Winder Setting Manual

Content
1. Winder Configuration
2. WEB Control Block
3. iS7 Terminals
4. Individual TEST
5. Interlocking TEST
6. PID TEST
7. WEB Parameters
8. Basic Trouble Shooting

2011. 05. 31

LS Industrial Systems
Winder Configuration Winder Manual

Direction

Encoder
Feedback
Gear Ratio Gear Ratio (Selectable)
G1 G2

Dancer/Load-cell
Feedback
Control INV 1 I1
INV 2
Panel (Master) (Spooler)
Spd Ref. Spd Ref
Encoder
V1 AO1 V1
Option

(Tension, WEB S/W

Main Speed) Encoder Card
(Ext. I/O Card)

V2

Tension Reference
iS7 WEB Control Block Winder Manual

Main Spd. [%] Speed Final Main Spd. Final Spd. Ref. [Hz]
Final Speed
Reference
Calculation
Part
Current Freq.
[Hz]
Diameter [%]

Diameter
Calculation

Diameter [%]

WEB PID
Web
Break Controller PID Output
Error Compensation [Hz]

PID Feedback [%]

WEB Break
iS7 Terminals Winder Manual
Unwinder
P1 Fx

iS7
P2 RST
R (L1) U Input P3 Bx
S (L2) Main Power Output V M P4 JOG
T (L3) W V1 Freq Ref Src
A1 Trip
P1 AO1 (0~10V)
P2 Analog Frequency
AO2 (0~20mA) AO1
P3 Output 5G Output (for Winder Main spd.)
P4 Frequency
P5 DC 24V 24V AO2
Digital Input (for Display unit)
P6
P7
P8 Winder (Web OS)
CM P1 Fx
A1
VR+ Relay 1 P2 RST
VR- (N.O./N.C.) C1
P3 Bx
V1 Analog Input B1
Voltage / Current P4 Web Preset
I1
5G A2 Input P5 Web Bobbin-L
Relay 2
V2 Ext. I/O (N.O.) C2 P6 Web Bobbin-H
V1 Main Spd Src
S+ Q1
Open Collector
S- RS-485 EG V2 Tension Reference
Output
CM
I1 PID F/B Source
A1 Trip
Output Frequency
AO1
(for Display unit)
Step 1. Master & Spooler Individual Test Winder Manual

Check the power terminals and control terminals ▣ Motor Auto-tuning

Group Code Function

DRV 14 Motor Capacity Motor Cap.
Check the direction of motor rotating BAS 11 Pole Number Motor Poles
 Command direction and actual motor direction 12 Rated Slip Rated Slip
13 Rated Curr Rated Current
in V/F Mode
14 Noload curr No-load current
 If it is opposite direction, 15 Rated Volt Rated Voltage
change any 2 terminals of inputs(U/V/W) 16 Efficiency Motor Efficiency
BAS 20 Auto Tuning Auto-tuning
each other
21 Rs Stator Resistance
22 Lsigma Leakage Inductance
Vector Auto-tuning 23 Ls Stator Inductance
 Set the actual data of motor in the drive 24 Tr Rotor time constant
 Rotational / Standstill Selectable
▣ Parameters for encoder

Group Code Function

BAS 20 Auto Tuning Auto-tuning
Check Encoder F/B APO 01 Enc Opt Mode Encoder Opt Mode
 Check wiring between encoder and option card 04 Enc Type Sel Encoder type
05 Enc Pulse Sel Encoder pulse Select
 Set encoder data in APO
06 Enc Pulse Num Encoder pulse No.
 Check motor direction and encoder pulse 08 Enc Monitor Pulse monitoring
Step 2. Master & Spooler Interlocking Test Winder Manual

Check Spd. Command from control panel

 Check the analog signal from control panel
to Master
 If there is some deviation,
adjust it with Bias and Gain values(V or I)
Control INV 1 INV 2
in IN Group in Master iS7 Panel (Master) (Spooler)

WEB S/W
Encoder
Check Master’s main speed command (Tension,
Main Spd)
Option
(Ext. I/O)

 Check the analog speed signal from Master

to Spooler
 If there is some deviation,
adjust it with Bias and Gain values(V or I)
in IN Group in Spooler iS7

Start testing Master & Spooler’s interlocking operating

 Check if any kind of problems coming up
Step 3. PID Control TEST Winder Manual

Check the direction of PID Feedback

 The direction of Feedback from a dancer or load-cell(+/-)
 You may check it in IN Group with the monitoring parameter
 If its direction is wrong, you may use the parameter for signal inverting in IN Group

Set the range of Tension sensors (Dancer/Load-cell)

 Set the point of 0% and 100% of PID Reference
 Match 4mA to 0% and 20mA to 100%
 You may use the parameters for Bias and Gain of I(A) in IN Group

PID Operation TEST

 APP 01 : Select 5 (Tension Ctrl)
 APP 05 : Select V or I as the main speed command
 APP 19, 20 : Set PID Reference (ex : 50% , Keypad)
 APP 21 : Select the signal type from tension sensors (V or I)
 Start PID Test and check the fluctuation of Feedback and speed according to sensor
Step 4. Unwinder (Master) Setting (1) Winder Manual

※ Master Drive
DRV 03 ACC Time
 Set the acc. time depending on the features
of material Control INV 1 INV 2
Panel (Master) (Spooler)
DRV 04 DeC Time WEB S/W
Encoder
 Set the dec. time depending on the features (Tension,
Main Spd)
Option
(Ext. I/O)

of material

DRV 06 Cmd Source

 Set the Run/Stop command type (Normally Fx/Rx-1)

DRV 07 Freq Ref Src

 Set the Frequency command type (V1 / I)

DRV 09 Control Mode

 V/F mode / Sensorless-1 mode

DRV 11 Jog Frequency

 If it need to set the material with low speed operation, you may use this fuction
Normally setting it to 3~10Hz (Depending on the machine)
Step 4. Unwinder (Master) Setting (2) Winder Manual

OUT 01 AO1 Mode (Voltage Type : 0~10V)

 Send main speed command to Spooler
 Set it 0 (Frequency), then Spooler follows Master

Master Spooler

AO1 : Frequency
V1

[Note] Speed

 If each Run signal of Master and Spooler is off at the

same time, Spooler may not follow Master’s speed exactly
Master
(Spooler will decelerate according to its dec. time
Run
Signal

 In order that Spooler follows Master exactly,

Spooler’s Run signal has to be off after Master stops Spooler
Run
Signal
Step 4. Unwinder (Master) Setting (3) Winder Manual

※ You may use DC Brake function in order to prevent Roll-back

ADV 14 DC-Block Time

 Output Block Time before braking. It needs to be short in applications need prompt stop

ADV 15 DC-Brake Time

 Set DC-Braking Time. The longer it needs to be, The higher inertia applications has

ADV 16 DC-Brake Level

 Set the DC-Braking Level. The longer it needs to be, The higher inertia applications has

ADV 17 DC-Brake Freq ADV14 ADV15

 Set the point that start braking. ADV 17

Frequency
It will be the frequency
that the winder starts rolling-back
Voltage

ADV 16
Current

Run
Step 5. Winder (Spooler) (1) Winder Manual

※ Spooler Drive

DRV 09 Control Mode : V/F, Sensorless, Vector

 Select the mode

APP 01 APP Mode : Tension Ctrl Control INV 1 INV 2

Panel (Master) (Spooler)
 Select Tension Ctrl for winder system WEB S/W
Encoder
(Tension, Option
Main Spd) (Ext. I/O)
APP 02 Tnsn Ctrl Mode : Winder
 Select Winder (Spooler)

APP 05 Main Spd Src

 Select V1 : If the command comes through Master’s AO1
Select FieldBus or Int485 : If it comes through Communications
You may check the current main speed[%] in APP 03 Main Spd Disp

APP 06 Main XcelT En : NO

 Set the dec. time for main speed command
It has to be No, if Spooler must follow Master’s Acc./Dec. patterns
Step 5. Winder (Spooler) (2) Winder Manual

APP 19 PID Ref Set

 Set PID Reference Value
Set the target position of dancer or load-cell [%]

PID REF : 100 [%]

Dancer Roll PID REF : 50 [%] Target position

PID REF : 0 [%]

APP 21 PID F/B Source

 Set PID Feedback Source
※ iS7 provides 2 Analog input terminals (1 Voltage(V1) / 1 Current type(I))
If Main speed command is V1, PID Feedback source is I

※ If you need more analog terminals, you may mount Ext. I/O Option card
(Ext. I/O provide 2 voltage type and 2 current type terminals)
Step 5. Winder (Spooler) (3) Winder Manual

APP 22 PID P-Gain

 Set P-gain for PID Control. If the error value is 100[%], the P controller’s output will be 100[%]
The higher P-gain is, the faster the response is but the system could be unstable

APP 23 PID I-Time

 Set I-gain for PID Control. If it is 10[sec] and the error value is 100[%],
I controller’s output time will be 10[sec]
 The lower I-gain is, the faster the response is but the system could be unstable

APP 27 PID Out LPF : 0

 Set PID Output Delay time
Normally set it to 0 for quick response
 The lower this is, the faster the response is but the system could be unstable
Step 5. Winder (Spooler) (4) Winder Manual

APP 31 PID Out Inv

 If it is set Yes, PID output will be inverted
 If the sensor’s direction is wrong, you may use it to correct the direction

Inverted Current F/B

PID F/B = 100[%] PID F/B = 0[%]

PID F/B = 0[%] PID F/B = 100[%]

APP 32 PID Out Scale

 Set the scale of PID output
 Normally set it high value to prevent saturation PID Controller

APP 51 PID Start Ramp

 Set the ramp time of PID output to prevent dancer or load-cell’s overshoot at starting
 It is the ramp time when PID output increases from 0 to 100[%]
Step 5. Winder (Spooler) (5) Winder Manual

APP 54 Fixed PID En : NO

 NO : PID output is proportional to main speed command
 YES : PID output is fixed regardless of main speed command

APP 55 Min Fixed PID

 APP54 is No, PID output is proportional to main speed command
 Dancer position will be too low at starting because PID output value is too low at low speed
In this case, you may use Min Fixed PID to adjust dancer position at starting

① APP 54 Fixed PID En : YES ② APP 54 Fixed PID En : NO

PID output PID output

[%] [%]

PID output is fixed as much as PID output is

the value in APP32 PID Out Scale proportional to
Main speed command

Main Speed APP55 Min Fixed PID value Main Speed

Command [%] command[%]
Step 5. Winder (Spooler) (6) Winder Manual

APP 63~66 Bobbin # Diamtr

 Select bobbin size with combination of digital inputs (4 kinds)
 Initialize the current bobbin size with “Web Preset” signal

DI “Web Bobbin-H” DI “Web Bobbin-L Selected bobbin

- - Bobbin 1 (APP63)
- On Bobbin 2 (APP64)
On - Bobbin 3 (APP65)
On On Bobbin 4 (APP66)

APP 67 Min Diameter

 It means the minimum sized bobbin

③ ④⑤
②
①

Bobbin 1 Bobbin 2 Bobbin 3 Bobbin 4

①/⑤ *100 ②/⑤ *100 ③/⑤ *100 ④/⑤ *100
=Min
Diameter
Step 5. Winder (Spooler) (7) Winder Manual

APP 92 Max Main Spd

 Set the max. speed[Hz] at 100[%] main speed command with the minimum size bobbin

MaxLineSpeed [mpm] MotorPole

[ Hz ] 
MaxMainSpd　 * GearRatio *
　MinBobbinS ize[m] *  120

※ Gear Ratio = Motor speed is faster than the final speed with gear