maximum line speed in feet per minute. taper tension - A function used in winding applications to build a uniformly wound roll. As the roll builds, the tension is steadily reduced to avoid a condition where the material being wound begins to collapse upon itself. That taper function will modify the set tension (tension used at empty core) using either a hyperbolic or linear function. See figure 1
T a p e r F u n c tio n
1. 00 0. 90 0. 80 0. 70 0. 60 0. 50 0. 40 0. 30 0. 20 0. 10 0. 00 13 17 21 25 29 33 37 41 D i a m e te r 45 1 5 9
TaperPcnt
H y p er Line ar
Figure 1 - Torque Taper Function
trim - A function in which a portion of field current is fed back to a regulator circuit that compensates for line-voltage variances and field-resistance changes caused by motor warm-up. type 3 position regulator - A feature that eliminates the need to provide a motor speed feedback device by bypassing the speed loop. underwind - See overwind vernier - A small auxiliary device used with a main device to obtain fine adjustment. vernier control - A method of improving resolution. The amount of vernier control is expressed as either the percent of the total operating range or of the actual operating value, whichever is appropriate to the circuit in use.
Glossary
Glossary-5
Glossary-6
INDEX
A
AC line, 13-3 (P.001), 3-9 Analog inputs, A-10 Analog outputs, 13-1, A-10 ANALOG TACH FEEDBACK (P.291), 3-13 ANALOG TACH GAIN ADJ (P.201), 3-13 ANALOG TACH ZERO ADJ (P.202), 3-13 ANALOG TRIM REF (P.195), 3-4 ANLG OUT 1 FILTER EN (P.406), 13-2 ANLG OUT 1 GAIN ADJ (P.400), 13-2 ANLG OUT 1 SELECT (P.404), 10-6 ANLG OUT 1 ZERO ADJ (P.402), 13-2 ANLG OUT 2 FILTER EN (P.407), 13-2 ANLG OUT 2 GAIN ADJ (P.401), 13-2 ANLG OUT 2 SELECT (P.405), 13-2 ANLG OUT 2 ZERO ADJ (P.403), 13-2 ANLG OUT 3 GAIN ADJ (P.420), 9-5, 13-2 ANLG OUT 3 SELECT (P.418), 9-4, 13-2 ANLG OUT 3 SIG TYPE (P.419), 9-5, 13-2 ANLG OUT 4 GAIN ADJ (P.422), 13-2 ANLG OUT 4 SELECT (P.421), 13-2 ANLG TACH VOLTS/1000 (P.203), 3-13 Application guidelines current regulators, A-3 flying splice unwinds, A-7 flying transfer winders, A-8 position regulators, A-4 speed regulators, A-3 tension regulators, A-5 voltage and field control, A-6 ARM VOLTAGE GAIN ADJ (P.204), 13-4 ARM VOLTAGE ZERO ADJ (P.205), 13-4 ARMATURE BRIDGE POL (P.394), 4-4 ARMATURE DELTA (P.399), 4-4 ARMATURE VOLTAGE (P.289), 5-5 Armature voltage feedback, 13-4 Automatic field weakening, 5-5
ACCELERATION TIME
C
(P.398), 4-1 CML FEEDBACK (P.397), 3-12, 4-4 CML FEEDBACK GAIN ADJ (P.300), 4-4 CML PI LEAD FREQUENCY (P.302), 4-5 CML PI PROP GAIN (P.301), 4-5 CML RAMP INPUT TP (P.390), 4-2 CML REF LIMIT SELECT (P.311), 4-2, 4-3 CML REF RATE LIMIT (P.303), 4-2, 4-3 CML REFERENCE (P.396), 4-2, 4-3, 4-4 CML SPEED REFERENCE (P.391), 4-1 CONTROL SOURCE SELECT (P.000), 3-2 Control source, selecting, 3-2 CT TURNS RATIO (P.010), 4-4, 4-5 CURRENT COMPOUND TP (P.293), 3-12 Current compounding, 3-12 CURRENT COMPOUNDING (P.209), 3-12 Current major outer control loop, configuring, 10-1 CURRENT MEM COMMAND (P.319), 3-17 CURRENT MEMORY BOOST (P.313), 3-17 CURRENT MEMORY DIN TP (P.499), 3-17 CURRENT MEMORY ENABLE (P.314), 3-17 Current memory function, 3-17 Current minor loop configuring, 4-1 configuring the reference, 4-1 configuring the regulator, 4-4 CURRENT/SPEED SWITCH (P.811), 4-3
CML ERROR
D
DANCER ACCEL TIME DANCER DECEL TIME
(P.873), 9-4 (P.819), 9-4
B
BASE SPEED BUILDUP CONSTANT
(P.017), 7-2 (P.871), 7-1, 7-2
Dancer loading configuring, 9-4 setup example, 9-5 DANCER LOADING (P.820), 9-4 DECELERATION TIME (P.002), 3-8, 3-9 DIAMETER ACCEL RATE (P.823), 6-3 DIAMETER ANALOG (P.821), 6-3 DIAMETER CALC ENABLE (P.826), 3-5, 6-3, 6-4 DIAMETER CALC OUTPUT (P.132), 6-4 Diameter calculator, 6-2, A-7 configuring, 6-1 validating the setup of, 6-4 Index-1
Index
Diameter calculator update threshold, configuring, 6-1 DIAMETER DECEL RATE (P.827), 6-3 DIAMETER REGISTER (P.874), 3-6, 6-3, 6-4 DIAMETER RESET TP (P.829), 6-2 DIAMETER RST DIN TP (P.497), 6-2 DIAMETER SELECT A TP (P.495), 6-2 DIAMETER SELECT B TP (P.496), 6-2 DIAMETER UPDATE RATE (P.867), 6-2 DIAMETER/TAPER GAIN (P.104), 3-4, 9-3 DIAMETER/TAPER IN TP (P.192), 6-2, 9-3 DIAMETER/TAPER SELECT (P.870), 6-2, 9-3 DIAMETER/TAPER ZERO (P.105), 3-4, 9-3 DIG OUT 1 CONTACT TYP (P.410), 13-2 DIG OUT 1 SELECT (P.409), 13-2 DIG OUT 2 CONTACT TYP (P.412), 13-2 DIG OUT 2 SELECT (P.411), 13-2 Digital inputs, A-9 Digital outputs, 13-2, A-10 DRAW PERCENTAGE OUT (P.196), 3-4 Drive design features, A-2 Drive hardware, 1-1 Drive limits, A-13 Drive operating capabilities machine parameter limits, A-12 steady-state and dynamic performance, A-14 Drive software, 1-1 Dynamic gain profiling, 12-5 Dynamic switching between current and speed regulation, 4-3
E
(P.830), 3-7, 6-2, 6-3, 6-4 ENCODER FEEDBACK (P.292), 3-13 ENCODER KIT (P.798), 3-13 ENCODER PPR (P.207), 3-13 Examples current compounding, 3-12 dancer loading setup, 9-5 setting up the scale block (position), 11-5 setting up the scale block (tension), 12-2 speed parameters, 3-7 testing the value of POSITION CROSS OVER (P.239), 11-3
EMPTY CORE DIAMETER
F
FEEDBACK SELECT (P.200), 3-1, 3-13, 5-5 Field auto weaken, 5-5 FIELD AUTO WEAKEN (P.517), 5-5 FIELD CURRENT 1 (P.522), 5-4
2 (P.523), 5-4 3 (P.524), 5-4 FIELD CURRENT 4 (P.525), 5-4 FIELD CURRENT 5 (P.526), 5-4 FIELD CURRENT 6 (P.527), 5-4 FIELD CURRENT 7 (P.528), 5-4 FIELD CURRENT 8 (P.529), 5-4 Field current regulator, configuring, 5-1 FIELD DELTA (P.588), 5-6 FIELD DELTA HIGH LIM (P.587), 5-5 FIELD ECONOMY ACTIVE (P.599), 5-1, 5-2 FIELD ECONOMY DELAY (P.501), 5-2 FIELD ECONOMY REF (P.511), 5-2 FIELD FEEDBACK (P.589), 5-4, 5-5 Field feedback, configuring, 5-5 FIELD INPUT 1 (P.530), 5-3 FIELD INPUT 1-8 (P.530-P.537), 5-2 FIELD INPUT 2 (P.531), 5-3 FIELD INPUT 3 (P.532), 5-3 FIELD INPUT 4 (P.533), 5-3 FIELD INPUT 5 (P.534), 5-3 FIELD INPUT 6 (P.535), 5-3 FIELD INPUT 7 (P.536), 5-3 FIELD INPUT 8 (P.537), 5-4 FIELD LOSS THRESHOLD (P.512), 5-4 FIELD PI LEAD FREQ (P.515), 5-6 FIELD PI PROP GAIN (P.514), 5-6 FIELD REF REGISTER (P.513), 5-2 FIELD REF SELECT (P.521), 5-2, 5-5 FIELD REFERENCE (P.590), 3-14, 5-1 Field reference, setting up, 5-1 Field regulator, 5-6 FIELD SHAPING LAG (P.538), 5-4 FIELD SHAPING TYPE (P.539), 5-3 Field weakening, automatic, 5-5 FLD CURRENT REGULATOR (P.586), 5-1 FLD FEEDBACK GAIN ADJ (P.516), 5-5 FLD WEAKEN LEAD FREQ (P.520), 5-6 FLD WEAKEN PROP GAIN (P.519), 5-6 FLD WEAKEN THRESHOLD (P.518), 5-5, 5-6 Flying splice unwinds, application guidelines for, A-7 Flying transfer winders, application guidelines for, A-8 FREQ IN (P.491), 13-3 FREQ IN FULL SCALE (P.424), 3-3 FREQ IN ZERO (P.423), 3-3 FREQ OUT FULL SCALE (P.427), 13-3 FREQ OUT SELECT (P.425), 13-3 FREQ OUT ZERO (P.426), 13-3 Frequency I/O, 13-2, A-11 FRICTION LOSS (P.123), 8-1, 8-2 FULL FIELD DIAMETER (P.124), 5-3 FULL ROLL DIAMETER (P.125), 6-3
FIELD CURRENT FIELD CURRENT
Index-2
G
Gain profiler, configuring, 10-1 Gain profiling, configuring, 3-14 GEAR IN SPEED (P.011) configuring speed loop feedback, 3-13 definition, 3-7 diameter calculator update threshold, 6-2 field shaping, 5-3 setting up S-Curve block, 3-9 GEARING (P.019), 6-1 Getting started what you need to do, 1-1 what you need to know, 1-1
L
block, setting up, 12-3 1 DELAY (P.604), 13-3 LEVEL DETECT 1A SEL (P.602), 13-3 LEVEL DETECT 1B SEL (P.610), 13-3 LEVEL DETECT 2 DELAY (P.607), 13-3 LEVEL DETECT 2A SEL (P.605), 13-3 LEVEL DETECT 2B SEL (P.611), 13-3 Level detectors, 13-3 LEVEL REGISTER 1(P.603), 13-3 LEVEL REGISTER 2 (P.606), 13-3 LIMIT block, setting up, 3-5 LINE SPEED (P.188), 3-3 LINE SPEED GAIN ADJ (P.101), 3-2 LINE SPEED HYSTERESIS (P.136), 3-6 LINE SPEED REF SELECT (P.103), 3-2 LINE SPEED SIG TYPE (P.100), 3-2 LINE SPEED ZERO ADJ (P.102), 3-3 Locating the appropriate chapters for your application, 2-1 LOSSES COMP SELECT (P.315), 4-1, 4-2 Losses compensation calibrating, 8-1 configuring, 8-1 LOSSES COMPENSATION (P.316), 4-2, 8-1
LEVEL DETECT LEAD/LAG
H
How to use this manual if you are using the OIM, 2-1 if you are using WebPak CS Software, 2-1
I
I/O functions analog inputs, A-10 analog outputs, A-10 digital inputs, A-9 digital outputs, A-10 frequency I/O, A-11 INERTIA COMP SELECT (P.221), 3-8, 4-1, 4-2 INERTIA COMPENSATION (P.244), 4-2, 7-2 Inertia compensation, configuring, 7-1 INERTIA GAIN ACCEL (P.245), 7-3 INERTIA GAIN DECEL (P.229), 7-3 Inertia-to-current scaling, 7-2 INSTANTANEOUS INERTIA (P.230), 3-14, 7-1, 7-2, 10-1 Instantaneous system inertia, configuring, 7-1 INV FAULT AVOID SEL (P.312), 4-5
M
Machine parameter limits, A-12 MAX DANCER LOAD (P.831), 9-4, 9-5 MAXIMUM CURRENT (P.007), 4-3, 10-3 MAXIMUM SPEED (P.004), 3-5, 3-7 MIN DANCER LOAD (P.832), 9-4, 9-5 MINIMUM SPEED (P.003), 3-5 MINIMUM SPEED BYPASS (P.111), 3-5 MOTOR HOT FLD AMPS (P.510), 5-1, 5-2, 5-3, 5-4 MOTOR RATED ARM AMPS (P.008), 4-4 MOTOR RATED ARM VOLTS (P.009), 5-3 MOTOR SPD AT MAX FLD (P.540), 5-3
J
J11 ANLG TACH VLT SCL
(P.792), 3-13 (P.793), 3-13 J15 REGULATOR TYPE (P.799), 4-1 J18 ARM I FB RESISTOR (P.395), 4-4, 4-5 JBAR, calculating, 3-16, 7-2, 10-2 JOG ACCEL/DECEL TIME (P.013), 3-10 JOG OFF DELAY TIME (P.121), 3-10 JOG RAMP OUTPUT (P.294), 3-10 JOG SPEED (P.012), 3-10 Jog, configuring, 3-9, 3-10 Jumper J15, 4-3
J14 ANLG TACH VLT RNG
N
(P.226), 3-16, 4-3 NEG CURRENT LIMIT SEL (P.224), 3-16 NEGATIVE CURRENT LIM (P.006), 3-16, 4-3 Network configuration, 3-3 NETWORK KIT (P.796), 4-4 NOMINAL AC LINE FREQ (P.306), 13-3 NOMINAL AC LINE VOLTS (P.307), 13-3
NEG CUR LIM INV EN
Index
Index-3
(P.130) configuring losses compensation, 8-1 dynamic gain profiling, 12-5 gain profiler for the current major OCL, 10-1 inertia-to-current scaling, 7-2 tension-to-current scaling, current major OCL, 10-3 NORM ROLL DIAMETER (P.131) configuring losses compensation, 8-1 configuring taper type, OCL reference, 9-3 diameter calculator, 6-1, 6-3, 6-4 dynamic gain profiling, tension OCL, 12-5 field shaping, 5-3 gain profiler for the current major OCL, 10-1 inertia-to-current scaling, 7-2 instantaneous system inertia, 7-1 LIMIT block, speed reference ramp, 3-5 tension-to-current scaling, 10-3
NORM FIELD REF
P
(P.309), 4-5 PI block, setting up, 3-15 POS CURRENT LIMIT SEL (P.223), 3-15 POS LEADLAG BYPASS (P.255), 11-3 POS LEADLAG LOW FREQ (P.231), 11-3 POS LEADLAG RATIO (P.232, 11-3 POS LL RATIO OUT (P.247), 11-2 POS LL WLO OUT (P.246), 11-2 POS PI KP OUT (P.248), 11-2 POS PI LEAD FREQ (P.234), 11-3 POS PI LIMIT (P.235), 11-5 POS PI PROP GAIN (P.236), 11-3 POS PI WLD OUT (P.249), 11-2 POS PROFILER ENABLE (P.253), 11-1, 11-2 POS RAMP OUTPUT (P.237), 11-4 POS RAMP TIME (P.233), 11-4 Position PI input, 11-4 POSITION CROSS OVER (P.239), 11-2, 11-3 POSITION CROSS OVER (P.239), testing the value of, 11-3 Position gain profiler, 11-1 Position outer loop, configuring, 11-1 Position PI input, configuring, 11-3 Position PI output, configuring, 11-5 POSITION REFERENCE (P.240), 11-4 Position regulators, application guidelines for, A-4 POSITION VERNIER (P.241), 11-5 POSITION ZETA (P.242), 11-2 POSITIVE CURRENT LIM (P.005), 3-15, 4-3
PHASE FIRE TEST DELTA
O
(P.815), 3-11 (P.848), 4-2 OCL PARALLEL OFFSET (P.810), 3-12 OCL PARALLEL OUT (P.816), 3-15, 3-16 OCL PROP TRIM GAIN (P.812), 3-11, 11-5, 12-5 OCL PROP TRIM SELECT (P.813), 10-4 OCL SELECT (P.817) CML reference, 4-2 current OCL, 10-1 position OCL, 11-1 speed mode select, 3-10 tension loop PI block, 12-3 tension OCL, 12-1 tension setpoint, 9-1 type 3 position regulator, 11-6 validating setting of P.841 and P.840, 10-5 OCL TYPE (P.818) dynamic gain profiling, 12-5 gain profiler for current major OCL, 10-2 position gain profiler, 11-2 position PI output, 11-5 speed mode select, 3-12 tension loop PI block, 12-3 tension PI output, 12-5, 12-6 tension PI output, current major OCL, 10-4 validating the settings of P.841 and P.840, 10-5 OCL TYPE 3 POSN REG (P.814), 3-10 OCL TYPE 3 POSN REG EN (P.814), 4-2, 11-1, 11-6 Operator Interface Module (OIM), 1-1 Outer control loop reference, configuring, 9-1 Outer loop type, selecting, 3-10, 3-12 Outer loop, selecting, 3-9, 3-10
OCL INVERT ENABLE OCL OUTPUT
Q
Quick Start, 1-1
R
(P.018), 3-8, 3-9 (P.866), 3-9, 7-2 Related publications, 1-1 REVERSE DISABLE (P.015), 3-6, 3-13 ROLL DIAMETER (P.865), 5-3, 6-3
RAMP STOP DECEL TIME REFERENCE RATE
S
Scale block, setting up, 12-2 Scaling, 2-2 S-CURVE block, setting up, 3-8 S-CURVE ROUNDING (P.014), 3-8 Self-tuning, 1-1
Index-4
Setup procedures, overview of, A-11 to A-12 SLACK TAKE UP DIN TP (P.494), 10-4, 12-6 Slack take-up function, 10-4 SLACK TENSION PI LIM (P.318), 10-4, 12-6 SPD LEADLAG LOW FREQ (P.214), 3-14 SPD LEADLAG RATIO (P.213), 3-14 SPD LEADLAG SELECT (P.216), 3-14 SPD LOOP ERROR (P.297), 3-15 SPD LOOP FEEDBACK (P.296), 6-2 SPD LOOP LAG BYPASS (P.217), 3-16 SPD LOOP LAG FREQ (P.215), 3-14, 3-16 SPD LOOP LAG OUTPUT (P.298), 3-16 SPD LOOP OUTPUT (P.299), 3-17, 4-1, 8-2, 10-3 SPD LOOP PI LEAD FREQ (P.212), 3-15, 12-6 SPD LOOP PI PROP GAIN (P.211), 3-15 SPD LOOP REFERENCE (P.295), 3-13, 3-15, 6-4 SPD SOURCE SELECT OUT (P.193) configuring losses compensation, 8-1 field shaping, 5-3 speed loop reference, 3-3 speed reference ramp, 3-4, 3-5 SPD SOURCE SELECT OUT (P.193), 3-5 SPEED CROSS OVER (P.133) gain profiler for the current major OCL, 10-2 position gain profiler, 11-1, 11-3 speed loop regulator with gain profiling, 3-14 tension OCL, 12-3 Speed feedback, 3-1 SPEED LAG FREQ OUT (P.252), 3-16 Speed loop configuration, 3-1 feedback, 3-13 reference, 3-1, 3-2 Speed loop regulator with gain profiling, 3-1, 3-14 Speed mode select, 3-1, 3-9 Speed parameters, general information about, 3-7 SPEED PI KP OUT (P.251), 3-16, 12-5 SPEED PI WLD OUT (P.250), 3-16 SPEED PROFILER ENABLE (P.127), 3-14, 3-15 SPEED RAMP BYPASS (P.112), 3-8 SPEED RAMP INPUT TP (P.198), 3-8 SPEED RAMP OUTPUT (P.199), 3-8, 3-11, 3-12, 6-2 Speed reference ramp, 3-1, 3-4 Speed regulators, application guidelines for, A-3 STALL TENSION FIX (P.134), 9-2 Stall tension mode, 9-2 STALL TENSION PERCENT (P.135), 9-2 STOP DECEL SELECT (P.122), 3-8, 3-9 STOP MODE SELECT (P.114), 3-8, 4-4 STOP SPEED THRESHOLD (P.113), 3-9 STORAGE (P.857), 11-2 SYSTEM INERTIA (P.222), 3-15, 7-1, 7-2 Index-5
T
(P.858), 9-3 Taper function, 9-3 TAPER PERCENT (P.859), 9-3 TAPER SET REGISTER (P.861, 9-3 TAPER SET SELECT (P.862), 9-3 TAPER TYPE (P.863), 9-3 Taper type, configuration, 9-3 Technical assistance from Reliance Electric, 1-2 TEN FDBK LL BYPASS (P.845), 12-3 TEN FDBK LL LOW FREQ (P.835), 12-3 TEN FDBK LL RATIO (P.836), 12-3 TEN LEADLAG SELECT (P.837), 10-4, 10-5, 12-4, 12-6 TEN LOOP ERROR (P.834), 10-3, 12-3 TEN OUT LL LOW FREQ (P.838), 12-6 TEN OUT LL RATIO (P.839), 12-6 TEN PI KP OUT (P.879), 10-2, 10-3, 12-5 TEN PI LEAD FREQ (P.840), 10-3, 12-3, 12-5 TEN PI PROP GAIN (P.841), 10-2, 10-6, 12-4, 12-5 TEN PROFILER ENABLE (P.878), 10-2, 10-5, 12-3, 12-5 TEN RAMP OUTPUT (P.842), 10-3, 10-4, 12-1, 12-6 TEN RAMP TIME (P.833), 10-3, 10-5, 12-1, 12-4 TEN TO CURRENT OUT (P.876), 10-2 TEN/DANCER FDBK SCALED (P.489), 11-5, 12-2 TENSION DEMAND (P.844), 9-4, 9-5, 10-2, 10-3, 12-1 TENSION FDBK MAX (P.851), 11-4, 12-2 TENSION FDBK MIN (P.852), 11-4, 12-2 TENSION LOOP PI block, setting up, 12-3 TENSION ON DIN TP (P.498), 9-2 Tension outer control loop, configuration, 12-1 Tension PI input, 12-1, 10-3 TENSION PI LIMIT (P.853), 10-4, 12-5, 12-6 Tension PI limits for the slack take-up function, 12-6 Tension PI output, 10-3, 12-5 Tension regulators, application guidelines for, A-5 TENSION SETPOINT (P.854), 9-1, 9-2, 9-5 TENSION SETPOINT GAIN (P.415), 9-1, 9-2 TENSION SETPOINT IN (P.492), 9-2 TENSION SETPOINT SEL (P.855), 9-1, 9-2, 10-5, 12-4 TENSION SETPOINT ZERO (P.414), 9-1, 9-2 Tension setpoint, configuring, 9-1 TENSION SETPT SIG TYPE (P.413), 9-1, 9-2 TENSION VERNIER (P.856), 10-3, 10-4, 12-5 TENSION/DANCER FDBK (P.493), 11-4, 12-2 TENSION/DANCER GAIN (P.417), 11-4, 12-2 TENSION/DANCER ZERO (P.416), 11-4, 12-2 Tension-to-current scaling, 10-2 TOP LINE SPEED (P.020) configuring trim, 3-4 current compounding, 3-13 definition, 3-7 diameter calculator update threshold, 6-2
TAPER ENABLE
inertia-to-current scaling, 7-2 losses compensation, 8-1 OCL proportional trim, 3-11 position gain profiler, 11-2 speed loop reference, 3-3 speed reference ramp, 3-5 TORQUE REFERENCE (P.189), 4-2 TRIM MODE SELECT (P.110), 3-4, 3-5, 3-8, 3-9 TRIM OUTPUT (P.197), 3-5 TRIM RANGE (P.109), 3-4 TRIM REF REGISTER (P.107), 3-3, 3-4 TRIM REFERENCE SELECT (P.108), 3-3, 3-4 Trim, configuring, 3-3 Type 3 position regulator, 11-6
U
UNDERWIND COMMAND UNWIND DIAMETER IN
(P.877), 13-4 (P.828), 6-2
V
Voltage and field control, application guidelines for, A-6
W
(P.126), 5-3 Web applications, basics of, A-1 WebPakCS, 1-1 WIDTH/BUILDUP FACTOR (P.872), 7-2 WINDAGE LOSS (P.243), 8-1, 8-2 WINDER CORE DIA 1 (P.822), 6-2, 6-3 WINDER CORE DIA 2 (P.824), 6-2, 6-3 WINDER CORE DIA 3 (P.825), 6-2, 6-3
WEAKENED FIELD DIA
Index
Index-6
U.S. Drives Technical Support Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives
Publication D2-3446 June 2000
Copyright 2000 Rockwell Automation, Inc. All Rights Reserved. Printed in USA

wp3000 rm001

Загружено:

Сведения о документе

Исходное описание:

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

wp3000 rm001

Загружено:

Авторское право:

Доступные форматы

WebPak 3000 DC Drive Application Workbook Version 1.

Instruction Manual D2-3446

WebPak 3000 DC Drive Application Workbook, Version 1.1

WebPak 3000 DC Drive Application Workbook, Version 1.1

Where to Find Additional Information

Hardware, including installation, wiring, and troubleshooting information: See

Software, including parameter descriptions and block diagrams: See D2-3444,

The Operator Interface Module (OIM), including setting parameters, saving

Configuration Software: See D2-3447, WebPakCS Configuration Software.

Getting Assistance from Reliance Electric

WebPak 3000 DC Drive Application Workbook, Version 1.1

If You Are Using WebPakCS Software to Configure the Drive

If You Are Using the OIM to Configure the Drive

How to Use This Manual

2.3.1 For Position Loops

2.3.2 For Current and Tension Loops

WebPak 3000 DC Drive Application Workbook, Version 1.1

Configuring the Speed Loop

The Speed Loop Reference

- The drive uses the reference from the OIM.

- The drive uses the reference from the network.

If the CONTROL SOURCE (P.000) = TERMBLK:

Range: ANALOG, FREQUENCY IN

If LINE SPEED REF SELECT (P.103) = ANALOG:

WebPak 3000 DC Drive Application Workbook, Version 1.1

Set TOP LINE SPEED (P.020).

If LINE SPEED REF SELECT (P.103) = FREQUENCY IN:

Set FREQ IN ZERO (P.423).

SOURCE SELECT OUT

If the CONTROL SOURCE (P.000) = NETWORK:

3.1.1 Configuring Trim (Optional)

Configuring the Speed Loop

Range: REGISTER, ANALOG, NETW IN REG 1, 2, 3

If TRIM REFERENCE SELECT (P.108) = REGISTER:

Set TRIM REF REGISTER (P.107).

If TRIM REFERENCE SELECT (P.108) = ANALOG

If necessary, adjust the gain using DIAMETER/TAPER GAIN (P.104).

If necessary, remove any offset using DIAMETER/TAPER ZERO (P.105).

ANALOG TRIM REF

(P.195) displays the scaled output of the analog input.

The Speed Reference Ramp

WebPak 3000 DC Drive Application Workbook, Version 1.1

- Used when the drive is configured as:

Range: NO TRIM, INCREMENTAL, PROPORTIONAL

3.2.1 The LIMIT Block

- Allows the drive to operate down to zero speed.

Range: ON, OFF

Set DIAMETER CALC ENABLE (P.826) to DISABLE.

Configuring the Speed Loop

Leave DIAMETER REGISTER (P.874) at its default value of 1.000.

v Set LINE SPEED HYSTERESIS (P.136).

WebPak 3000 DC Drive Application Workbook, Version 1.1

feet per minute.

ATTENTION: The drives overspeed protection is based on GEAR IN SPEED

3.2.2 The S-CURVE Block

Range: ON, OFF

If SPEED RAMP BYPASS (P.112) = OFF:

v Set STOP MODE SELECT (P.114). The choices are:

Range: RAMP, COAST/DB, CURRENT LIMIT

WebPak 3000 DC Drive Application Workbook, Version 1.1

The choices for STOP DECEL SELECT (P.122) are:

Range: P.002, P.018