Contents

Mitsubishi A800 FR-A840-FR-A842-07700-315K Inverter Function Manual PDF

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Summary of Content for Mitsubishi A800 FR-A840-FR-A842-07700-315K Inverter Function Manual PDF

Roll to Roll Function

800-R2R IN

VER TER

A 800 Plus

IN

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N M

A N

U A

L (R O

LL TO R

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N C

TIO N

M A

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ROLL TO ROLL FUNCTION MANUAL FR-A820-00046(0.4K)-04750(90K)-R2R FR-A840-00023(0.4K)-06830(280K)-R2R FR-A842-07700(315K)-12120(500K)-R2R

The FR-A800-R2R inverter has dedicated functions for roll to roll applications, in addition to the functions of the standard type FR-A800 inverter. This Roll to Roll Function Manual explains the functions dedicated to the FR-A800-R2R inverter. For the functions not found in this Function Manual, refer to the Instruction Manual of the FR-A800 inverter. In addition to this Roll to Roll Function Manual, please read the Instruction Manual of the FR-A800 inverter carefully. Do not use this product until you have a full knowledge of the equipment, safety information and instructions. Please forward this Function Manual to the end user.

INVERTER

IB(NA)-0600622ENG-G(2111) MEE Printed in Japan Specifications subject to change without notice.

HEAD OFFICE: TOKYO BUILDING 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN

CONTENTS 1

1 INTRODUCTION 5 1.1 FR-A800-R2R overview 5

1.2 SND rating 8 1.2.1 Multiple rating setting........................................................................................................................................8

2 PARAMETER LIST 11 2.1 Parameter list (by parameter number) 11

2.2 Parameter list (by function group) 33

3 DANCER FEEDBACK SPEED CONTROL 44 3.1 Dedicated function list 44

3.2 System configuration example 45

3.3 Control block diagram 46 3.3.1 Analog input signals and pulse train input signals ..........................................................................................47

3.4 Parameter setting procedure for dancer feedback speed control 48 3.4.1 Parameter setting procedure ..........................................................................................................................48 3.4.2 Offline auto tuning...........................................................................................................................................55 3.4.3 Speed control gain adjustment .......................................................................................................................59 3.4.4 PID gain adjustment .......................................................................................................................................63

3.5 Dancer feedback speed control details 64 3.5.1 Dancer feedback speed control function selection .........................................................................................65 3.5.2 Winding/unwinding shaft selection..................................................................................................................67 3.5.3 Line speed command input.............................................................................................................................67 3.5.4 Compensation for line speed command input ................................................................................................76 3.5.5 Acceleration/deceleration time setting for line speed command.....................................................................79 3.5.6 Line speed command acceleration/deceleration pattern ................................................................................82 3.5.7 Dancer roll setting...........................................................................................................................................85 3.5.8 Dancer roll position detection .........................................................................................................................88 3.5.9 PID offset displacement..................................................................................................................................88 3.5.10 Dancer roll malposition detection....................................................................................................................89 3.5.11 Tension PI gain tuning....................................................................................................................................91 3.5.12 PID control gain setting...................................................................................................................................99 3.5.13 Integral control action setting........................................................................................................................100 3.5.14 Differential control action setting...................................................................................................................101 3.5.15 PID control gain selection .............................................................................................................................101 3.5.16 PID manipulated amount ..............................................................................................................................104 3.5.17 Reel change function ....................................................................................................................................106 3.5.18 Analog output signal function for dancer tension setting ..............................................................................108

CONTENTS

2 CONTENTS

4 TENSION SENSOR FEEDBACK SPEED CONTROL 113

4.1 Dedicated function list 113

4.2 System configuration example 114

4.3 Control block diagram 115

4.4 Parameter setting procedure for tension sensor feedback speed control 116 4.4.1 Parameter setting procedure........................................................................................................................ 116 4.4.2 PID gain adjustment ..................................................................................................................................... 122

4.5 Tension sensor feedback speed control details 123 4.5.1 Tension feedback setting ............................................................................................................................. 124 4.5.2 Tension feedback detection ......................................................................................................................... 126 4.5.3 PID offset displacement ............................................................................................................................... 126 4.5.4 Tension feedback malposition detection ...................................................................................................... 127

5 TENSION SENSORLESS TORQUE CONTROL 130 5.1 Dedicated function list 130

5.2 System configuration example 130

5.3 Control block diagram 131 5.3.1 Block diagram of tension sensorless torque control function ....................................................................... 131

5.4 Parameter setting procedure for tension sensorless torque control 132 5.4.1 Parameter setting procedure........................................................................................................................ 132

5.5 Tension sensorless torque control details 139 5.5.1 Tension sensorless torque control setting method....................................................................................... 139 5.5.2 Input method of tension command ............................................................................................................... 140 5.5.3 Torque generation direction setting.............................................................................................................. 143 5.5.4 Speed limit.................................................................................................................................................... 146 5.5.5 Taper function .............................................................................................................................................. 151 5.5.6 Inertia compensation function ...................................................................................................................... 157 5.5.7 Mechanical loss compensation function....................................................................................................... 163 5.5.8 Stall mode function....................................................................................................................................... 165

6 TENSION SENSOR FEEDBACK TORQUE CONTROL 167

6.1 Dedicated function list 167

6.2 System configuration example 167

6.3 Control block diagram 168 6.3.1 Block diagram of tension sensor feedback torque control function .............................................................. 168

6.4 Parameter setting procedure for tension sensorless torque control 169

CONTENTS 3

6.4.1 Parameter setting procedure ........................................................................................................................169

6.5 Tension sensor feedback torque control details 176 6.5.1 Tension sensor feedback torque control function selection..........................................................................177 6.5.2 Winding/unwinding shaft selection................................................................................................................178 6.5.3 Tension feedback setting..............................................................................................................................178 6.5.4 Tension feedback malposition detection.......................................................................................................180 6.5.5 Tension feedback detection..........................................................................................................................181 6.5.6 PID offset displacement................................................................................................................................182 6.5.7 PID control gain setting.................................................................................................................................182 6.5.8 Integral control action setting........................................................................................................................182 6.5.9 Differential control action setting...................................................................................................................182 6.5.10 PID control gain selection .............................................................................................................................182 6.5.11 Signed winding diameter compensation torque command selection............................................................183 6.5.12 Converting the PID manipulated amount to values in different units ............................................................183

7 SPEED CONTROL OF INTERMEDIATE SHAFTS 184

7.1 System configuration example 184

7.2 Parameter setting procedure for speed control of intermediate shafts 185 7.2.1 Parameter setting procedure ........................................................................................................................185 7.2.2 Offline auto tuning.........................................................................................................................................188 7.2.3 Speed control gain adjustment .....................................................................................................................188

8 SPEED CONTROL OF REFERENCE SHAFT 189 8.1 System configuration example 189

8.2 Parameter setting procedure for speed control of reference shaft 190 8.2.1 Parameter setting procedure ........................................................................................................................190 8.2.2 Offline auto tuning.........................................................................................................................................193

9 WINDING DIAMETER COMPENSATION FUNCTION 194

9.1 Winding diameter calculation and winding diameter compensation function 195

9.2 Winding diameter calculation setting 196 9.2.1 Block diagram...............................................................................................................................................196 9.2.2 Basic setting for winding diameter calculation ..............................................................................................197 9.2.3 Winding diameter calculation using actual line speed (actual line speed method).......................................199 9.2.4 Winding diameter calculation using material thickness (thickness method) .................................................203 9.2.5 Line speed at winding diameter calculated value activation .........................................................................204 9.2.6 Averaging process for winding diameter calculation.....................................................................................205 9.2.7 Minimum/maximum winding diameter ..........................................................................................................206 9.2.8 Winding diameter compensation speed filter................................................................................................207 9.2.9 Target winding diameter achieved................................................................................................................208 9.2.10 Winding diameter calculation at a start (dancer feedback speed control) ....................................................208 9.2.11 Initial winding diameter calculation at a start (Tension sensor feedback speed control / tension sensorless

torque control / tension sensor feedback torque control)..............................................................................212

4 CONTENTS

9.2.12 Winding diameter / winding length storage .................................................................................................. 213 9.2.13 Speed control proportional gain selection according to the winding diameter calculation result.................. 216

10 ROLL TO ROLL FUNCTION RELATED PARAMETERS 218

10.1 Monitoring of dedicated functions 218 10.1.1 Monitoring of roll to roll dedicated functions ................................................................................................. 218 10.1.2 Monitor reference ......................................................................................................................................... 224 10.1.3 PID measured tension value ........................................................................................................................ 226

10.2 Roll to roll dedicated I/O signal 227 10.2.1 Input signal ................................................................................................................................................... 227 10.2.2 Output signal ................................................................................................................................................ 230

10.3 Two-way operation function 232

10.4 Operation command source and speed command source (Pr.338, Pr.339) 233

10.5 Encoder input option selection 234

11 APPENDIX 235 11.1 Differences in the functions from the standard inverter 235

11.2 Parameter write selection 237

11.3 Compatible options 240

11.4 Registers dedicated to CC-Link 241

11.5 Common specifications 242

11.6 Application examples 243 11.6.1 Dancer feedback speed control with roll diameter compensation for printers.............................................. 243 11.6.2 Dancer feedback speed control with roll diameter compensation for wire drawing machines ..................... 248 11.6.3 Tension sensorless torque control with roll diameter compensation for printers.......................................... 252 11.6.4 Tension sensor feedback torque control with roll diameter compensation for fabric inspection machines .. 256

11.7 Parameters (functions) and instruction codes under different control methods 261

11.8 Index 283

FR-A800-R2R overview

INTRODUCTION 5

1

1 INTRODUCTION

1.1 FR-A800-R2R overview The FR-A800-R2R inverter with dedicated functions is useful for winding machines with dancer rolls when a difference

between the minimum diameter and the maximum diameter is large, a fast feeding speed is required, etc. This product is also useful for roll to roll winding applications such as for wire drawing machines and paper rolling machines

for printers. The following four control functions are available for keeping a constant tension on the workpiece.

The following table shows the main parameter settings required to enable the four control functions.

To use the winding diameter calculation function during speed control without feedback, set Pr.128 = "40 or 41" and turn ON the X114 signal. To feed paper or wire, turn ON all X114, X115, and X116 signals and disable winding diameter compensation and PID compensation so that the

line speed command for tension control (dancer feedback speed control / tension sensor feedback speed control) is used for the feed operation.

The following table shows the combinations of control method/mode of the inverter and the validity of the four control functions.

: Valid, : Invalid The setting values of 100 and above are used when the fast-response operation is selected. (For the SND rating, the fast-response operation is

not available.) Advanced magnetic flux vector control is applied if a vector control compatible option is not installed. V/F control is applied when Pr.80 or Pr.81 is "9999", regardless of the Pr.800 setting. The control method can be changed using the MC signal while the inverter is stopped.

Control function Description Dancer feedback speed control Speed control to keep the line speed and the dancer roll position constant. Tension sensor feedback speed control Speed control to keep the line speed and the tension sensor feedback constant.

Tension sensorless torque control Torque control to keep a constant tension on the workpiece without using a dancer roll and a tension controller.

Tension sensor feedback torque control Torque control to more accurately keep a constant tension on the workpiece using feedback from the tension sensor.

Control function Pr.178 to Pr.186 (Input terminal function selection)

Pr.128 PID action selection Control method

Dancer feedback speed control 114 (Assign the X114 signal to an input terminal.)

40 or 41 Vector control or Real sensorless vector control is recommended.

Tension sensor feedback speed control Tension sensorless torque control Setting not required Tension sensor feedback torque control 40 or 41

Pr.80 (Pr.453),

Pr.81 (Pr.454)

Pr.800 setting

Pr.451 setting

Control method Control mode

Validity of control function Dancer feedback

speed control / tension sensor feedback

speed control

Tension sensorless torque control / tension sensor feedback torque

control MC-ON MC-OFF MC-ON MC-OFF

Motor capacity, number of motor poles

0, 100

Vector control

Speed control 1, 101 Torque control

2, 102 Speed control/torque control switchover

9, 109 Vector control test operation 10, 110

Real sensorless vector control

Speed control 11, 111 Torque control

12, 112 Speed control/torque control switchover

20 (initial value)

20 Advanced magnetic flux vector control

Speed control

9999 (initial value)

Advanced magnetic flux vector control for the second motor

9999 V/F control

FR-A800-R2R overview

6 INTRODUCTION

Speed command / torque command information The speed command / torque command differs depending on whether the controls are enabled or disabled as follows.

Speed command / torque command and calibration parameters The following tables show the speed command / torque command which differ depending on the combination of the X114 signal (Tension control selection) and Pr.128 PID action selection, and calibration parameters for each command. Speed command during dancer feedback speed control / tension sensor feedback speed control

Torque command during tension sensorless torque control

Torque command during tension sensor feedback torque control

The frequency command cannot be input using the terminal selected as the line speed command input terminal in Pr.361 Line speed command input selection. Set "0" in Pr.361 to input a frequency command. (For example, to input a frequency command while Pr.361 = "3", input the command from a terminal other than terminal 2.) Set "0" in Pr.361 to use the same terminal to input a line speed command and a frequency command. In this case, the bias and gain parameter settings must be consistent for both command types. Calibration parameters for frequency command input: Pr.125, Pr.126, C2 (Pr.902) to C7 (Pr.905), C12 (Pr.917) to C15 (Pr.918) Calibration parameters for line speed command input: Pr.350 to Pr.353

To feed paper or wire, turn ON all X114, X115, and X116 signals and disable winding diameter compensation and PID compensation so that the line speed command for tension control (dancer feedback speed control / tension sensor feedback speed control) is used for the feed operation.

The setting unit can be selected by using Pr.358 Line speed unit. The setting increment can be selected by using Pr.1401 Tension command increment.

Dancer feedback speed control /Tension sensor feedback speed control Speed command

Disabled Frequency [Hz] Enabled Line speed [m/min]

Tension sensorless torque control / Tension sensor feedback torque control Torque command

Disabled Torque [%] Enabled Tension [N]

X114 signal (Tension control

selection)

Pr.128 setting (PID action selection)

Dancer feedback speed control / Tension sensor feedback speed control

Speed command

Analog input calibration

Speed command setting unit Calibration parameter

OFF 0 (initial value)

Disabled Frequency

Hz Pr.125, Pr.126, C2 (Pr.902) to C7 (Pr.905), C12 (Pr.917) to C15 (Pr.918)

40 or 41

ON 0 (initial value) 40 or 41 Enabled Line speed m/min Pr.350 to Pr.353

X114 signal (Tension control

selection)

Tension sensorless torque control

Torque command

Analog input calibration Torque command setting increment Calibration parameter

OFF Disabled Torque % C16 (Pr.919) to C19 (Pr.920), C38 (Pr.932) to C41 (Pr.933)

ON Enabled Tension N Pr.1402 to Pr.1405

X114 signal (Tension control

selection)

Pr.128 setting (PID action selection)

Tension sensor feedback Torque control

Torque command

Analog input calibration

Torque command setting increment Calibration parameter

OFF 0 (initial value)

Disabled Torque % C16 (Pr.919) to C19 (Pr.920), C38 (Pr.932) to C41 (Pr.933)40 or 41

ON 0 (initial value) 40 or 41 Enabled Tension N Pr.1402 to Pr.1405

CAUTION The X114 signal and Pr.128 must be set in any combination shown in the tables above to prevent the

motor from operating at an unintended speed. Before operating the inverter, use parameters shown in the tables above to calibrate each command

value according to whether each control is enabled or disabled.

FR-A800-R2R overview

INTRODUCTION 7

1

Inverter model Unpack the product and check the rating plate and the capacity plate of the inverter to ensure that the model agrees with the order and the product is intact.

Applicable for the FR-A820-00340(5.5K) or higher, and the FR-A840-00170(5.5K) or higher.

FR-A800-R2R dedicated functions The FR-A800-R2R has the following dedicated functions for roll to roll applications, in addition to the functions of the standard FR-A800 inverter. For information on the other functional differences, refer to page 235.

Abbreviations

Notes on descriptions in this Instruction Manual Connection diagrams in this Instruction Manual appear with the control logic of the input terminals as sink logic, unless

otherwise specified.

FR-A800-R2R dedicated functions Dancer feedback speed control function Tension sensor feedback speed control function Tension sensorless torque control function Tension sensor feedback torque control function Winding diameter compensation function

Abbreviation / generic name Description DU Operation panel (FR-DU08) Operation panel Operation panel (FR-DU08) and LCD operation panel (FR-LU08) Parameter unit Parameter unit (FR-PU07) PU Operation panel and parameter unit Inverter Mitsubishi Electric FR-A800 series inverter FR-A800-R2R FR-A800-R2R roll to roll dedicated inverter

Vector control compatible option FR-A8AP/FR-A8AL/FR-A8APR/FR-A8APS (plug-in option), FR-A8TP (control terminal option)

Pr. Parameter number (Number assigned to function) Vector control dedicated motor SF-V5RU High-performance energy-saving motor with encoder SF-PR-SC

F R - A 8 2 0 - 00046 - 1 - 60 R2R

400 V class

Symbol Voltage class 200 V class

4 2

Symbol Description

0.4K to 500K 00023 to 12120

Inverter ND rated capacity (kW) Inverter SLD rated current (A)

Separated converter type

Symbol Structure, functionality Standard model

2 0

Symbol Application Roll to roll dedicated modelR2R

Symbol Circuit board coating (IEC60721-3-3: 1994 3C2/3S2 compatible) Plated conductor

With With

With Without

06

60 Without WithoutNone

CA

Symbol Type

Communication type

RS-485

Ethernet

FM 2

CAE2

1

FME1

SND rating

8 INTRODUCTION

1.2 SND rating

1.2.1 Multiple rating setting

Changeover of the parameter initial values and setting ranges When inverter reset and all parameter clear are performed after setting Pr.570, the parameter initial values are changed

according to each rating as follows.

Five rating types of different rated current and permissible load are available. The optimal inverter rating can be chosen in accordance with the application, enabling equipment size to be reduced. As well as the ratings of the FR-A800 standard type inverters, the SND rating is available for the FR-A800-R2R series.

Pr. Name Initial value Setting range

Description (overload current rating, surrounding air temperature)

570 E301 Multiple rating setting 2

0 SLD rating 110% 60 s, 120% 3 s (inverse-time characteristics) Surrounding air temperature of 40C

1 LD rating 120% 60 s, 150% 3 s (inverse-time characteristics) Surrounding air temperature of 50C

2 ND rating 150% 60 s, 200% 3 s (inverse-time characteristics) Surrounding air temperature of 50C

3 HD rating 200% 60 s, 250% 3 s (inverse-time characteristics) Surrounding air temperature of 50C

12 SND rating 150% 60 s (inverse-time characteristics) Surrounding air temperature of 50C

Pr. Name Pr.570 setting

0 1 2 (initial value) 3 12

0 Torque boost

7 Acceleration time

8 Deceleration time

9 Electronic thermal O/L relay SLD rated current

LD rated current

ND rated current

HD rated current

SND rated current

12 DC injection brake operation voltage

22 Stall prevention operation level 110% 120% 150% 200% 150%

48 Second stall prevention operation level 110% 120% 150% 200% 150%

56 Current monitoring reference SLD rated current

LD rated current

ND rated current

HD rated current

SND rated current

114 Third stall prevention operation level 110% 120% 150% 200% 150% 148 Stall prevention level at 0 V input 110% 120% 150% 200% 150% 149 Stall prevention level at 10 V input 120% 150% 200% 250% 200% 150 Output current detection level 110% 120% 150% 200% 150%

165 Stall prevention operation level for restart 110% 120% 150% 200% 150%

557 Current average value monitor signal output reference current

SLD rated current

LD rated current

ND rated current

HD rated current

SND rated current

874 OLT level setting 110% 120% 150% 200% 150%

893 Energy saving monitor reference (motor capacity)

SLD rated motor capacity

LD rated motor capacity

ND rated motor capacity

HD rated motor capacity

SND rated motor capacity

SND rating

INTRODUCTION 9

1

Initial values differ depending on the rating as follows. The value in the parentheses is the initial value for the 400 V class.

The rated current and motor capacity values differ according to the inverter capacity. For the inverter rated specifications, refer to the Instruction Manual (Startup/Hardware) of the inverter.

The initial value for the FR-A820-00077(0.75K) or lower and FR-A840-00038(0.75K) or lower is set to the 85% of the inverter rated current.

NOTE When Pr.570 = "0" (SLD rating), carrier frequency automatic reduction is enabled regardless of the setting in Pr.260 PWM

frequency automatic switchover. To use FR-A820-03160(55K) / FR-A840-01800(55K) inverter with the LD or SLD rating, the DC reactor corresponding to the

applied motor, which is available as an option, is required. When the FR-A820-03160(55K) / FR-A840-01800(55K) inverter is used with the LD or SLD rating, the setting increment and

the setting range of the parameters in the FR-A820-03800(75K) / FR-A840-02160(75K) or higher inverter are applied. In an example of Pr.9, the setting increment changes from 0.01 A to 0.1 A and the setting range changes from "0 to 500 A" to "0 to 3600 A".

Restrictions For setting the SND rating, the following limitations apply.

Pr. Pr.570 setting

200 V class: FR-A820-[]-R2R 00046 (0.4K)

00077 (0.75K)

00105 (1.5K)

00167 (2.2K)

00250 (3.7K)

00340 (5.5K)

00490 (7.5K)

00630 (11K)

00770 (15K)

00930 (18.5K)

01250 (22K)

01540 (30K)

01870 (37K)

02330 (45K)

03160 (55K)

03800 (75K)

04750 (90K)

400 V class: FR-A840-[]-R2R

00023 (0.4K)

00038 (0.75K)

00052 (1.5K)

00083 (2.2K)

00126 (3.7K)

00170 (5.5K)

00250 (7.5K)

00310 (11K)

00380 (15K)

00470 (18.5K)

00620 (22K)

00770 (30K)

00930 (37K)

01160 (45K)

01800 (55K)

02160 (75K)

02600 (90K) or higher

0 (%)

0, 1 6 4 4 4 3 3 2 2 2 2 2 2 1.5 1.5 1 1 1 2 6 6 4 4 4 3 3 2 2 2 2 2 2 2 2 1 1 3 6 6 6 4 4 4 3 3 2 2 2 2 2 2 2 2 1 12 6 4 4 4 3 3 3 (2) 2 2 2 2 2 1.5 1.5 1.5 1 1

7 (s)

0, 1 5 5 5 5 5 5 15 15 15 15 15 15 15 15 15 15 15 2 5 5 5 5 5 5 5 15 15 15 15 15 15 15 15 15 15 3 5 5 5 5 5 5 5 5 15 15 15 15 15 15 15 15 15 12 5 5 5 5 5 5 5 (15) 15 15 15 15 15 15 15 15 15 15

8 (s)

0, 1 10 10 10 10 10 10 30 30 30 30 30 30 30 30 30 30 30 2 5 5 5 5 5 5 5 15 15 15 15 15 15 15 15 15 15 3 5 5 5 5 5 5 5 5 15 15 15 15 15 15 15 15 15 12 5 5 5 5 5 5 5 (15) 15 15 15 15 15 15 15 15 15 15

12 (%)

0, 1 4 4 4 4 4 4 2 2 2 2 2 2 2 2 1 1 1 2 4 4 4 4 4 4 4 2 2 2 2 2 2 2 2 1 1 3 4 4 4 4 4 4 4 4 2 2 2 2 2 2 2 2 1 12 4 4 4 4 4 4 4 (2) 2 2 2 2 2 2 2 2 1 1

Item Description Maximum frequency The setting range of Pr.18 High speed maximum frequency is limited to 0 to 200 Hz. Carrier frequency The carrier frequency is fixed at 2 kHz. Pr.72 PWM frequency selection is invalid.

Fast-response operation The fast-response operation setting is not available. For Pr.800 Control method selection and Pr.451 Second motor control method selection, setting "100 to 102, 106, 109 (Pr.800 only), 110 to 112" is invalid.

SND rating

10 INTRODUCTION

Average current load detection For the SND rating, the Y239 signal is output when the output current average value reaches or exceeds 50% of the

inverter rated current. For the SND rating, when the instantaneous load factor reaches or exceeds 155% of the inverter rated current while the

output current average value is 50% or more of the inverter rated current, the protective function (E.THS) is activated, shutting off the inverter output.

NOTE The output current average value is reset to the initial value by the inverter's power reset or the reset signal input. Avoid

unnecessary reset and power-OFF. E.THS is available for the FR-A840-03250(110K) or higher.

The data code is used for checking the fault detail via communication or for setting Pr.997 Fault initiation. (Refer to the Instruction Manual (Detailed) of the FR-A800 inverter.)

Operation panel indication E.THS FR-LU08

indication Fault 12

Name Overload trip (Data code: 252 (HFC))

Description For the SND rating, when the instantaneous load factor reaches or exceeds 155% of the inverter rated current while the output current average value is 50% or more of the inverter rated current, the inverter trips.

Check point

Check that acceleration/deceleration time is not too short. Check that torque boost setting is not too large (small). Check that load pattern selection setting is appropriate for the load pattern of the machine. Check the motor for the use under overload. Check that the encoder wiring and the specifications (encoder power supply, resolution, differential/ complementary) are correct. Check also that the motor wiring (U, V, W) is correct (under vector control).

Corrective action

Set the acceleration time longer. Adjust the torque boost setting. Set the load pattern selection setting according to the load pattern of the using machine. Reduce the load. Check the wiring and specifications of the encoder and the motor. Perform the setting according to the specifications of the encoder and the motor (under vector control).

% value to the inverter rated current

Instantaneous load factor

50%

Output current average value

155% E.THS

Y239

Time

ON

Parameter list (by parameter number)

PARAMETER LIST 11

2

2 PARAMETER LIST

2.1 Parameter list (by parameter number) For simple variable-speed operation of the inverter, the initial values of the parameters may be used as they are. Set the necessary parameters to meet the load and operational specifications. Parameter's setting, change and check can be made on the operation panel (FR-DU08).

NOTE

indicates simple mode parameters. Use Pr.160 User group read selection to indicate the simple mode parameters only (initial setting is to indicate the extended mode parameters).

The changing of the parameter settings may be restricted in some operating statuses. Use Pr.77 Parameter write selection to change the setting of the restriction.

Refer to page 261 for instruction codes for communication and availability of Parameter clear, all clear, and Parameter copy.

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

0 G000 Torque boost 0 to 30% 0.1%

6%

4% 3% 2% 1%

1 H400 Maximum frequency 0 to 120 Hz 0.01 Hz 120 Hz 146 60 Hz

2 H401 Minimum frequency 0 to 120 Hz 0.01 Hz 0 Hz

3 G001 Base frequency 0 to 590 Hz 0.01 Hz 60 Hz 50 Hz

4 D301 Multi-speed setting (high speed) 0 to 590 Hz 0.01 Hz 60 Hz 50 Hz

5 D302 Multi-speed setting (middle speed) 0 to 590 Hz 0.01 Hz 30 Hz

6 D303 Multi-speed setting (low speed) 0 to 590 Hz 0.01 Hz 10 Hz

7 F010 Acceleration time 0 to 3600 s 0.1 s 5 s

15 s

8 F011 Deceleration time 0 to 3600 s 0.1 s 5 s 15 s

9 H000 Electronic thermal O/L relay

0 to 500 A 0.01 A Inverter rated current

0 to 3600 A 0.1 A

10 G100 DC injection brake operation frequency 0 to 120 Hz, 9999 0.01 Hz 3 Hz

11 G101 DC injection brake operation time 0 to 10 s, 8888 0.1 s 0.5 s

12 G110 DC injection brake operation voltage 0 to 30% 0.1%

4% 2%

1% 13 F102 Starting frequency 0 to 60 Hz 0.01 Hz 0.5 Hz 208 14 G003 Load pattern selection 0 to 5, 12 to 15 1 0

15 D200 Jog frequency 0 to 590 Hz 0.01 Hz 5 Hz 227

16 F002 Jog acceleration/deceleration time 0 to 3600 s 0.1 s 0.5 s 227

17 T720 MRS input selection 0, 2, 4 1 0

18 H402 High speed maximum frequency 0 to 590 Hz 0.01 Hz 120 Hz 60 Hz

19 G002 Base frequency voltage 0 to 1000 V, 8888, 9999 0.1 V 9999 8888

20 F000 Acceleration/deceleration reference frequency 1 to 590 Hz 0.01 Hz 60 Hz 50 Hz

21 F001 Acceleration/deceleration time increments 0, 1 1 0 79

22 H500 Stall prevention operation level (Torque limit level) 0 to 400% 0.1% 150%

Simple

Simple

Simple

Simple

Simple

Simple

Simple

Simple

Simple

Simple

Simple

Parameter list (by parameter number)

12 PARAMETER LIST

23 H610 Stall prevention operation level compensation factor at double speed

0 to 200%, 9999 0.1% 9999

24 to 27

D304 to

D307

Multi-speed setting (4 speed to 7 speed) 0 to 590 Hz, 9999 0.01 Hz 9999

28 D300 Multi-speed input compensation selection 0, 1 1 0

29 F100 Acceleration/deceleration pattern selection 0 to 6 1 0

30 E300 Regenerative function selection 0 to 2, 10, 11, 20, 21, 100 to 102, 110, 111, 120, 121

1 0

31 H420 Frequency jump 1A

0 to 590 Hz, 9999 0.01 Hz

9999

32 H421 Frequency jump 1B 9999

33 H422 Frequency jump 2A 9999

34 H423 Frequency jump 2B 9999

35 H424 Frequency jump 3A 9999

36 H425 Frequency jump 3B 9999

37 M000 Speed display 0, 1 to 9998 1 0

41 M441 Up-to-frequency sensitivity 0 to 100% 0.1% 10%

42 M442 Output frequency detection 0 to 590 Hz 0.01 Hz 6 Hz

43 M443 Output frequency detection for reverse rotation 0 to 590 Hz, 9999 0.01 Hz 9999

44 F020 Second acceleration/ deceleration time 0 to 3600 s 0.1 s 5 s

45 F021 Second deceleration time 0 to 3600 s, 9999 0.1 s 9999

46 G010 Second torque boost 0 to 30%, 9999 0.1% 9999

47 G011 Second V/F (base frequency) 0 to 590 Hz, 9999 0.01 Hz 9999

48 H600 Second stall prevention operation level 0 to 400% 0.1% 150%

49 H601 Second stall prevention operation frequency 0 to 590 Hz, 9999 0.01 Hz 0 Hz

50 M444 Second output frequency detection 0 to 590 Hz 0.01 Hz 30 Hz

51 H010 Second electronic thermal O/L relay

0 to 500 A, 9999 0.01 A 9999 0 to 3600 A, 9999 0.1 A

52 M100 Operation panel main monitor selection

0, 5 to 14, 17 to 20, 22 to 36, 38, 40 to 46, 50 to 57, 61 to 64, 67, 71 to 74, 81 to 93, 95 to 98, 100

1 0 218

54 M300 FM/CA terminal function selection

1 to 3, 5 to 14, 17 to 19, 21, 22, 24, 26 to 28, 30, 32 to 34, 36, 46, 50, 61, 62, 70, 81, 87 to 90, 92, 93, 95 to 98

1 1 108, 218

55 M040 Frequency monitoring reference 0 to 590 Hz 0.01 Hz 60 Hz 50 Hz 218

56 M041 Current monitoring reference 0 to 500 A 0.01 A Inverter rated current 218

0 to 3600 A 0.1 A

57 A702 Restart coasting time 0, 0.1 to 30 s, 9999 0.1 s 9999

58 A703 Restart cushion time 0 to 60 s 0.1 s 1 s

60 G030 Energy saving control selection 0, 4, 9 1 0

65 H300 Retry selection 0 to 5 1 0

66 H611 Stall prevention operation reduction starting frequency 0 to 590 Hz 0.01 Hz 60 Hz 50 Hz

67 H301 Number of retries at fault occurrence 0 to 10, 101 to 110 1 0

68 H302 Retry waiting time 0.1 to 600 s 0.1 s 1 s

69 H303 Retry count display erase 0 1 0

70 G107 Special regenerative brake duty 0 to 100% 0.1% 0%

71 C100 Applied motor 0, 1, 3 to 6, 13 to 16, 20, 23, 24, 30, 33, 34, 40, 43, 44, 50, 53, 54, 70, 73, 74

1 0 55

72 E600 PWM frequency selection 0 to 15 1 2

0 to 6, 25

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Parameter list (by parameter number)

PARAMETER LIST 13

2

73 T000 Analog input selection 0 to 7, 10 to 17 1 1 76, 208

74 T002 Input filter time constant 0 to 8 1 1 67, 108, 140

75

Reset selection/disconnected PU detection/PU stop selection

0 to 3, 14 to 17, 1000 to 1003, 1014 to 1017

1

14

0 to 3, 14 to 17, 100 to 103, 114 to 117, 1000 to 1003, 1014 to 1017, 1100 to 1103, 1114 to 1117

E100 Reset selection 0 to 3 0E101 Disconnected PU detection

0, 1E102 PU stop selection 1

E107 Reset limit 0 00, 1

76 M510 Fault code output selection 0 to 2 1 0

77 E400 Parameter write selection 0 to 2 1 0 237

78 D020 Reverse rotation prevention selection 0 to 2 1 0 208

79 D000 Operation mode selection 0 to 4, 6, 7 1 0

80 C101 Motor capacity 0.4 to 55 kW, 9999 0.01 kW 9999 55 0 to 3600 kW, 9999 0.1 kW

81 C102 Number of motor poles 2, 4, 6, 8, 10, 12, 9999 1 9999 55, 195

82 C125 Motor excitation current 0 to 500 A, 9999 0.01 A 9999

0 to 3600 A, 9999 0.1 A

83 C104 Rated motor voltage 0 to 1000 V 0.1 V 200 V 55 400 V

84 C105 Rated motor frequency 10 to 400 Hz, 9999 0.01 Hz 9999 55 85 G201 Excitation current break point 0 to 400 Hz, 9999 0.01 Hz 9999

86 G202 Excitation current low-speed scaling factor 0 to 300%, 9999 0.1% 9999

89 G932 Speed control gain (Advanced magnetic flux vector) 0 to 200%, 9999 0.1% 9999

90 C120 Motor constant (R1) 0 to 50 , 9999 0.001 9999

0 to 400 m, 9999 0.01 m

91 C121 Motor constant (R2) 0 to 50 , 9999 0.001 9999

0 to 400 m, 9999 0.01 m

92 C122 Motor constant (L1) 0 to 6000 mH, 9999 0.1 mH 9999 0 to 400 mH, 9999 0.01 mH

93 C123 Motor constant (L2) 0 to 6000 mH, 9999 0.1 mH 9999

0 to 400 mH, 9999 0.01 mH

94 C124 Motor constant (X) 0 to 100%, 9999 0.1%

9999 0.01%

95 C111 Online auto tuning selection 0 to 2 1 0

96 C110 Auto tuning setting/status 0, 1, 11, 101 1 0 55

100 R253 Second acceleration time for line speed command 0 to 3600 s 0.1 s 15 s 79

101 R254 Second deceleration time for line speed command 0 to 3600 s 0.1 s 15 s 79

102 R255 Third acceleration time for line speed command 0 to 3600 s 0.1 s 15 s 79

103 R256 Third deceleration time for line speed command 0 to 3600 s 0.1 s 15 s 79

110 F030 Third acceleration/deceleration time 0 to 3600 s, 9999 0.1 s 9999

111 F031 Third deceleration time 0 to 3600 s, 9999 0.1 s 9999

112 G020 Third torque boost 0 to 30%, 9999 0.1% 9999

113 G021 Third V/F (base frequency) 0 to 590 Hz, 9999 0.01 Hz 9999

114 H602 Third stall prevention operation level 0 to 400% 0.1% 150%

115 H603 Third stall prevention operation frequency 0 to 590 Hz 0.01 Hz 0 Hz

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Simple

Parameter list (by parameter number)

14 PARAMETER LIST

116 M445 Third output frequency detection 0 to 590 Hz 0.01 Hz 60 Hz 50 Hz

117 N020 PU communication station number 0 to 31 1 0

118 N021 PU communication speed 48, 96, 192, 384, 576, 768, 1152 1 192

119

PU communication stop bit length / data length 0, 1, 10, 11

1

1

N022 PU communication data length 0, 1 0

N023 PU communication stop bit length 0, 1 1

120 N024 PU communication parity check 0 to 2 1 2

121 N025 Number of PU communication retries 0 to 10, 9999 1 1

122 N026 PU communication check time interval 0, 0.1 to 999.8 s, 9999 0.1 s 9999

123 N027 PU communication waiting time setting 0 to 150 ms, 9999 1 ms 9999

124 N028 PU communication CR/LF selection 0 to 2 1 1

125 T022 Terminal 2 frequency setting gain frequency 0 to 590 Hz 0.01 Hz 60 Hz 50 Hz 6

126 T042 Terminal 4 frequency setting gain frequency 0 to 590 Hz 0.01 Hz 60 Hz 50 Hz 6

127 A612 PID control automatic switchover frequency 0 to 590 Hz, 9999 0.01 Hz 9999

128 A610 PID action selection 0, 40, 41 1 0 65, 177R100

129 A613 PID proportional band 0.1 to 1000%, 9999 0.1% 100% 99R110

130 A614 PID integral time 0.1 to 3600 s, 9999 0.1 s 1 s 99R111

131 A601 PID upper limit 400 to 600%, 9999 0.1% 9999 89, 127, 180

132 A602 PID lower limit 400 to 600%, 9999 0.1% 9999 89, 127, 180

133 A611 PID action set point 400 to 600% 0.01% 500% 85, 124R101

134 A615 PID differential time 0.01 to 10 s, 9999 0.01 s 9999 99R112 135 R161 Integral clamp (positive polarity) 0 to 100%, 9999 0.1% 9999 100

136 R162 Integral clamp (negative polarity) 0 to 100%, 9999 0.1% 9999 100

137 R163 PID upper/lower limit hysteresis width 0 to 100%, 9999 0.1% 9999

89, 127, 180

140 F200 Backlash acceleration stopping frequency 0 to 590 Hz 0.01 Hz 1 Hz

141 F201 Backlash acceleration stopping time 0 to 360 s 0.1 s 0.5 s

142 F202 Backlash deceleration stopping frequency 0 to 590 Hz 0.01 Hz 1 Hz

143 F203 Backlash deceleration stopping time 0 to 360 s 0.1 s 0.5 s

144 M002 Speed setting switchover 0, 2, 4, 6, 8, 10, 12, 102, 104, 106, 108, 110, 112 1 4

145 E103 PU display language selection 0 to 7 1

147 F022 Acceleration/deceleration time switching frequency 0 to 590 Hz, 9999 0.01 Hz 9999

148 H620 Stall prevention level at 0 V input 0 to 400% 0.1% 150%

149 H621 Stall prevention level at 10 V input 0 to 400% 0.1% 200%

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Simple

Simple

Parameter list (by parameter number)

PARAMETER LIST 15

2

150 M460 Output current detection level 0 to 400% 0.1% 150%

151 M461 Output current detection signal delay time 0 to 10 s 0.1 s 0 s

152 M462 Zero current detection level 0 to 400% 0.1% 5%

153 M463 Zero current detection time 0 to 10 s 0.01 s 0.5 s

154 H631 Voltage reduction selection during stall prevention operation

0, 1, 10, 11 1 1

155 T730 RT signal function validity condition selection 0, 10 1 0

156 H501 Stall prevention operation selection 0 to 31, 100, 101 1 0

157 M430 OL signal output timer 0 to 25 s, 9999 0.1 s 0 s

158 M301 AM terminal function selection

1 to 3, 5 to 14, 17 to 19, 21, 22, 24, 26 to 28, 30, 32 to 34, 36, 46, 50, 52 to 54, 61, 62, 67, 70, 81 to 84, 87 to 93, 95 to 98

1 1 108, 218

159

R450 DA1 output sign selection 0 to 2 1 0 218

160 E440 User group read selection 0, 1, 9999 1 0

161 E200 Frequency setting/key lock operation selection 0, 1, 10, 11 1 0

162 A700 Automatic restart after instantaneous power failure selection

0 to 3, 10 to 13 1 0

163 A704 First cushion time for restart 0 to 20 s 0.1 s 0 s

164 A705 First cushion voltage for restart 0 to 100% 0.1% 0%

165 A710 Stall prevention operation level for restart 0 to 400% 0.1% 150%

166 M433 Output current detection signal retention time 0 to 10 s, 9999 0.1 s 0.1 s

167 M464 Output current detection operation selection 0, 1, 10, 11 1 0

168 E000

Parameter for manufacturer setting. Do not set.E080

169 E001 E081

170 M020 Watt-hour meter clear 0, 10, 9999 1 9999

171 M030 Operation hour meter clear 0, 9999 1 9999

172 E441 User group registered display/ batch clear 9999, (0 to 16) 1 0

173 E442 User group registration 0 to 1999, 9999 1 9999

174 E443 User group clear 0 to 1999, 9999 1 9999

178 T700 STF terminal function selection

0 to 13, 16 to 18, 20, 23 to 28, 32, 42 to 44, 46 to 48, 50 to 53, 60, 62, 64 to 67, 70 to 72, 74, 81, 92, 93, 100 to 109, 111 to 117, 120 to 126, 9999

1 60 227

179 T701 STR terminal function selection

0 to 13, 16 to 18, 20, 23 to 28, 32, 42 to 44, 46 to 48, 50 to 53, 61, 62, 64 to 67, 70 to 72, 74, 81, 92, 93, 100 to 109, 111 to 117, 120 to 126, 9999

1 61 227

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Simple

Parameter list (by parameter number)

16 PARAMETER LIST

180 T702 RL terminal function selection

0 to 13, 16 to 18, 20, 23 to 28, 32, 42 to 44, 46 to 48, 50 to 53, 62, 64 to 67, 70 to 72, 74, 81, 92, 93, 100 to 109, 111 to 117, 120 to 126, 9999

1 0 227 181 T703 RM terminal function selection 1 1 227 182 T704 RH terminal function selection 1 2 227 183 T705 RT terminal function selection 1 3 227 184 T706 AU terminal function selection 1 4 227 185 T707 JOG terminal function selection 1 5 227 186 T708 CS terminal function selection 1 6 227

187 T709 MRS terminal function selection 1 24 227 10

188 T710 STOP terminal function selection 1 25 227

189 T711 RES terminal function selection 1 62 227

190 M400 RUN terminal function selection 0 to 8, 10 to 16, 25, 26, 30 to 35, 39 to 48, 55, 64, 67, 68, 79, 80, 85, 90 to 99, 100 to 108, 110 to 116, 125, 126, 130 to 135, 139 to 148, 155, 164, 167, 168, 179, 180, 185, 190 to 199, 206 to 208, 211 to 213, 231 to 239, 306 to 308, 311 to 313, 331 to 339, 9999

1 0 230

191 M401 SU terminal function selection 1 1 230

192 M402 IPF terminal function selection 1 2

230 9999

193 M403 OL terminal function selection 1 3 230

194 M404 FU terminal function selection 1 4 230

195 M405 ABC1 terminal function selection

0 to 8, 10 to 16, 25, 26, 30 to 35, 39 to 48, 55, 64, 67, 68, 79, 80, 85, 90, 91, 94 to 99, 100 to 108, 110 to 116, 125, 126, 130 to 135, 139 to 148, 155, 164, 167, 168, 179, 180, 185, 190, 191, 194 to 199, 206 to 208, 211 to 213, 231 to 239, 306 to 308, 311 to 313, 331 to 339, 9999

1 99 230

196 M406 ABC2 terminal function selection 1 9999 230

232 to

239

D308 to

D315

Multi-speed setting (8 speed to 15 speed) 0 to 590 Hz, 9999 0.01 Hz 9999

240 E601 Soft-PWM operation selection 0, 1 1 1

241 M043 Analog input display unit switchover 0, 1 1 0

242 T021 Terminal 1 added compensation amount (terminal 2) 0 to 100% 0.1% 100%

243 T041 Terminal 1 added compensation amount (terminal 4) 0 to 100% 0.1% 75%

244 H100 Cooling fan operation selection 0, 1, 101 to 105 1 1

245 G203 Rated slip 0 to 50%, 9999 0.01% 9999

246 G204 Slip compensation time constant 0.01 to 10 s 0.01 s 0.5 s

247 G205 Constant-power range slip compensation selection 0, 9999 1 9999

249 H101 Earth (ground) fault detection at start 0, 1 1 0

250 G106 Stop selection 0 to 100 s, 1000 to 1100 s, 8888, 9999 0.1 s 9999

251 H200 Output phase loss protection selection 0, 1 1 1

252 T050 Override bias 0 to 1000% 0.1% 50% 76 253 T051 Override gain 0 to 1000% 0.1% 150% 76 255 E700 Life alarm status display (0 to 15) 1 0

256 E701 Inrush current limit circuit life display (0 to 100%) 1% 100%

257 E702 Control circuit capacitor life display (0 to 100%) 1% 100%

258 E703 Main circuit capacitor life display (0 to 100%) 1% 100%

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Parameter list (by parameter number)

PARAMETER LIST 17

2

259 E704 Main circuit capacitor life measuring 0, 1 1 0

260 E602 PWM frequency automatic switchover 0, 1 1 1

261 A730 Power failure stop selection 0 to 2, 11, 12, 21, 22 1 0

262 A731 Subtracted frequency at deceleration start 0 to 20 Hz 0.01 Hz 3 Hz

263 A732 Subtraction starting frequency 0 to 590 Hz, 9999 0.01 Hz 60 Hz 50 Hz

264 A733 Power-failure deceleration time 1 0 to 3600 s 0.1 s 5 s

265 A734 Power-failure deceleration time 2 0 to 3600 s, 9999 0.1 s 9999

266 A735 Power failure deceleration time switchover frequency 0 to 590 Hz 0.01 Hz 60 Hz 50 Hz

267 T001 Terminal 4 input selection 0 to 2 1 0

268 M022 Monitor decimal digits selection 0, 1, 9999 1 9999

269 E023 Parameter for manufacturer setting. Do not set.

270 R342 Acceleration/deceleration time during stall condition 0 to 3600 s 0.1 s 15 s 165

271 R537 Second acceleration time for inertia compensation 0 to 3600 s 0.1 s 15 s 157

272 R538 Second deceleration time for inertia compensation 0 to 3600 s 0.1 s 15 s 157

276 R400 Line speed monitoring reference 0 to 6553.4 m/min 0.1 m/min 1000 m/min 218, 224

278 R051 Actual line speed voltage/ current gain 0 to 100%, 9999 0.1% 9999 199

279 R052 Actual line speed gain 0 to 6553.4 m/min, 9999 0.1 m/min 9999 199

280 R053 Actual line speed voltage/ current bias 0 to 100%, 9999 0.1% 9999 199

281 R054 Actual line speed bias 0 to 6553.4 m/min, 9999 0.1 m/min 9999 199

282 R055 Actual line speed pulse input bias 0 to 500, 9999 0.01 9999 199

283 R056 Actual line speed pulse input gain 0 to 500, 9999 0.01 9999 199

284 R057 Actual line speed input filter time constant 0 to 5 s 0.01 s 0.02 s 199

285 A107 Overspeed detection frequency

0 to 30 Hz, 9999 0.01 Hz 9999 H416 Speed deviation excess detection frequency

286 G400 Droop gain 0 to 100% 0.1% 0%

287 G401 Droop filter time constant 0 to 1 s 0.01 s 0.3 s

288 G402 Droop function activation selection 0, 1, 2, 10, 11, 20 to 22 1 0

289 M431 Inverter output terminal filter 5 to 50 ms, 9999 1 ms 9999

290 M044 Monitor negative output selection 0 to 7 1 0 218

291 D100 Pulse train I/O selection

[FM type] 0, 1, 10, 11, 20, 21, 100 1 0 [AM type] 0, 1

294 A785 UV avoidance voltage gain 0 to 200% 0.1% 100%

295 E201 Frequency change increment amount setting 0, 0.01, 0.10, 1.00, 10.00 0.01 0

296 E410 Password lock level 0 to 6, 99, 100 to 106, 199, 9999 1 9999

297 E411 Password lock/unlock (0 to 5), 1000 to 9998, 9999 1 9999

298 A711 Frequency search gain 0 to 32767, 9999 1 9999

299 A701 Rotation direction detection selection at restarting 0, 1, 9999 1 0

331 N030 RS-485 communication station number 0 to 31 (0 to 247) 1 0

332 N031 RS-485 communication speed 3, 6, 12, 24, 48, 96, 192, 384, 576, 768, 1152 1 96

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Parameter list (by parameter number)

18 PARAMETER LIST

333

RS-485 communication stop bit length / data length 0, 1, 10, 11 1 1

N032 RS-485 communication data length 0, 1 1 0

N033 RS-485 communication stop bit length 0, 1 1 1

334 N034 RS-485 communication parity check selection 0 to 2 1 2

335 N035 RS-485 communication retry count 0 to 10, 9999 1 1

336 N036 RS-485 communication check time interval 0 to 999.8 s, 9999 0.1 s 0 s

337 N037 RS-485 communication waiting time setting 0 to 150 ms, 9999 1 ms 9999

338 D010 Communication operation command source 0, 1 1 0 233

339 D011 Communication speed command source 0 to 2 1 0 233

340 D001 Communication startup mode selection 0 to 2, 10, 12 1 0

341 N038 RS-485 communication CR/LF selection 0 to 2 1 1

342 N001 Communication EEPROM write selection 0, 1 1 0

343 N080 Communication error count 1 0

350 R210 Line speed command voltage/ current bias 0 to 100% 0.1% 0% 67

351 R211 Line speed command bias 0 to 6553.4 m/min 0.1 m/min 0 m/min 67

352 R212 Line speed command voltage/ current gain 0 to 100% 0.1% 50% 67

353 R213 Line speed command gain 0 to 6553.4 m/min, 9999 0.1 m/min 0 m/min 67

354 R220 Line speed command pulse input bias 0 to 500 0.01 0 67

355 R221 Line speed command pulse input gain 0 to 500 0.01 100 67

356 R222 Line speed command digital input bias 0 to 65535 1 0 67

357 R223 Line speed command digital input gain 0 to 65535 1 65535 67

358 R201 Line speed unit 0 to 3 1 0 67, 224

359

C141 Encoder rotation direction 0, 1, 100, 101 1 1

360 R202 Line speed command value 0 to 6553.4 m/min 0.1 m/min 0 m/min 67

361 R200 Line speed command input selection 0 to 8, 10, 9999 1 9999 67

362 R050 Actual line speed input selection 0 to 7, 9, 9999 1 0 199

363 R102 Dancer / tension sensor feedback input selection 3 to 6, 9, 9999 1 9999

85, 124, 178

364 R411

Dancer tension setting input selection / taper function enable/ disable selection for tension sensor feedback speed control 1

3 to 6, 9999 1 9999 108

365 R302 Tension command value (RAM) 0 to 500 N 0.01 N 0 N 140

366 R303 Tension command value (RAM, EEPROM) 0 to 500 N 0.01 N 0 N 140

367

G240 Speed feedback range 0 to 590 Hz, 9999 0.01 Hz 9999

368

G241 Feedback gain 0 to 100 0.1 1

369

C140 Number of encoder pulses 0 to 4096 1 1024

374 H800 Overspeed detection level 0 to 590 Hz, 9999 0.01 Hz 9999

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Parameter list (by parameter number)

PARAMETER LIST 19

2

376

C148 Encoder signal loss detection enable/disable selection 0, 1 1 0

380 F300 Acceleration S-pattern 1 0 to 50% 1% 0

381 F301 Deceleration S-pattern 1 0 to 50% 1% 0

382 F302 Acceleration S-pattern 2 0 to 50% 1% 0

383 F303 Deceleration S-pattern 2 0 to 50% 1% 0

384 D101 Input pulse division scaling factor 0 to 250 1 0 67,

199 385 D110 Frequency for zero input pulse 0 to 590 Hz 0.01 Hz 0

386 D111 Frequency for maximum input pulse 0 to 590 Hz 0.01 Hz 60 Hz 50 Hz

393 R250 Line speed command acceleration/deceleration reference

1 to 6553.4 m/min 0.1 m/min 1000 m/min 79

394 R251 First acceleration time for line speed command 0 to 3600 s 0.1 s 15 s 79

395 R252 First deceleration time for line speed command 0 to 3600 s 0.1 s 15 s 79

398 R203 Draw rate 0 to 200% 0.01% 100% 67

414 A800 PLC function operation selection 0 to 2, 11, 12 1 0

415 A801 Inverter operation lock mode setting 0, 1 1 0

416 A802 Pre-scale function selection 0 to 5 1 0

417 A803 Pre-scale setting value 0 to 32767 1 1

422 B003 Position control gain 0 to 150 sec-1 1 sec-1 25 sec-1

423 R422 Dancer / tension sensor feedback detection level 0 to 100% 0.01% 10% 88,

126

424 R104 Dancer / tension sensor feedback input offset 400 to 600% 0.01% 500% 88,

126

425 R160 Break detection waiting time 0 to 100 s, 9999 0.01 s 9999 89, 127, 180

426 R412 Dancer tension setting bias 0 to 200% 0.1% 0% 108 427 R413 Dancer tension setting gain 0 to 200% 0.1% 100% 108 428 B009 Command pulse selection 0 to 5 1 0 67

430 R410

Dancer tension setting / taper function enable/disable selection for tension sensor feedback speed control 2

1 to 100, 9999 0.1 100 108

432

D120 Pulse train torque command bias 0 to 400% 1% 0%

433

D121 Pulse train torque command gain 0 to 400% 1% 150%

450 C200 Second applied motor

0, 1, 3 to 6, 13 to 16, 20, 23, 24, 30, 33, 34, 40, 43, 44, 50, 53, 54, 70, 73, 74, 9999

1 9999 55

451 G300 Second motor control method selection

10 to 12, 20, 110 to 112, 9999 1 9999 5

453 C201 Second motor capacity 0.4 to 55 kW, 9999 0.01 kW 9999 55

0 to 3600 kW, 9999 0.1 kW

454 C202 Number of second motor poles 2, 4, 6, 8, 10, 12, 9999 1 9999 55

455 C225 Second motor excitation current 0 to 500 A, 9999 0.01 A 9999

0 to 3600 A, 9999 0.1 A

456 C204 Rated second motor voltage 0 to 1000 V 0.1 V 200 V 55 400 V

457 C205 Rated second motor frequency 10 to 400 Hz, 9999 0.01 Hz 9999 55

458 C220 Second motor constant (R1) 0 to 50 , 9999 0.001 9999 0 to 400 m, 9999 0.01 m

459 C221 Second motor constant (R2) 0 to 50 , 9999 0.001 9999

0 to 400 m, 9999 0.01 m

460 C222 Second motor constant (L1) 0 to 6000 mH, 9999 0.1 mH 9999

0 to 400 mH, 9999 0.01 mH

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Parameter list (by parameter number)

20 PARAMETER LIST

461 C223 Second motor constant (L2) 0 to 6000 mH, 9999 0.1 mH 9999

0 to 400 mH, 9999 0.01 mH

462 C224 Second motor constant (X) 0 to 100%, 9999 0.1% 9999 0.01%

463 C210 Second motor auto tuning setting/status 0, 1, 11, 101 1 0 55

464 R113 PID proportional band for values below set point 0.1 to 1000%, 9999 0.1% 9999 101

465 R114 PID integral time for values below set point 0.1 to 3600 s, 9999 0.1 s 9999 101

466 R115 PID differential time for values below set point 0.01 to 10 s, 9999 0.01 s 9999 101

467 R116 Second PID proportional band 0.1 to 1000%, 9999 0.1% 9999 101 468 R117 Second PID integral time 0.1 to 3600 s, 9999 0.1 s 9999 101 469 R118 Second PID differential time 0.01 to 10 s, 9999 0.01 s 9999 101

470 R119 Second PID proportional band for values below set point 0.1 to 1000%, 9999 0.1% 9999 101

471 R120 Second PID integral time for values below set point 0.1 to 3600 s, 9999 0.1 s 9999 101

472 R121 Second PID differential time for values below set point 0.01 to 10 s, 9999 0.01 s 9999 101

473 R122 Third PID proportional band 0.1 to 1000%, 9999 0.1% 9999 101 474 R123 Third PID integral time 0.1 to 3600 s, 9999 0.1 s 9999 101 475 R124 Third PID differential time 0.01 to 10 s, 9999 0.01 s 9999 101

476 R125 Third PID proportional band for values below set point 0.1 to 1000%, 9999 0.1% 9999 101

477 R126 Third PID integral time for values below set point 0.1 to 3600 s, 9999 0.1 s 9999 101

478 R127 Third PID differential time for values below set point 0.01 to 10 s, 9999 0.01 s 9999 101

479 R128 Fourth PID proportional band 0.1 to 1000%, 9999 0.1% 9999 101 480 R129 Fourth PID integral time 0.1 to 3600 s, 9999 0.1 s 9999 101 481 R130 Fourth PID differential time 0.01 to 10 s, 9999 0.01 s 9999 101

482 R131 Fourth PID proportional band for values below set point 0.1 to 1000%, 9999 0.1% 9999 101

483 R132 Fourth PID integral time for values below set point 0.1 to 3600 s, 9999 0.1 s 9999 101

484 R133 Fourth PID differential time for values below set point 0.01 to 10 s, 9999 0.01 s 9999 101

485 R149 Integral control activation 0 to 3 1 0 100 486 R140 Deviation A 400.1 to 600% 0.1% 600% 101 487 R141 Deviation B 400 to 599.9% 0.1% 400% 101 488 R142 Deviation C1 400.1 to 599.9%, 9999 0.1% 9999 101 489 R143 Deviation C2 400.1 to 599.9%, 9999 0.1% 9999 101 490 R144 PID gain A 0.1 to 1000%, 9999 0.1% 9999 101 491 R145 PID gain B 0.1 to 1000%, 9999 0.1% 9999 101 492 R146 PID gain C1 0.1 to 1000%, 9999 0.1% 9999 101 493 R147 PID gain C2 0.1 to 1000%, 9999 0.1% 9999 101 494 R148 PID gain D 0.1 to 1000%, 9999 0.1% 9999 101 495 M500 Remote output selection 0, 1, 10, 11 1 0

496 M501 Remote output data 1 0 to 4095 1 0

497 M502 Remote output data 2 0 to 4095 1 0

498 A804 PLC function flash memory clear 0, 9696 (0 to 9999) 1 0

502 N013 Stop mode selection at communication error 0 to 2, 11, 12 1 0

503 E710 Maintenance timer 1 0 (1 to 9998) 1 0

504 E711 Maintenance timer 1 warning output set time 0 to 9998, 9999 1 9999

505 M001 Speed setting reference 1 to 590 Hz 0.01 Hz 60 Hz 50 Hz

516 F400 S-pattern time at a start of acceleration 0.1 to 2.5 s 0.1 s 0.1 s

517 F401 S-pattern time at a completion of acceleration 0.1 to 2.5 s 0.1 s 0.1 s

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Parameter list (by parameter number)

PARAMETER LIST 21

2

518 F402 S-pattern time at a start of deceleration 0.1 to 2.5 s 0.1 s 0.1 s

519 F403 S-pattern time at a completion of deceleration 0.1 to 2.5 s 0.1 s 0.1 s

539 N002 MODBUS RTU communication check time interval 0 to 999.8 s, 9999 0.1 s 9999

547 N040 USB communication station number 0 to 31 1 0

548 N041 USB communication check time interval 0 to 999.8 s, 9999 0.1 s 9999

549 N000 Protocol selection 0, 1 1 0

550 D012 NET mode operation command source selection 0, 1, 9999 1 9999

551 D013 PU mode operation command source selection 1 to 3, 9999 1 9999

552 H429 Frequency jump range 0 to 30 Hz, 9999 0.01 Hz 9999

553 A603 PID deviation limit 0.0 to 100.0%, 9999 0.1% 9999 89, 127, 180

554 A604 PID signal operation selection 0 to 3 1 0

89, 91, 127, 180

555 E720 Current average time 0.1 to 1 s 0.1 s 1 s

556 E721 Data output mask time 0 to 20 s 0.1 s 0 s

557 E722 Current average value monitor signal output reference current

0 to 500 A 0.01 A Inverter rated current

0 to 3600 A 0.1 A

560 A712 Second frequency search gain 0 to 32767, 9999 1 9999

561 H020 PTC thermistor protection level 0.5 to 30 k, 9999 0.01 k 9999

563 M021 Energization time carrying-over times (0 to 65535) 1 0

564 M031 Operating time carrying-over times (0 to 65535) 1 0

565 G301 Second motor excitation current break point 0 to 400 Hz, 9999 0.01 Hz 9999

566 G302 Second motor excitation current low-speed scaling factor 0 to 300%, 9999 0.1% 9999

569 G942 Second motor speed control gain 0 to 200%, 9999 0.1% 9999

570 E301 Multiple rating setting 0 to 3, 12 1 2 8 571 F103 Holding time at a start 0 to 10 s, 9999 0.1 s 9999

573 A680 4 mA input check selection 1 to 3, 9999 1 9999 T052

574 C211 Second motor online auto tuning 0, 1 1 0

598 H102 Undervoltage level 350 to 430 V, 9999 0.1 V 9999

599 T721 X10 terminal input selection 0, 1 1 0

1

600 H001 First free thermal reduction frequency 1 0 to 590 Hz, 9999 0.01 Hz 9999

601 H002 First free thermal reduction ratio 1 1 to 100% 1% 100%

602 H003 First free thermal reduction frequency 2 0 to 590 Hz, 9999 0.01 Hz 9999

603 H004 First free thermal reduction ratio 2 1 to 100% 1% 100%

604 H005 First free thermal reduction frequency 3 0 to 590 Hz, 9999 0.01 Hz 9999

606 T722 Power failure stop external signal input selection 0, 1 1 1

607 H006 Motor permissible load level 110 to 250% 1% 150%

608 H016 Second motor permissible load level 110 to 250%, 9999 1% 9999

609 R430 PID measured tension monitor filter 0 to 5 s 0.01 s 0 s 226

610 R431 PID measured tension monitor increment 0 to 2, 9999 1 9999 226

611 F003 Acceleration time at a restart 0 to 3600 s, 9999 0.1 s 9999

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Parameter list (by parameter number)

22 PARAMETER LIST

617 G080 Reverse rotation excitation current low-speed scaling factor 0 to 300%, 9999 0.1% 9999

620 R570 Line speed bias for reel change 0 to 2000 m/min 0.1 m/min 1000 m/min 106

621 R423 Allowable deviation from target line speed 0 to 6553.4 m/min 0.1 m/min 0 m/min 79,

106

622 R204 Line speed command for starting 0 to 6553.4 m/min 0.1 m/min 0 m/min 67

635 R214 Line speed command added compensation value voltage/ current bias

0 to 100%, 9999 0.1% 9999 76

636 R215 Line speed command added compensation value bias

0 to 6553.4 m/min, 9999 0.1 m/min 9999 76

637 R216 Line speed command added compensation value voltage/ current gain

0 to 100%, 9999 0.1% 9999 76

638 R217 Line speed command added compensation value gain

0 to 6553.4 m/min, 9999 0.1 m/min 9999 76

639 R030 Speed control proportional term applied diameter 1 1 to 99%, 9999 1% 9999 216

640 R031 Speed control proportional term applied diameter 2 1 to 99%, 9999 1% 9999 216

641 R032 Speed control proportional gain 1 0 to 1000%, 9999 1% 9999 216 642 R033 Speed control proportional gain 2 0 to 1000%, 9999 1% 9999 216 643 R034 Speed control proportional gain 3 0 to 1000%, 9999 1% 9999 216 644 R035 Speed control proportional gain 4 0 to 1000%, 9999 1% 9999 216

645 R004 Winding diameter storage selection 0, 1 1 0 213

646 R003 Stored winding diameter 1 to 6553 mm 1 mm 1 mm 213

647 R041 Operation time with stored winding diameter 0 to 100 s 0.01 s 0 s 213

648 R420 Target winding diameter 1 to 6553 mm 1 mm 1 mm 213

650 R270 Terminal 4 input compensation selection 0, 1 1 0 76

653 G410 Speed smoothing control 0 to 200% 0.1% 0

654 G411 Speed smoothing cutoff frequency 0 to 120 Hz 0.01 20 Hz

655 M530 Analog remote output selection 0, 1, 10, 11 1 0

656 M531 Analog remote output 1

800 to 1200%

0.1% 1000%

657 M532 Analog remote output 2 0.1% 1000%

658 M533 Analog remote output 3 0.1% 1000%

659 M534 Analog remote output 4 0.1% 1000%

663 M060 Control circuit temperature signal output level 0 to 100C 1C 0C

665 G125 Regeneration avoidance frequency gain 0 to 200% 0.1% 100%

668 A786 Power failure stop frequency gain 0 to 200% 0.1% 100%

673 G060 SF-PR slip amount adjustment operation selection 2, 4, 6, 9999 1 9999

674 G061 SF-PR slip amount adjustment gain 0 to 500% 0.1% 100%

675 A805 User parameter auto storage function selection 1, 9999 1 9999

679 G420 Second droop gain 0 to 100%, 9999 0.1% 9999

680 G421 Second droop filter time constant 0 to 1 s, 9999 0.01 s 9999

681 G422 Second droop function activation selection

0, 1, 2, 10, 11, 20 to 22, 9999 1 9999

682 G423 Second droop break point gain 0.1 to 100%, 9999 0.1% 9999

683 G424 Second droop break point torque 0.1 to 100%, 9999 0.1% 9999

684 C000 Tuning data unit switchover 0, 1 1 0

686 E712 Maintenance timer 2 0 (1 to 9998) 1 0

687 E713 Maintenance timer 2 warning output set time 0 to 9998, 9999 1 9999

688 E714 Maintenance timer 3 0 (1 to 9998) 1 0

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Parameter list (by parameter number)

PARAMETER LIST 23

2

689 E715 Maintenance timer 3 warning output set time 0 to 9998, 9999 1 9999

690 H881 Deceleration check time 0 to 3600 s, 9999 0.1 s 1 s

692 H011 Second free thermal reduction frequency 1 0 to 590 Hz, 9999 0.01 Hz 9999

693 H012 Second free thermal reduction ratio 1 1 to 100% 1% 100%

694 H013 Second free thermal reduction frequency 2 0 to 590 Hz, 9999 0.01 Hz 9999

695 H014 Second free thermal reduction ratio 2 1 to 100% 1% 100%

696 H015 Second free thermal reduction frequency 3 0 to 590 Hz, 9999 0.01 Hz 9999

699 T740 Input terminal filter 5 to 50 ms, 9999 1 ms 9999

707 C107 Motor inertia (integer) 10 to 999, 9999 1 9999 55, 157

724 C108 Motor inertia (exponent) 0 to 7, 9999 1 9999 55, 157

744 C207 Second motor inertia (integer) 10 to 999, 9999 1 9999 55, 157

745 C208 Second motor inertia (exponent) 0 to 7, 9999 1 9999 55, 157

753 R539 Empty reel inertia (integer) 10 to 999, 9999 1 9999 157 754 R540 Empty reel inertia (exponent) 0 to 7, 101 to 104, 9999 1 9999 157 755

M610 Cumulative pulse clear signal selection 0 to 3 1 0

756

M611 Cumulative pulse division scaling factor 1 to 16384 1 1

757

M612 Control terminal option- Cumulative pulse division scaling factor

1 to 16384 1 1

758

M613 Cumulative pulse storage 0 to 3 1 0

774 M101 Operation panel monitor selection 1 1 to 3, 5 to 14, 17 to 20, 22

to 36, 38, 40 to 46, 50 to 57, 61 to 64, 67, 71 to 74, 81 to 93, 95 to 98, 100, 9999

1 9999 218

775 M102 Operation panel monitor selection 2 1 9999 218

776 M103 Operation panel monitor selection 3 1 9999 218

778 A682 4 mA input check filter 0 to 10 s 0.01 s 0 s T054

799 M520 Pulse increment setting for output power 0.1, 1, 10, 100, 1000 kWh 0.1 kWh 1 kWh

800 G200 Control method selection 0 to 2, 9 to 12, 20, 100 to 102, 109 to 112 1 20 5

801 H704 Output limit level 0 to 400%, 9999 0.1% 9999

802 G102 Pre-excitation selection 0, 1 1 0

803 G210 Constant output range torque characteristic selection 0 to 2, 10, 11 1 0

804 R300 Tension / Torque command source selection 0 to 6 1 0 140D400

805 D401 Torque command value (RAM) 600 to 1400% 1% 1000%

806 D402 Torque command value (RAM,EEPROM) 600 to 1400% 1% 1000%

807 H410 Speed limit selection 0 to 2 1 0 146

808 H411 Forward rotation speed limit/ speed limit 0 to 400 Hz 0.01 Hz 60 Hz 50 Hz 146

809 H412 Reverse rotation speed limit/ reverse-side speed limit 0 to 400 Hz, 9999 0.01 Hz 9999 146

810 H700 Torque limit input method selection 0 to 2 1 0

811 D030 Set resolution switchover 0, 1, 10, 11 1 0

812 H701 Torque limit level (regeneration) 0 to 400%, 9999 0.1% 9999

813 H702 Torque limit level (3rd quadrant) 0 to 400%, 9999 0.1% 9999

814 H703 Torque limit level (4th quadrant) 0 to 400%, 9999 0.1% 9999

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Parameter list (by parameter number)

24 PARAMETER LIST

815 H710 Torque limit level 2 0 to 400%, 9999 0.1% 9999

816 H720 Torque limit level during acceleration 0 to 400%, 9999 0.1% 9999

817 H721 Torque limit level during deceleration 0 to 400%, 9999 0.1% 9999

818 C112 Easy gain tuning response level setting 1 to 15 1 2 59

819 C113 Easy gain tuning selection 0 to 2 1 0 59 820 G211 Speed control P gain 1 0 to 1000% 1% 60% 59 821 G212 Speed control integral time 1 0 to 20 s 0.001 s 0.333 s 59 822 T003 Speed setting filter 1 0 to 5 s, 9999 0.001 s 9999 67 823

G215 Speed detection filter 1 0 to 0.1 s 0.001 s 0.001 s

824 G213 Torque control P gain 1 (current loop proportional gain) 0 to 500% 1% 100%

825 G214 Torque control integral time 1 (current loop integral time) 0 to 500 ms 0.1 ms 5 ms

826 T004 Torque setting filter 1 0 to 5 s, 9999 0.001 s 9999 140 827 G216 Torque detection filter 1 0 to 0.1 s 0.001 s 0 s

828 G224 Model speed control gain 0 to 1000% 1% 60%

829 R504 Taper ratio setting input filter time constant 0 to 5 s 0.01 s 0.02 s 151

830 G311 Speed control P gain 2 0 to 1000%, 9999 1% 9999

831 G312 Speed control integral time 2 0 to 20 s, 9999 0.001 s 9999

832 T005 Speed setting filter 2 0 to 5 s, 9999 0.001 s 9999 67 833

G315 Speed detection filter 2 0 to 0.1 s, 9999 0.001 s 9999

834 G313 Torque control P gain 2 0 to 500%, 9999 1% 9999

835 G314 Torque control integral time 2 0 to 500 ms, 9999 0.1 ms 9999

836 T006 Torque setting filter 2 0 to 5 s, 9999 0.001 s 9999 140 837 G316 Torque detection filter 2 0 to 0.1 s, 9999 0.001 s 9999

840 G230 Torque bias selection 0 to 3, 24, 25, 9999 1 9999

841 G231 Torque bias 1 600 to 1400%, 9999 1% 9999

842 G232 Torque bias 2 600 to 1400%, 9999 1% 9999

843 G233 Torque bias 3 600 to 1400%, 9999 1% 9999

844 G234 Torque bias filter 0 to 5 s, 9999 0.001 s 9999

845 G235 Torque bias operation time 0 to 5 s, 9999 0.01 s 9999

846 G236 Torque bias balance compensation 0 to 10 V, 9999 0.1 V 9999

847 G237 Fall-time torque bias terminal 1 bias 0 to 400%, 9999 1% 9999

848 G238 Fall-time torque bias terminal 1 gain 0 to 400%, 9999 1% 9999

849 T007 Analog input offset adjustment 0 to 200% 0.1% 100%

850 G103 Brake operation selection 0 to 2 1 0

851

C240 Control terminal option-Number of encoder pulses 0 to 4096 1 2048

852

C241 Control terminal option-Encoder rotation direction 0, 1, 100, 101 1 1

853

H417 Speed deviation time 0 to 100 s 0.1 s 1 s

854 G217 Excitation ratio 0 to 100% 1% 100%

855

C248 Control terminal option-Signal loss detection enable/disable selection

0, 1 1 0

858 T040 Terminal 4 function assignment 0, 1, 4, 9999 1 0

859 C126 Torque current/Rated PM motor current

0 to 500 A, 9999 0.01 A 9999 0 to 3600 A, 9999 0.1 A

860 C226 Second motor torque current/ Rated PM motor current

0 to 500 A, 9999 0.01 A 9999

0 to 3600 A, 9999 0.1 A 862

C242 Encoder option selection 0, 1 1 0 234

863

M600 Control terminal option-Encoder pulse division ratio 1 to 32767 1 1

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Parameter list (by parameter number)

PARAMETER LIST 25

2

864 M470 Torque detection 0 to 400% 0.1% 150%

865 M446 Low speed detection 0 to 590 Hz 0.01 Hz 1.5 Hz

866 M042 Torque monitoring reference 0 to 400% 0.1% 150% 218, 224

867 M321 AM output filter 0 to 5 s 0.01 s 0.01 s

868 T010 Terminal 1 function assignment 0 to 6, 9999 1 0 76, 140

869 M334 Current output filter 0 to 5 s 0.01 s 0.02 s

870 M440 Speed detection hysteresis 0 to 5 Hz 0.01 Hz 0 Hz

872 H201 Input phase loss protection selection 0, 1 1 0

873

H415 Speed limit 0 to 400 Hz 0.01 Hz 20 Hz

874 H730 OLT level setting 0 to 400% 0.1% 150%

875 H030 Fault definition 0, 1 1 0

876

H022 Thermal protector input 0, 1 1 1

877 G220 Speed feed forward control/ model adaptive speed control selection

0 to 2 1 0

878 G221 Speed feed forward filter 0 to 1 s 0.01 s 0 s

879 G222 Speed feed forward torque limit 0 to 400% 0.1% 150%

880 C114 Load inertia ratio 0 to 200 times 0.1 times 7 times 59 881 G223 Speed feed forward gain 0 to 1000% 1% 0%

882 G120 Regeneration avoidance operation selection 0 to 2 1 0

883 G121 Regeneration avoidance operation level 300 to 1000 V 0.1 V

380 VDC

760 VDC

884 G122 Regeneration avoidance at deceleration detection sensitivity

0 to 5 1 0

885 G123 Regeneration avoidance compensation frequency limit value

0 to 590 Hz, 9999 0.01 Hz 6 Hz

886 G124 Regeneration avoidance voltage gain 0 to 200% 0.1% 100%

888 E420 Free parameter 1 0 to 9999 1 9999

889 E421 Free parameter 2 0 to 9999 1 9999

891 M023 Cumulative power monitor digit shifted times 0 to 4, 9999 1 9999

892 M200 Load factor 30 to 150% 0.1% 100%

893 M201 Energy saving monitor reference (motor capacity)

0.1 to 55 kW 0.01 kW Inverter rated capacity

0 to 3600 kW 0.1 kW

894 M202 Control selection during commercial power-supply operation

0 to 3 1 0

895 M203 Power saving rate reference value 0, 1, 9999 1 9999

896 M204 Power unit cost 0 to 500, 9999 0.01 9999

897 M205 Power saving monitor average time 0, 1 to 1000 h, 9999 1 h 9999

898 M206 Power saving cumulative monitor clear 0, 1, 10, 9999 1 9999

899 M207 Operation time rate (estimated value) 0 to 100%, 9999 0.1% 9999

C0 (900)

M310 FM/CA terminal calibration 108

C1 (901)

M320 AM terminal calibration 108

C2 (902)

T200 Terminal 2 frequency setting bias frequency 0 to 590 Hz 0.01 Hz 0 Hz 6

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Parameter list (by parameter number)

26 PARAMETER LIST

C3 (902)

T201 Terminal 2 frequency setting bias 0 to 300% 0.1% 0%

6, 108, 124, 151

125 (903)

T202 Terminal 2 frequency setting gain frequency 0 to 590 Hz 0.01 Hz 60 Hz 50 Hz 6

C4 (903)

T203 Terminal 2 frequency setting gain 0 to 300% 0.1% 100%

6, 108, 124, 151

C5 (904)

T400 Terminal 4 frequency setting bias frequency 0 to 590 Hz 0.01 Hz 0 Hz 6

C6 (904)

T401 Terminal 4 frequency setting bias 0 to 300% 0.1% 20%

6, 108, 124, 151

126 (905)

T402 Terminal 4 frequency setting gain frequency 0 to 590 Hz 0.01 Hz 60 Hz 50 Hz 6

C7 (905)

T403 Terminal 4 frequency setting gain 0 to 300% 0.1% 100%

6, 108, 124, 151

C12 (917)

T100 Terminal 1 bias frequency (speed) 0 to 590 Hz 0.01 Hz 0 Hz 6

C13 (917)

T101 Terminal 1 bias (speed) 0 to 300% 0.1% 0%

6, 108, 124, 151

C14 (918)

T102 Terminal 1 gain frequency (speed) 0 to 590 Hz 0.01 Hz 60 Hz 50 Hz 6

C15 (918)

T103 Terminal 1 gain (speed) 0 to 300% 0.1% 100%

6, 108, 124, 151

C16 (919)

T110 Terminal 1 bias command (torque/magnetic flux) 0 to 400% 0.1% 0% 6

C17 (919)

T111 Terminal 1 bias (torque/ magnetic flux) 0 to 300% 0.1% 0% 6

C18 (920)

T112 Terminal 1 gain command (torque/magnetic flux) 0 to 400% 0.1% 150% 6

C19 (920)

T113 Terminal 1 gain (torque/ magnetic flux) 0 to 300% 0.1% 100% 6

C8 (930)

M330 Current output bias signal 0 to 100% 0.1% 0%

C9 (930)

M331 Current output bias current 0 to 100% 0.1% 0%

C10 (931)

M332 Current output gain signal 0 to 100% 0.1% 100%

C11 (931)

M333 Current output gain current 0 to 100% 0.1% 100%

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Parameter list (by parameter number)

PARAMETER LIST 27

2

C38 (932)

T410 Terminal 4 bias command (torque/magnetic flux) 0 to 400% 0.1% 0% 6

C39 (932)

T411 Terminal 4 bias (torque/ magnetic flux) 0 to 300% 0.1% 20% 6

C40 (933)

T412 Terminal 4 gain command (torque/magnetic flux) 0 to 400% 0.1% 150% 6

C41 (933)

T413 Terminal 4 gain (torque/ magnetic flux) 0 to 300% 0.1% 100% 6

977 E302 Input voltage mode selection 0, 1 1 0

989 E490 Parameter copy alarm release 10 1

10 100 100

990 E104 PU buzzer control 0, 1 1 1

991 E105 PU contrast adjustment 0 to 63 1 58

992 M104 Operation panel setting dial push monitor selection

0 to 3, 5 to 14, 17 to 20, 22 to 36, 38, 40 to 46, 50 to 57, 61 to 64, 67, 71 to 74, 81 to 93, 95 to 98, 100

1 0 218

994 G403 Droop break point gain 0.1 to 100%, 9999 0.1% 9999

995 G404 Droop break point torque 0.1 to 100% 0.1% 100%

997 H103 Fault initiation 0 to 255, 9999 1 9999

999 E431 Automatic parameter setting

1, 2, 10 to 13, 20, 21, 9999 1 9999

1000 E108 Direct setting selection 0 to 2 1 0

1003 G601 Notch filter frequency 0, 8 to 1250 Hz 1 Hz 0

1004 G602 Notch filter depth 0 to 3 1 0

1005 G603 Notch filter width 0 to 3 1 0

1006 E020 Clock (year) 2000 to 2099 1 2000

1007 E021 Clock (month, day)

101 to 131, 201 to 229, 301 to 331, 401 to 430, 501 to 531, 601 to 630, 701 to 731, 801 to 831, 901 to 930, 1001 to 1031, 1101 to 1130, 1201 to 1231

1 101

1008 E022 Clock (hour, minute)

0 to 59, 100 to 159, 200 to 259, 300 to 359, 400 to 459, 500 to 559, 600 to 659, 700 to 759, 800 to 859, 900 to 959, 1000 to 1059, 1100 to 1159, 1200 to 1259, 1300 to 1359, 1400 to 1459, 1500 to 1559, 1600 to 1659, 1700 to 1759, 1800 to 1859, 1900 to 1959, 2000 to 2059, 2100 to 2159, 2200 to 2259, 2300 to 2359

1 0

1015 A607 Integral stop selection at limited manipulated amount 0, 1 1 0 100

1016 H021 PTC thermistor protection detection time 0 to 60 s 1 s 0 s

1018 M045 Monitor with sign selection 0, 9999 1 9999

1020 A900 Trace operation selection 0 to 4 1 0

1021 A901 Trace mode selection 0 to 2 1 0

1022 A902 Sampling cycle 0 to 9 1 2

1023 A903 Number of analog channels 1 to 8 1 4

1024 A904 Sampling auto start 0, 1 1 0

1025 A905 Trigger mode selection 0 to 4 1 0

1026 A906 Number of sampling before trigger 0 to 100% 1% 90%

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Simple

Parameter list (by parameter number)

28 PARAMETER LIST

1027 A910 Analog source selection (1ch) 1 to 3, 5 to 14, 17 to 20, 22 to 24, 26 to 36, 40 to 42, 46, 52 to 54, 61 to 64, 67, 71 to 74, 81 to 93, 95 to 98, 201 to 213, 230 to 232, 235 to 238

1

201 218 1028 A911 Analog source selection (2ch) 202 218 1029 A912 Analog source selection (3ch) 203 218 1030 A913 Analog source selection (4ch) 204 218 1031 A914 Analog source selection (5ch) 205 218 1032 A915 Analog source selection (6ch) 206 218 1033 A916 Analog source selection (7ch) 207 218 1034 A917 Analog source selection (8ch) 208 218 1035 A918 Analog trigger channel 1 to 8 1 1

1036 A919 Analog trigger operation selection 0, 1 1 0

1037 A920 Analog trigger level 600 to 1400 1 1000

1038 A930 Digital source selection (1ch)

1 to 255 1

1

1039 A931 Digital source selection (2ch) 2

1040 A932 Digital source selection (3ch) 3

1041 A933 Digital source selection (4ch) 4

1042 A934 Digital source selection (5ch) 5

1043 A935 Digital source selection (6ch) 6

1044 A936 Digital source selection (7ch) 7

1045 A937 Digital source selection (8ch) 8

1046 A938 Digital trigger channel 1 to 8 1 1

1047 A939 Digital trigger operation selection 0, 1 1 0

1048 E106 Display-off waiting time 0 to 60 min 1 min 0 min

1049 E110 USB host reset 0, 1 1 0

1072 R304 Tension reverse selection 0, 1 1 0 143

1103 F040 Deceleration time at emergency stop 0 to 3600 s 0.1 s 5 s 180

1106 M050 Torque monitor filter 0 to 5 s, 9999 0.01 s 9999

1107 M051 Running speed monitor filter 0 to 5 s, 9999 0.01 s 9999

1108 M052 Excitation current monitor filter 0 to 5 s, 9999 0.01 s 9999

1113 H414 Speed limit method selection 0 to 2, 10 1 0 146

1114 D403 Torque command reverse selection 0, 1 1 0 143R305

1115 G218 Speed control integral term clear time 0 to 9998 ms 1 ms 0 s

1116 G206 Constant output range speed control P gain compensation 0 to 100% 0.1% 0%

1117 G261 Speed control P gain 1 (per-unit system) 0 to 300, 9999 0.01 9999

1118 G361 Speed control P gain 2 (per-unit system) 0 to 300, 9999 0.01 9999

1119 G262 Model speed control gain (per- unit system) 0 to 300, 9999 0.01 9999

1121 G260 Per-unit speed control reference frequency 0 to 400 Hz 0.01 Hz

120 Hz

60 Hz

1134 A605 PID upper limit manipulated value 0 to 100% 0.1% 100% 104

1135 A606 PID lower limit manipulated value 0 to 100% 0.1% 100% 104

1136 R330 Tension sensor feedback voltage/current bias 0 to 100% 0.1% 0% 178

1137 R331 Tension sensor feedback bias 0 to 500N 0.01N 0N 178

1138 R332 Tension sensor feedback voltage/current gain 0 to 100% 0.1% 100% 178

1139 R333 Tension sensor feedback gain 0 to 500N 0.01N 0N 178

1140 R334 Signed winding diameter compensation torque command selection

0, 9999 1 0 183

1141 R290 Line speed command acceleration/deceleration pattern

0, 1 1 0 82

1142 R291 Line speed command acceleration start S-curve time 0.1 to 2.5 s 0.1 s 0.1 s 82

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Parameter list (by parameter number)

PARAMETER LIST 29

2

1143 R292 Line speed command acceleration completion S-curve time

0.1 to 2.5 s 0.1 s 0.1 s 82

1144 R293 Line speed command deceleration start S-curve time 0.1 to 2.5 s 0.1 s 0.1 s 82

1145 R294 Line speed command deceleration completion S-curve time

0.1 to 2.5 s 0.1 s 0.1 s 82

1146 R224 Line speed command input filter time constant 0 to 5 s 0.01 s 0 s 67

1147 R205 Line speed command maximum value 0 to 6553.4 m/min 0.1 m/min 6553.4 m/

min 67

1148 R105 PID manipulated line speed bias 0 to 6553.4 m/min 0.1 m/min 6553.4 m/ min 104

1149 R106 PID manipulated line speed gain 0 to 6553.4 m/min 0.1 m/min 9999 104 1150

to 1199

A810 to

A859 User parameters 1 to 50 0 to 65535 1 0

1211 R171 Tension PI gain tuning timeout time 1 to 9999 s 1 s 50 s 91

1215 R172 Limit cycle output upper limit 0 to 100% 0.1% 0% 91 1217 R173 Limit cycle hysteresis 0.1 to 10% 0.1% 1% 91

1219 R170 Tension PI gain tuning start/ status

1, 8 (0, 2, 3, 9, 12, 13, 90 to 96) 1 0 91

1222 R175 Target amplitude 0 to 100%, 9999 0.1% 9999 91

1223 R174 Manipulated amount for operation 0 to 10% 0.1% 1% 91

1226 R176 Tension PI gain tuning response level setting 1 to 7 1 2 91

1227 R103 Dancer / tension sensor feedback input filter time constant

0 to 5 s 0.01 s 0 s 85, 124, 178

1230 R002 Winding/unwinding selection 0, 1 1 0 67, 163, 178

1231 R010 Material thickness d1 0 to 20 mm, 9999 0.001 mm 9999 203 1232 R011 Material thickness d2 0 to 20 mm 0.001 mm 1 mm 203 1233 R012 Material thickness d3 0 to 20 mm 0.001 mm 1 mm 203 1234 R013 Material thickness d4 0 to 20 mm 0.001 mm 1 mm 203 1235 R020 Maximum winding diameter 1 1 to 6553 mm 1 mm 2 mm 206 1236 R021 Minimum winding diameter 1 1 to 6553 mm 1 mm 1 mm 206 1237 R022 Maximum winding diameter 2 1 to 6553 mm 1 mm 2 mm 206 1238 R023 Minimum winding diameter 2 1 to 6553 mm 1 mm 1 mm 206 1239 R024 Maximum winding diameter 3 1 to 6553 mm 1 mm 2 mm 206 1240 R025 Minimum winding diameter 3 1 to 6553 mm 1 mm 1 mm 206 1241 R026 Maximum winding diameter 4 1 to 6553 mm 1 mm 2 mm 206 1242 R027 Minimum winding diameter 4 1 to 6553 mm 1 mm 1 mm 206 1243 R600 Gear ratio numerator 1 to 65534 1 1 197 1244 R601 Gear ratio denominator 1 to 65534 1 1 197

1245 R042 Sampling time for winding diameter calculation 0.01 to 1 s, 9999 0.01 s 9999 199

1246 R040 Line speed at winding diameter calculated value activation 0 to 6553.4 m/min 0.1 m/min 1 m/min 204

1247 R000 Winding diameter change increment amount limit 0 to 9.998 mm, 9999 0.001 mm 9999 197

1248 R001 Winding diameter change limit disable time 0 to 100 s 0.01 s 0 s 197

1249 R043 Number of averaging for winding diameter calculation 0 to 10 1 4 205

1250 R260 Winding diameter compensation speed filtering waiting time 0 to 100 s 0.01 s 0 s 207

1251 R261 Winding diameter compensation speed filter time constant 0 to 100 s 0.01 s 0 s 207

1252 R070 Dancer lower limit position 400 to 600% 0.01% 400% 208

1253 R071 Initial winding diameter calculation deadband 0 to 50% 0.1% 1% 208

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Parameter list (by parameter number)

30 PARAMETER LIST

1254 R072 Initial winding diameter calculation deadband 2 0 to 50%, 9999 0.1% 9999 208

1255 R073 Accumulated amount 1 to 5000 mm, 8888, 9999 1 mm 9999 208 1256 R074 Speed control P gain at start 0 to 1000% 1% 60% 208

1257 R075 Speed control integral time at start 0 to 20 s 0.001 s 2 s 208

1258 R076 Integral term limit at start 0 to 100% 0.1% 2.5% 208 1259 R077 PID term limit at start 0 to 100% 0.1% 2.5% 208

1262 R005 Winding length increment 0 to 5 1 3 213, 224

1263 R006 Stored winding length (lower 4 digits) 0 to 9999(m) 1(m) 0(m) 213

1264 R421 Winding length detection (lower 4 digits) 0 to 9999(m) 1(m) 1000(m) 213

1265 R230 Line multi-speed setting (high- speed) 0 to 6553.4 m/min 0.1 m/min 0 m/min 67

1266 R231 Line multi-speed setting (middle-speed) 0 to 6553.4 m/min 0.1 m/min 0 m/min 67

1267 R232 Line multi-speed setting (low- speed) 0 to 6553.4 m/min 0.1 m/min 0 m/min 67

1268 R233 Line multi-speed setting (speed 4) 0 to 6553.4 m/min 0.1 m/min 0 m/min 67 1269 R234 Line multi-speed setting (speed 5) 0 to 6553.4 m/min 0.1 m/min 0 m/min 67 1270 R235 Line multi-speed setting (speed 6) 0 to 6553.4 m/min 0.1 m/min 0 m/min 67 1271 R236 Line multi-speed setting (speed 7) 0 to 6553.4 m/min 0.1 m/min 0 m/min 67 1272 R237 Line multi-speed setting (speed 8) 0 to 6553.4 m/min 0.1 m/min 0 m/min 67 1273 R238 Line multi-speed setting (speed 9) 0 to 6553.4 m/min 0.1 m/min 0 m/min 67

1274 R239 Line multi-speed setting (speed 10) 0 to 6553.4 m/min 0.1 m/min 0 m/min 67

1275 R240 Line multi-speed setting (speed 11) 0 to 6553.4 m/min 0.1 m/min 0 m/min 67

1276 R241 Line multi-speed setting (speed 12) 0 to 6553.4 m/min 0.1 m/min 0 m/min 67

1277 R242 Line multi-speed setting (speed 13) 0 to 6553.4 m/min 0.1 m/min 0 m/min 67

1278 R243 Line multi-speed setting (speed 14) 0 to 6553.4 m/min 0.1 m/min 0 m/min 67

1279 R244 Line multi-speed setting (speed 15) 0 to 6553.4 m/min 0.1 m/min 0 m/min 67

1280 R401 Winding diameter monitoring reference 1 to 6553 mm 1 mm 1000 mm 218,

224

1281 R402 Commanded tension monitoring reference 0 to 500 N 0.01 N 100 N

218, 224

1282 R320 Tension command cushion time 0 to 360 s 0.01 s 0 s 151 1283 R321 Cushion time reference tension 0.01 to 500 N 0.01 N 100 N 151

1284 R500 Taper mode selection 0 to 4 1 0 108, 151

1285 R501 Taper setting analog input selection 3 to 6, 9999 1 9999 108,

151

1286 R503 Winding diameter at taper start 0 to 6553 mm, 9999 1 mm 9999 108, 151

1287 R502 Taper ratio setting 0 to 100%, 9999 0.1% 0% 108, 151

1288 R510 Data table winding diameter 1 0 to 6553 mm, 9999 1 mm 9999 108, 151

1289 R511 Data table taper ratio 1 0 to 100% 0.1% 0% 108, 151

1290 R512 Data table winding diameter 2 0 to 6553 mm, 9999 1 mm 9999 108, 151

1291 R513 Data table taper ratio 2 0 to 100% 0.1% 0% 108, 151

1292 R514 Data table winding diameter 3 0 to 6553 mm, 9999 1 mm 9999 108, 151

1293 R515 Data table taper ratio 3 0 to 100% 0.1% 0% 108, 151

1294 R516 Data table winding diameter 4 0 to 6553 mm, 9999 1 mm 9999 108, 151

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Parameter list (by parameter number)

PARAMETER LIST 31

2

1295 R517 Data table taper ratio 4 0 to 100% 0.1% 0% 108, 151

1296 R518 Data table winding diameter 5 0 to 6553 mm, 9999 1 mm 9999 108, 151

1297 R519 Data table taper ratio 5 0 to 100% 0.1% 0% 108, 151

1298 R007 Stored winding length (upper 4 digits) 0 to 9999(m) 1(m) 0(m) 213

1299 R008 Stored winding length increment 0 to 2 1 0 213

1300 to

1343

N500 to

N543 Communication option parameters. For details, refer to the Instruction Manual of the option.

1346 R424 Winding length detection (upper 4 digits) 0 to 9999(m) 1(m) 0(m) 213

1348 G263 P/PI control switchover frequency 0 to 400 Hz 0.01 Hz 0 Hz

1349 G264 Emergency stop operation selection 0, 1, 10, 11 1 0

1350 to

1359

N550 to

N559 Communication option parameters. For details, refer to the Instruction Manual of the option.

1382 R150 PID set point cushion time 0 to 360 s 0.01 s 0 s 85

1383 R335 PID torque control manipulated tension bias [N] 0 to 500 N 0.01 N 0 N 183

1384 R336 PID torque control manipulated tension gain [N] 0 to 500 N , 9999 0.01 N 9999 183

1401 R301 Tension command increment 0 to 2 1 0 140, 224

1402 R310 Tension command input voltage bias 0 to 100% 0.1% 0% 140

1403 R311 Tension command bias 0 to 500 N 0.01 N 0 N 140

1404 R312 Tension command input voltage gain 0 to 100% 0.1% 100% 140

1405 R313 Tension command gain 0 to 500 N 0.01 N 100 N 140

1406 R340 Commanded tension reduction scaling factor during stall condition

0 to 200% 0.1% 20% 165

1407 R341 Speed limit during stall condition 0 to 60 Hz 0.01 Hz 1 Hz 165

1409 R343 Tension command cushion time during stall condition 0 to 360 s, 9999 0.01 s 9999 165

1410 R530 Motor inertia 0 to 500 kgm2, 9999 0.01 kgm2 0 kgm2 157 1411 R531 Empty reel inertia 0 to 500 kgm2, 9999 0.01 kgm2 0 kgm2 157 1412 R532 Roll width 0 to 5000 mm 1 mm 0 mm 157 1413 R533 Material specific gravity 0 to 20 g/cm3 0.001 g/cm3 0 g/cm3 157

1414 R535 First acceleration time for inertia compensation 0 to 3600 s 0.1 s 15 s 157

1415 R536 First deceleration time for inertia compensation 0 to 3600 s 0.1 s 15 s 157

1418 R534 Inertia compensation cushion time 0 to 360 s 0.01 s 0 s 157

1419 R550 Mechanical loss setting frequency bias 900 to 1100% 0.1% 1000% 163

1420 R551 Mechanical loss setting frequency 1 0 to 400 Hz, 9999 0.01 Hz 9999 163

1421 R552 Mechanical loss 1 900 to 1100% 0.1% 1000% 163

1422 R553 Mechanical loss setting frequency 2 0 to 400 Hz, 9999 0.01 Hz 9999 163

1423 R554 Mechanical loss 2 900 to 1100% 0.1% 1000% 163

1424 R555 Mechanical loss setting frequency 3 0 to 400 Hz, 9999 0.01 Hz 9999 163

1425 R556 Mechanical loss 3 900 to 1100% 0.1% 1000% 163

1426 R557 Mechanical loss setting frequency 4 0 to 400 Hz, 9999 0.01 Hz 9999 163

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Parameter list (by parameter number)

32 PARAMETER LIST

Differs according to the capacity. 6%: FR-A820-00046(0.4K), 00077(0.75K), FR-A840-00023(0.4K), 00038(0.75K) 4%: FR-A820-00105(1.5K) to 00250(3.7K), FR-A840-00052(1.5K) to 00126(3.7K) 3%: FR-A820-00340(5.5K), 00490(7.5K), FR-A840-00170(5.5K), 00250(7.5K) 2%: FR-A820-00630(11K) to 03160(55K), FR-A840-00310(11K) to 01800(55K) 1%: FR-A820-03800(75K) or higher, FR-A840-02160(75K) or higher

The setting range or initial value for the FR-A820-03160(55K) or lower and FR-A840-01800(55K) or lower. The setting range or initial value for the FR-A820-03800(75K) or higher and FR-A840-02160(75K) or higher. The initial value for the FR-A820-00490(7.5K) or lower and FR-A840-00250(7.5K) or lower. The initial value for the FR-A820-00630(11K) or higher and FR-A840-00310(11K) and higher. Differs according to the capacity.

4%: FR-A820-00490(7.5K) or lower, FR-A840-00250(7.5K) or lower 2%: FR-A820-00630(11K) to 03160(55K), FR-A840-00310(11K) to 01800(55K) 1%: FR-A820-03800(75K) or higher, FR-A840-02160(75K)or higher

The value for the 200 V class. The value for the 400 V class. The setting is available only when a plug-in option that supports Vector control is installed. For details of the Vector control compatible options

supporting the parameter, refer to the Instruction Manual (Detailed) of the FR-A800 inverter or the Instruction Manual of the Vector control compatible option.

The parameter number in parentheses is that used (displayed) on the LCD operation panel and the parameter unit. The increment varies depending on the Pr.358 setting. The increment varies depending on the Pr.1262 setting. The setting varies with the Pr.1401 setting. The initial value is for standard models. The initial value is for separated converter types. The setting is available only when the FR-A8AZ is installed. For the details, refer to the Instruction Manual (Detailed) of the FR-A800 inverter in the enclosed CD-ROM. For the details, refer to the Instruction Manual of the FR-A8AL.

1427 R558 Mechanical loss 4 900 to 1100% 0.1% 1000% 163

1428 R559 Mechanical loss setting frequency 5 0 to 400 Hz, 9999 0.01 Hz 9999 163

1429 R560 Mechanical loss 5 900 to 1100% 0.1% 1000% 163

1480 H520 Load characteristics measurement mode 0, 1 (2 to 5, 81 to 85) 1 0

1481 H521 Load characteristics load reference 1 0 to 400%, 8888, 9999 0.1% 9999

1482 H522 Load characteristics load reference 2 0 to 400%, 8888, 9999 0.1% 9999

1483 H523 Load characteristics load reference 3 0 to 400%, 8888, 9999 0.1% 9999

1484 H524 Load characteristics load reference 4 0 to 400%, 8888, 9999 0.1% 9999

1485 H525 Load characteristics load reference 5 0 to 400%, 8888, 9999 0.1% 9999

1486 H526 Load characteristics maximum frequency 0 to 590 Hz 0.01 Hz 60 Hz 50 Hz

1487 H527 Load characteristics minimum frequency 0 to 590 Hz 0.01 Hz 6 Hz

1488 H531 Upper limit warning detection width 0 to 400%, 9999 0.1% 20%

1489 H532 Lower limit warning detection width 0 to 400%, 9999 0.1% 20%

1490 H533 Upper limit fault detection width 0 to 400%, 9999 0.1% 9999

1491 H534 Lower limit fault detection width 0 to 400%, 9999 0.1% 9999

1492 H535 Load status detection signal delay time / load reference measurement waiting time

0 to 60 s 0.1s 1s

1499 E415 Parameter for manufacturer setting. Do not set. Pr.CLR Parameter clear (0, )1 1 0

ALL.CL All parameter clear (0, )1 1 0

Err.CL Fault history clear (0, )1 1 0

Pr.CPY Parameter copy (0, )1 to 3 1 0

Pr.CHG Initial value change list

AUTO Automatic parameter setting

Pr.Md Group parameter setting (0, )1, 2 1 0

Pr. Pr. group Name Setting range

Minimum setting

increments

Initial value Refer to

page

Customer settingFM CA

Parameter list (by function group)

PARAMETER LIST 33

2

2.2 Parameter list (by function group)

R: Roll to roll function setting Parameters that set the roll to roll functions.

Pr. group Pr. Name

Refer to

page

R000 1247 Winding diameter change increment amount limit 197

R001 1248 Winding diameter change limit disable time 197

R002 1230 Winding/unwinding selection 67, 163, 178

R003 646 Stored winding diameter 213

R004 645 Winding diameter storage selection 213

R005 1262 Winding length increment 213, 224

R006 1263 Stored winding length (lower 4 digits) 213

R007 1298 Stored winding length (upper 4 digits) 213

R008 1299 Stored winding length increment 213 R010 1231 Material thickness d1 203 R011 1232 Material thickness d2 203 R012 1233 Material thickness d3 203 R013 1234 Material thickness d4 203 R020 1235 Maximum winding diameter 1 206 R021 1236 Minimum winding diameter 1 206 R022 1237 Maximum winding diameter 2 206 R023 1238 Minimum winding diameter 2 206 R024 1239 Maximum winding diameter 3 206 R025 1240 Minimum winding diameter 3 206 R026 1241 Maximum winding diameter 4 206 R027 1242 Minimum winding diameter 4 206

R030 639 Speed control proportional term applied diameter 1 216

R031 640 Speed control proportional term applied diameter 2 216

R032 641 Speed control proportional gain 1 216 R033 642 Speed control proportional gain 2 216 R034 643 Speed control proportional gain 3 216 R035 644 Speed control proportional gain 4 216

R040 1246 Line speed at winding diameter calculated value activation 204

R041 647 Operation time with stored winding diameter 213

R042 1245 Sampling time for winding diameter calculation 199

R043 1249 Number of averaging for winding diameter calculation 205

R050 362 Actual line speed input selection 199

R051 278 Actual line speed voltage/current gain 199

R052 279 Actual line speed gain 199

R053 280 Actual line speed voltage/current bias 199

R054 281 Actual line speed bias 199 R055 282 Actual line speed pulse input bias 199 R056 283 Actual line speed pulse input gain 199

R057 284 Actual line speed input filter time constant 199

R070 1252 Dancer lower limit position 208

R071 1253 Initial winding diameter calculation deadband 208

R072 1254 Initial winding diameter calculation deadband 2 208

R073 1255 Accumulated amount 208 R074 1256 Speed control P gain at start 208

R075 1257 Speed control integral time at start 208

R076 1258 Integral term limit at start 208 R077 1259 PID term limit at start 208 R100 128 PID action selection 65, 177 R101 133 PID action set point 65, 124

R102 363 Dancer / tension sensor feedback input selection

85, 124, 178

R103 1227 Dancer / tension sensor feedback input filter time constant

85, 124, 178

R104 424 Dancer / tension sensor feedback input offset 88, 126

R105 1148 PID manipulated line speed bias 104 R106 1149 PID manipulated line speed gain 104 R110 129 PID proportional band 99 R111 130 PID integral time 99 R112 134 PID differential time 99

R113 464 PID proportional band for values below set point 101

R114 465 PID integral time for values below set point 101

R115 466 PID differential time for values below set point 101

R116 467 Second PID proportional band 101 R117 468 Second PID integral time 101 R118 469 Second PID differential time 101

R119 470 Second PID proportional band for values below set point 101

R120 471 Second PID integral time for values below set point 101

R121 472 Second PID differential time for values below set point 101

R122 473 Third PID proportional band 101 R123 474 Third PID integral time 101 R124 475 Third PID differential time 101

R125 476 Third PID proportional band for values below set point 101

R126 477 Third PID integral time for values below set point 101

R127 478 Third PID differential time for values below set point 101

R128 479 Fourth PID proportional band 101 R129 480 Fourth PID integral time 101 R130 481 Fourth PID differential time 101

R131 482 Fourth PID proportional band for values below set point 101

R132 483 Fourth PID integral time for values below set point 101

R133 484 Fourth PID differential time for values below set point 101

R140 486 Deviation A 101 R141 487 Deviation B 101

Pr. group Pr. Name

Refer to

page

Parameter list (by function group)

34 PARAMETER LIST

R142 488 Deviation C1 101 R143 489 Deviation C2 101 R144 490 PID gain A 101 R145 491 PID gain B 101 R146 492 PID gain C1 101 R147 493 PID gain C2 101 R148 494 PID gain D 101 R149 485 Integral control activation 100 R150 1382 PID set point cushion time 85 R160 425 Break detection waiting time 89, 180 R161 135 Integral clamp (positive polarity) 100 R162 136 Integral clamp (negative polarity) 100

R163 137 PID upper/lower limit hysteresis width

89, 127, 180

R170 1219 Tension PI gain tuning start/ status 91

R171 1211 Tension PI gain tuning timeout time 91

R172 1215 Limit cycle output upper limit 91 R173 1217 Limit cycle hysteresis 91

R174 1223 Manipulated amount for operation 91

R175 1222 Target amplitude 91

R176 1226 Tension PI gain tuning response level setting 91

R200 361 Line speed command input selection 67

R201 358 Line speed unit 67, 224 R202 360 Line speed command value 67 R203 398 Draw rate 67 R204 622 Line speed command for starting 67

R205 1147 Line speed command maximum value 67

R210 350 Line speed command voltage/ current bias 67

R211 351 Line speed command bias 67

R212 352 Line speed command voltage/ current gain 67

R213 353 Line speed command gain 67

R214 635 Line speed command added compensation value voltage/ current bias

76

R215 636 Line speed command added compensation value bias 76

R216 637 Line speed command added compensation value voltage/ current gain

76

R217 638 Line speed command added compensation value gain 76

R220 354 Line speed command pulse input bias 67

R221 355 Line speed command pulse input gain 67

R222 356 Line speed command digital input bias 67

R223 357 Line speed command digital input gain 67

R224 1146 Line speed command input filter time constant 67

R230 1265 Line multi-speed setting (high- speed) 67

R231 1266 Line multi-speed setting (middle- speed) 67

Pr. group Pr. Name

Refer to

page

R232 1267 Line multi-speed setting (low- speed) 67

R233 1268 Line multi-speed setting (speed 4) 67

R234 1269 Line multi-speed setting (speed 5) 67

R235 1270 Line multi-speed setting (speed 6) 67

R236 1271 Line multi-speed setting (speed 7) 67

R237 1272 Line multi-speed setting (speed 8) 67

R238 1273 Line multi-speed setting (speed 9) 67

R239 1274 Line multi-speed setting (speed 10) 67

R240 1275 Line multi-speed setting (speed 11) 67

R241 1276 Line multi-speed setting (speed 12) 67

R242 1277 Line multi-speed setting (speed 13) 67

R243 1278 Line multi-speed setting (speed 14) 67

R244 1279 Line multi-speed setting (speed 15) 67

R250 393 Line speed command acceleration/deceleration reference

79

R251 394 First acceleration time for line speed command 79

R252 395 First deceleration time for line speed command 79

R253 100 Second acceleration time for line speed command 79

R254 101 Second deceleration time for line speed command 79

R255 102 Third acceleration time for line speed command 79

R256 103 Third deceleration time for line speed command 79

R260 1250 Winding diameter compensation speed filtering waiting time 207

R261 1251 Winding diameter compensation speed filter time constant 207

R270 650 Terminal 4 input compensation selection 76

R290 1141 Line speed command acceleration/deceleration pattern 82

R291 1142 Line speed command acceleration start S-curve time 82

R292 1143 Line speed command acceleration completion S-curve time

82

R293 1144 Line speed command deceleration start S-curve time 82

R294 1145 Line speed command deceleration completion S-curve time

82

R300 804 Tension / Torque command source selection 140

R301 1401 Tension command increment 140, 224

R302 365 Tension command value (RAM) 140

R303 366 Tension command value (RAM, EEPROM) 140

R304 1072 Tension reverse selection 143

Pr. group Pr. Name

Refer to

page

Parameter list (by function group)

PARAMETER LIST 35

2

E: Environment setting

R305 1114 Torque command reverse selection 143

R310 1402 Tension command input voltage bias 140

R311 1403 Tension command bias 140

R312 1404 Tension command input voltage gain 140

R313 1405 Tension command gain 140 R320 1282 Tension command cushion time 151 R321 1283 Cushion time reference tension 151

R330 1136 Tension sensor feedback voltage/ current bias 178

R331 1137 Tension sensor feedback bias 178

R332 1138 Tension sensor feedback voltage/ current gain 178

R333 1139 Tension sensor feedback gain 178

R334 1140 Signed winding diameter compensation torque command selection

183

R335 1383 PID torque control manipulated tension bias [N] 183

R336 1384 PID torque control manipulated tension gain [N] 183

R340 1406 Commanded tension reduction scaling factor during stall condition

165

R341 1407 Speed limit during stall condition 165

R342 270 Acceleration/deceleration time during stall condition 165

R343 1409 Tension command cushion time during stall condition 165

R400 276 Line speed monitoring reference 218, 224

R401 1280 Winding diameter monitoring reference

218, 224

R402 1281 Commanded tension monitoring reference

218, 224

R410 430 Dancer tension setting / taper function enable/disable selection for tension sensor feedback speed control 2

108

R411 364 Dancer tension setting input selection / taper function enable/ disable selection for tension sensor feedback speed control 1

108

R412 426 Dancer tension setting bias 108 R413 427 Dancer tension setting gain 108 R420 648 Target winding diameter 213

R421 1264 Winding length detection (lower 4 digits) 213

R422 423 Dancer / tension sensor feedback detection level 88, 126

R423 621 Allowable deviation from target line speed 79, 106

R424 1346 Winding length detection (upper 4 digits) 213

R430 609 PID measured tension monitor filter 226

R431 610 PID measured tension monitor increment 226

R450 159 DA1 output sign selection 218

R500 1284 Taper mode selection 108, 151

R501 1285 Taper setting analog input selection

108, 151

Pr. group Pr. Name

Refer to

page

R502 1287 Taper ratio setting 108, 151

R503 1286 Winding diameter at taper start 108, 151

R504 829 Taper ratio setting input filter time constant 151

R510 1288 Data table winding diameter 1 108, 151

R511 1289 Data table taper ratio 1 108, 151

R512 1290 Data table winding diameter 2 108, 151

R513 1291 Data table taper ratio 2 108, 151

R514 1292 Data table winding diameter 3 108, 151

R515 1293 Data table taper ratio 3 108, 151

R516 1294 Data table winding diameter 4 108, 151

R517 1295 Data table taper ratio 4 108, 151

R518 1296 Data table winding diameter 5 108, 151

R519 1297 Data table taper ratio 5 108, 151

R530 1410 Motor inertia 157 R531 1411 Empty reel inertia 157 R532 1412 Roll width 157 R533 1413 Material specific gravity 157

R534 1418 Inertia compensation cushion time 157

R535 1414 First acceleration time for inertia compensation 157

R536 1415 First deceleration time for inertia compensation 157

R537 271 Second acceleration time for inertia compensation 157

R538 272 Second deceleration time for inertia compensation 157

R539 753 Empty reel inertia (integer) 157 R540 754 Empty reel inertia (exponent) 157

R550 1419 Mechanical loss setting frequency bias 163

R551 1420 Mechanical loss setting frequency 1 163

R552 1421 Mechanical loss 1 163

R553 1422 Mechanical loss setting frequency 2 163

R554 1423 Mechanical loss 2 163

R555 1424 Mechanical loss setting frequency 3 163

R556 1425 Mechanical loss 3 163

R557 1426 Mechanical loss setting frequency 4 163

R558 1427 Mechanical loss 4 163

R559 1428 Mechanical loss setting frequency 5 163

R560 1429 Mechanical loss 5 163 R570 620 Line speed bias for reel change 106 R600 1243 Gear ratio numerator 197 R601 1244 Gear ratio denominator 197

Pr. group Pr. Name

Refer to

page

Parameter list (by function group)

36 PARAMETER LIST

parameters Parameters that set the inverter operation characteristics.

F: Parameters for the settings of the acceleration/deceleration time and the acceleration/deceleration pattern

Parameters for the motor acceleration/deceleration characteristics.

Pr. group Pr. Name

Refer to

page

E000 168 Parameter for manufacturer setting. Do not set.

E001 169 Parameter for manufacturer setting. Do not set.

E020 1006 Clock (year)

E021 1007 Clock (month, day)

E022 1008 Clock (hour, minute)

E023 269 Parameter for manufacturer setting. Do not set.

E080 168 Parameter for manufacturer setting. Do not set.

E081 169 Parameter for manufacturer setting. Do not set.

E100 75 Reset selection

E101 75 Disconnected PU detection

E102 75 PU stop selection

E103 145 PU display language selection

E104 990 PU buzzer control

E105 991 PU contrast adjustment

E106 1048 Display-off waiting time

E107 75 Reset limit

E108 1000 Direct setting selection

E110 1049 USB host reset

E200 161 Frequency setting/key lock operation selection

E201 295 Frequency change increment amount setting

E300 30 Regenerative function selection

E301 570 Multiple rating setting 8 E302 977 Input voltage mode selection

E400 77 Parameter write selection 237 E410 296 Password lock level

E411 297 Password lock/unlock

E415 1499 Parameter for manufacturer setting. Do not set.

E420 888 Free parameter 1

E421 889 Free parameter 2

E431 999 Automatic parameter setting

E440 160 User group read selection

E441 172 User group registered display/ batch clear

E442 173 User group registration

E443 174 User group clear

E490 989 Parameter copy alarm release

E600 72 PWM frequency selection

E601 240 Soft-PWM operation selection

E602 260 PWM frequency automatic switchover

E700 255 Life alarm status display

E701 256 Inrush current limit circuit life display

E702 257 Control circuit capacitor life display

E703 258 Main circuit capacitor life display

E704 259 Main circuit capacitor life measuring

E710 503 Maintenance timer 1

E711 504 Maintenance timer 1 warning output set time

E712 686 Maintenance timer 2

E713 687 Maintenance timer 2 warning output set time

E714 688 Maintenance timer 3

E715 689 Maintenance timer 3 warning output set time

E720 555 Current average time

E721 556 Data output mask time

E722 557 Current average value monitor signal output reference current

Pr. group Pr. Name

Refer to

page

F000 20 Acceleration/deceleration reference frequency

F001 21 Acceleration/deceleration time increments 79

F002 16 Jog acceleration/deceleration time 227

F003 611 Acceleration time at a restart

F010 7 Acceleration time

F011 8 Deceleration time

F020 44 Second acceleration/deceleration time

F021 45 Second deceleration time

F022 147 Acceleration/deceleration time switching frequency

F030 110 Third acceleration/deceleration time

F031 111 Third deceleration time

F040 1103 Deceleration time at emergency stop 180

F100 29 Acceleration/deceleration pattern selection

F102 13 Starting frequency 208 F103 571 Holding time at a start

F200 140 Backlash acceleration stopping frequency

F201 141 Backlash acceleration stopping time

F202 142 Backlash deceleration stopping frequency

F203 143 Backlash deceleration stopping time

F300 380 Acceleration S-pattern 1

F301 381 Deceleration S-pattern 1

F302 382 Acceleration S-pattern 2

F303 383 Deceleration S-pattern 2

F400 516 S-pattern time at a start of acceleration

F401 517 S-pattern time at a completion of acceleration

F402 518 S-pattern time at a start of deceleration

Pr. group Pr. Name

Refer to

page

Parameter list (by function group)

PARAMETER LIST 37

2

D: Operation command and frequency command

Parameters that specify the inverter's command source, and parameters that set the motor driving frequency and torque.

H: Protective function parameters Parameters to protect the motor and the inverter.

F403 519 S-pattern time at a completion of deceleration

Pr. group Pr. Name

Refer to

page D000 79 Operation mode selection

D001 340 Communication startup mode selection

D010 338 Communication operation command source 233

D011 339 Communication speed command source 233

D012 550 NET mode operation command source selection

D013 551 PU mode operation command source selection

D020 78 Reverse rotation prevention selection 208

D030 811 Set resolution switchover

D100 291 Pulse train I/O selection

D101 384 Input pulse division scaling factor

D110 385 Frequency for zero input pulse

D111 386 Frequency for maximum input pulse

D120 432 Pulse train torque command bias

D121 433 Pulse train torque command gain

D200 15 Jog frequency 227

D300 28 Multi-speed input compensation selection

D301 4 Multi-speed setting (high speed)

D302 5 Multi-speed setting (middle speed)

D303 6 Multi-speed setting (low speed)

D304 to

D307

24 to 27

Multi-speed setting (4 speed to 7 speed)

D308 to

D315

232 to

239

Multi-speed setting (8 speed to 15 speed)

D400 804 Tension / Torque command source selection 140

D401 805 Torque command value (RAM)

D402 806 Torque command value (RAM,EEPROM)

D403 1114 Torque command reverse selection 143

Pr. group Pr. Name

Refer to

page H000 9 Electronic thermal O/L relay

H001 600 First free thermal reduction frequency 1

Pr. group Pr. Name

Refer to

page

H002 601 First free thermal reduction ratio 1

H003 602 First free thermal reduction frequency 2

H004 603 First free thermal reduction ratio 2

H005 604 First free thermal reduction frequency 3

H006 607 Motor permissible load level

H010 51 Second electronic thermal O/L relay

H011 692 Second free thermal reduction frequency 1

H012 693 Second free thermal reduction ratio 1

H013 694 Second free thermal reduction frequency 2

H014 695 Second free thermal reduction ratio 2

H015 696 Second free thermal reduction frequency 3

H016 608 Second motor permissible load level

H020 561 PTC thermistor protection level

H021 1016 PTC thermistor protection detection time

H022 876

Thermal protector input

H030 875 Fault definition

H100 244 Cooling fan operation selection

H101 249 Earth (ground) fault detection at start

H102 598 Undervoltage level

H103 997 Fault initiation

H200 251 Output phase loss protection selection

H201 872 Input phase loss protection selection

H300 65 Retry selection

H301 67 Number of retries at fault occurrence

H302 68 Retry waiting time

H303 69 Retry count display erase

H400 1 Maximum frequency 146 H401 2 Minimum frequency

H402 18 High speed maximum frequency

H410 807 Speed limit selection 146

H411 808 Forward rotation speed limit/ speed limit 146

H412 809 Reverse rotation speed limit/ reverse-side speed limit 146

H414 1113 Speed limit method selection 146

H415 873

Speed limit

H416 285 Speed deviation excess detection frequency

H417 853

Speed deviation time

H420 31 Frequency jump 1A

H421 32 Frequency jump 1B

H422 33 Frequency jump 2A

H423 34 Frequency jump 2B

H424 35 Frequency jump 3A

H425 36 Frequency jump 3B

Pr. group Pr. Name

Refer to

page

Parameter list (by function group)

38 PARAMETER LIST

M: Monitor display and monitor

output signal Parameters regarding the inverter's operating status. These

parameters are used to set the monitors and output signals.H429 552 Frequency jump range

H500 22 Stall prevention operation level (Torque limit level)

H501 156 Stall prevention operation selection

H520 1480 Load characteristics measurement mode

H521 1481 Load characteristics load reference 1

H522 1482 Load characteristics load reference 2

H523 1483 Load characteristics load reference 3

H524 1484 Load characteristics load reference 4

H525 1485 Load characteristics load reference 5

H526 1486 Load characteristics maximum frequency

H527 1487 Load characteristics minimum frequency

H531 1488 Upper limit warning detection width

H532 1489 Lower limit warning detection width

H533 1490 Upper limit fault detection width

H534 1491 Lower limit fault detection width

H535 1492 Load status detection signal delay time / load reference measurement waiting time

H600 48 Second stall prevention operation level

H601 49 Second stall prevention operation frequency

H602 114 Third stall prevention operation level

H603 115 Third stall prevention operation frequency

H610 23 Stall prevention operation level compensation factor at double speed

H611 66 Stall prevention operation reduction starting frequency

H620 148 Stall prevention level at 0 V input

H621 149 Stall prevention level at 10 V input

H631 154 Voltage reduction selection during stall prevention operation

H700 810 Torque limit input method selection

H701 812 Torque limit level (regeneration)

H702 813 Torque limit level (3rd quadrant)

H703 814 Torque limit level (4th quadrant)

H704 801 Output limit level

H710 815 Torque limit level 2

H720 816 Torque limit level during acceleration

H721 817 Torque limit level during deceleration

H730 874 OLT level setting

H800 374 Overspeed detection level

H881 690 Deceleration check time

Pr. group Pr. Name

Refer to

page

Pr. group Pr. Name

Refer to

page M000 37 Speed display

M001 505 Speed setting reference

M002 144 Speed setting switchover

M020 170 Watt-hour meter clear

M021 563 Energization time carrying-over times

M022 268 Monitor decimal digits selection

M023 891 Cumulative power monitor digit shifted times

M030 171 Operation hour meter clear

M031 564 Operating time carrying-over times

M040 55 Frequency monitoring reference 218 M041 56 Current monitoring reference 218

M042 866 Torque monitoring reference 218, 224

M043 241 Analog input display unit switchover

M044 290 Monitor negative output selection 218 M045 1018 Monitor with sign selection

M050 1106 Torque monitor filter

M051 1107 Running speed monitor filter

M052 1108 Excitation current monitor filter

M060 663 Control circuit temperature signal output level

M100 52 Operation panel main monitor selection 218

M101 774 Operation panel monitor selection 1 218

M102 775 Operation panel monitor selection 2 218

M103 776 Operation panel monitor selection 3 218

M104 992 Operation panel setting dial push monitor selection 218

M200 892 Load factor

M201 893 Energy saving monitor reference (motor capacity)

M202 894 Control selection during commercial power-supply operation

M203 895 Power saving rate reference value

M204 896 Power unit cost

M205 897 Power saving monitor average time

M206 898 Power saving cumulative monitor clear

M207 899 Operation time rate (estimated value)

M300 54 FM/CA terminal function selection

108, 218

M301 158 AM terminal function selection 108, 218

M310 C0

(900)

FM/CA terminal calibration 108

M320 C1

(901)

AM terminal calibration 108

Parameter list (by function group)

PARAMETER LIST 39

2

T: Multi-function input terminal parameters

Parameters for the input terminals where inverter commands are received through.

M321 867 AM output filter

M330 C8

(930)

Current output bias signal

M331 C9

(930)

Current output bias current

M332 C10 (931)

Current output gain signal

M333 C11 (931)

Current output gain current

M334 869 Current output filter

M400 190 RUN terminal function selection 230 M401 191 SU terminal function selection 230 M402 192 IPF terminal function selection 230 M403 193 OL terminal function selection 230 M404 194 FU terminal function selection 230 M405 195 ABC1 terminal function selection 230 M406 196 ABC2 terminal function selection 230 M430 157 OL signal output timer

M431 289 Inverter output terminal filter

M433 166 Output current detection signal retention time

M440 870 Speed detection hysteresis

M441 41 Up-to-frequency sensitivity

M442 42 Output frequency detection

M443 43 Output frequency detection for reverse rotation

M444 50 Second output frequency detection

M445 116 Third output frequency detection

M446 865 Low speed detection

M460 150 Output current detection level

M461 151 Output current detection signal delay time

M462 152 Zero current detection level

M463 153 Zero current detection time

M464 167 Output current detection operation selection

M470 864 Torque detection

M500 495 Remote output selection

M501 496 Remote output data 1

M502 497 Remote output data 2

M510 76 Fault code output selection

M520 799 Pulse increment setting for output power

M530 655 Analog remote output selection

M531 656 Analog remote output 1

M532 657 Analog remote output 2

M533 658 Analog remote output 3

M534 659 Analog remote output 4

M600 863 Control terminal option-Encoder pulse division ratio

M610 755 Cumulative pulse clear signal selection

M611 756 Cumulative pulse division scaling factor

M612 757 Control terminal option- Cumulative pulse division scaling factor

M613 758 Cumulative pulse storage

Pr. group Pr. Name

Refer to

page

Pr. group Pr. Name

Refer to

page T000 73 Analog input selection 76, 208 T001 267 Terminal 4 input selection

T002 74 Input filter time constant 67, 108, 140

T003 822 Speed setting filter 1 67 T004 826 Torque setting filter 1 140 T005 832 Speed setting filter 2 67 T006 836 Torque setting filter 2 140 T007 849 Analog input offset adjustment

T010 868 Terminal 1 function assignment 76, 140

T021 242 Terminal 1 added compensation amount (terminal 2)

T022 125 Terminal 2 frequency setting gain frequency 6

T040 858 Terminal 4 function assignment

T041 243 Terminal 1 added compensation amount (terminal 4)

T042 126 Terminal 4 frequency setting gain frequency 6

T050 252 Override bias 76 T051 253 Override gain 76 T052 573 4 mA input check selection

T054 778 4 mA input check filter

T100 C12 (917)

Terminal 1 bias frequency (speed) 6

T101 C13 (917)

Terminal 1 bias (speed)

6, 85, 108, 124, 151

T102 C14 (918)

Terminal 1 gain frequency (speed) 6

T103 C15 (918)

Terminal 1 gain (speed)

6, 85, 108, 124, 151

T110 C16 (919)

Terminal 1 bias command (torque/magnetic flux) 6

T111 C17 (919)

Terminal 1 bias (torque/magnetic flux) 6

T112 C18 (920)

Terminal 1 gain command (torque/magnetic flux) 6

T113 C19 (920)

Terminal 1 gain (torque/magnetic flux) 6

T200 C2

(902)

Terminal 2 frequency setting bias frequency 6

T201 C3

(902)

Terminal 2 frequency setting bias

6, 85, 108, 124, 151

Parameter list (by function group)

40 PARAMETER LIST

C: Motor constant parameters Parameters for the applied motor setting.

A: Application parameters Parameters to set a specific application.

T202 125

(903)

Terminal 2 frequency setting gain frequency 6

T203 C4

(903)

Terminal 2 frequency setting gain

6, 85, 108, 124, 151

T400 C5

(904)

Terminal 4 frequency setting bias frequency 6

T401 C6

(904)

Terminal 4 frequency setting bias

6, 85, 108, 124, 151

T402 126

(905)

Terminal 4 frequency setting gain frequency 6

T403 C7

(905)

Terminal 4 frequency setting gain

6, 85, 108, 124, 151

T410 C38 (932)

Terminal 4 bias command (torque/magnetic flux) 6

T411 C39 (932)

Terminal 4 bias (torque/magnetic flux) 6

T412 C40 (933)

Terminal 4 gain command (torque/magnetic flux) 6

T413 C41 (933)

Terminal 4 gain (torque/magnetic flux) 6

T700 178 STF terminal function selection 227 T701 179 STR terminal function selection 227 T702 180 RL terminal function selection 227 T703 181 RM terminal function selection 227 T704 182 RH terminal function selection 227 T705 183 RT terminal function selection 227 T706 184 AU terminal function selection 227 T707 185 JOG terminal function selection 227 T708 186 CS terminal function selection 227 T709 187 MRS terminal function selection 227 T710 188 STOP terminal function selection 227 T711 189 RES terminal function selection 227 T720 17 MRS input selection

T721 599 X10 terminal input selection

T722 606 Power failure stop external signal input selection

T730 155 RT signal function validity condition selection

T740 699 Input terminal filter

Pr. group Pr. Name

Refer to

page C000 684 Tuning data unit switchover

C100 71 Applied motor 55 C101 80 Motor capacity 55 C102 81 Number of motor poles 55, 195

Pr. group Pr. Name

Refer to

page C104 83 Rated motor voltage 55 C105 84 Rated motor frequency 55 C107 707 Motor inertia (integer) 55, 157 C108 724 Motor inertia (exponent) 55, 157 C110 96 Auto tuning setting/status 55 C111 95 Online auto tuning selection

C112 818 Easy gain tuning response level setting 59

C113 819 Easy gain tuning selection 59 C114 880 Load inertia ratio 59 C120 90 Motor constant (R1)

C121 91 Motor constant (R2)

C122 92 Motor constant (L1)

C123 93 Motor constant (L2)

C124 94 Motor constant (X)

C125 82 Motor excitation current

C126 859 Torque current/Rated PM motor current

C140 369 Number of encoder pulses

C141 359 Encoder rotation direction

C148 376 Encoder signal loss detection enable/disable selection

C200 450 Second applied motor 55 C201 453 Second motor capacity 55 C202 454 Number of second motor poles 55 C204 456 Rated second motor voltage 55 C205 457 Rated second motor frequency 55 C207 744 Second motor inertia (integer) 55, 157 C208 745 Second motor inertia (exponent) 55, 157

C210 463 Second motor auto tuning setting/status 55

C211 574 Second motor online auto tuning

C220 458 Second motor constant (R1)

C221 459 Second motor constant (R2)

C222 460 Second motor constant (L1)

C223 461 Second motor constant (L2)

C224 462 Second motor constant (X)

C225 455 Second motor excitation current

C226 860 Second motor torque current/ Rated PM motor current

C240 851

Control terminal option-Number of encoder pulses

C241 852

Control terminal option-Encoder rotation direction

C242 862 Encoder option selection 234

C248 855

Control terminal option-Signal loss detection enable/disable selection

Pr. group Pr. Name

Refer to

page A107 285 Overspeed detection frequency

A601 131 PID upper limit 89, 127, 180

A602 132 PID lower limit 89, 127, 180

Pr. group Pr. Name

Refer to

page

Parameter list (by function group)

PARAMETER LIST 41

2 B: Position control parameters Parameters for the position control setting.

N: Operation via communication and its settings

Parameters for communication operation. These parameters

set the communication specifications and operation.

A603 553 PID deviation limit 89, 127, 180

A604 554 PID signal operation selection 89, 91, 127, 180

A605 1134 PID upper limit manipulated value 104 A606 1135 PID lower limit manipulated value 104

A607 1015 Integral stop selection at limited manipulated amount 100

A610 128 PID action selection 65, 177 A611 133 PID action set point 65, 124

A612 127 PID control automatic switchover frequency

A613 129 PID proportional band 99 A614 130 PID integral time 99 A615 134 PID differential time 99 A680 573 4 mA input check selection

A682 778 4 mA input check filter

A700 162 Automatic restart after instantaneous power failure selection

A701 299 Rotation direction detection selection at restarting

A702 57 Restart coasting time

A703 58 Restart cushion time

A704 163 First cushion time for restart

A705 164 First cushion voltage for restart

A710 165 Stall prevention operation level for restart

A711 298 Frequency search gain

A712 560 Second frequency search gain

A730 261 Power failure stop selection

A731 262 Subtracted frequency at deceleration start

A732 263 Subtraction starting frequency

A733 264 Power-failure deceleration time 1

A734 265 Power-failure deceleration time 2

A735 266 Power failure deceleration time switchover frequency

A785 294 UV avoidance voltage gain

A786 668 Power failure stop frequency gain

A800 414 PLC function operation selection

A801 415 Inverter operation lock mode setting

A802 416 Pre-scale function selection

A803 417 Pre-scale setting value

A804 498 PLC function flash memory clear

A805 675 User parameter auto storage function selection

A810 to

A859

1150 to

1199 User parameters 1 to 50

A900 1020 Trace operation selection

A901 1021 Trace mode selection

A902 1022 Sampling cycle

A903 1023 Number of analog channels

A904 1024 Sampling auto start

A905 1025 Trigger mode selection

A906 1026 Number of sampling before trigger

A910 1027 Analog source selection (1ch) 218

Pr. group Pr. Name

Refer to

page A911 1028 Analog source selection (2ch) 218 A912 1029 Analog source selection (3ch) 218 A913 1030 Analog source selection (4ch) 218 A914 1031 Analog source selection (5ch) 218 A915 1032 Analog source selection (6ch) 218 A916 1033 Analog source selection (7ch) 218 A917 1034 Analog source selection (8ch) 218 A918 1035 Analog trigger channel

A919 1036 Analog trigger operation selection

A920 1037 Analog trigger level

A930 1038 Digital source selection (1ch)

A931 1039 Digital source selection (2ch)

A932 1040 Digital source selection (3ch)

A933 1041 Digital source selection (4ch)

A934 1042 Digital source selection (5ch)

A935 1043 Digital source selection (6ch)

A936 1044 Digital source selection (7ch)

A937 1045 Digital source selection (8ch)

A938 1046 Digital trigger channel

A939 1047 Digital trigger operation selection

Pr. group Pr. Name

Refer to

page B003 422 Position control gain

B009 428 Command pulse selection 67

Pr. group Pr. Name

Refer to

page N000 549 Protocol selection

N001 342 Communication EEPROM write selection

N002 539 MODBUS RTU communication check time interval

N013 502 Stop mode selection at communication error

N020 117 PU communication station number

N021 118 PU communication speed

N022 119 PU communication data length

N023 119 PU communication stop bit length

N024 120 PU communication parity check

N025 121 Number of PU communication retries

N026 122 PU communication check time interval

N027 123 PU communication waiting time setting

N028 124 PU communication CR/LF selection

Pr. group Pr. Name

Refer to

page

Parameter list (by function group)

42 PARAMETER LIST

G: Control Parameters Parameters for motor control.

N030 331 RS-485 communication station number

N031 332 RS-485 communication speed

N032 333 RS-485 communication data length

N033 333 RS-485 communication stop bit length

N034 334 RS-485 communication parity check selection

N035 335 RS-485 communication retry count

N036 336 RS-485 communication check time interval

N037 337 RS-485 communication waiting time setting

N038 341 RS-485 communication CR/LF selection

N040 547 USB communication station number

N041 548 USB communication check time interval

N080 343 Communication error count

N500 to

N543

1300 to

1343

Communication option parameters. For details, refer to the Instruction Manual of the option.

N550 to

N559

1350 to

1359

Communication option parameters. For details, refer to the Instruction Manual of the option.

Pr. group Pr. Name

Refer to

page G000 0 Torque boost

G001 3 Base frequency

G002 19 Base frequency voltage

G003 14 Load pattern selection

G010 46 Second torque boost

G011 47 Second V/F (base frequency)

G020 112 Third torque boost

G021 113 Third V/F (base frequency)

G030 60 Energy saving control selection

G060 673 SF-PR slip amount adjustment operation selection

G061 674 SF-PR slip amount adjustment gain

G080 617 Reverse rotation excitation current low-speed scaling factor

G100 10 DC injection brake operation frequency

G101 11 DC injection brake operation time

G102 802 Pre-excitation selection

G103 850 Brake operation selection

G106 250 Stop selection

G107 70 Special regenerative brake duty

G110 12 DC injection brake operation voltage

G120 882 Regeneration avoidance operation selection

G121 883 Regeneration avoidance operation level

Pr. group Pr. Name

Refer to

page

G122 884 Regeneration avoidance at deceleration detection sensitivity

G123 885 Regeneration avoidance compensation frequency limit value

G124 886 Regeneration avoidance voltage gain

G125 665 Regeneration avoidance frequency gain

G200 800 Control method selection 5 G201 85 Excitation current break point

G202 86 Excitation current low-speed scaling factor

G203 245 Rated slip

G204 246 Slip compensation time constant

G205 247 Constant-power range slip compensation selection

G206 1116 Constant output range speed control P gain compensation

G210 803 Constant output range torque characteristic selection

G211 820 Speed control P gain 1 59 G212 821 Speed control integral time 1 59

G213 824 Torque control P gain 1 (current loop proportional gain)

G214 825 Torque control integral time 1 (current loop integral time)

G215 823

Speed detection filter 1

G216 827 Torque detection filter 1

G217 854 Excitation ratio

G218 1115 Speed control integral term clear time

G220 877 Speed feed forward control/ model adaptive speed control selection

G221 878 Speed feed forward filter

G222 879 Speed feed forward torque limit

G223 881 Speed feed forward gain

G224 828 Model speed control gain

G230 840 Torque bias selection

G231 841 Torque bias 1

G232 842 Torque bias 2

G233 843 Torque bias 3

G234 844 Torque bias filter

G235 845 Torque bias operation time

G236 846 Torque bias balance compensation

G237 847 Fall-time torque bias terminal 1 bias

G238 848 Fall-time torque bias terminal 1 gain

G240 367 Speed feedback range

G241 368 Feedback gain

G260 1121 Per-unit speed control reference frequency

G261 1117 Speed control P gain 1 (per-unit system)

G262 1119 Model speed control gain (per- unit system)

G263 1348 P/PI control switchover frequency

G264 1349 Emergency stop operation selection

Pr. group Pr. Name

Refer to

page

Parameter list (by function group)

PARAMETER LIST 43

2

The setting is available only when a plug-in option that supports Vector control is installed.

The parameter number in parentheses is that used (displayed) on the LCD operation panel and the parameter unit.

The initial value is for standard models. The initial value is for separated converter types. The setting is available only when the FR-A8AZ is installed. For the details, refer to the Instruction Manual (Detailed) of

the FR-A800 inverter in the enclosed CD-ROM. For the details, refer to the Instruction Manual of the FR-A8AL.

G300 451 Second motor control method selection 5

G301 565 Second motor excitation current break point

G302 566 Second motor excitation current low-speed scaling factor

G311 830 Speed control P gain 2

G312 831 Speed control integral time 2

G313 834 Torque control P gain 2

G314 835 Torque control integral time 2

G315 833

Speed detection filter 2

G316 837 Torque detection filter 2

G361 1118 Speed control P gain 2 (per-unit system)

G400 286 Droop gain

G401 287 Droop filter time constant

G402 288 Droop function activation selection

G403 994 Droop break point gain

G404 995 Droop break point torque

G410 653 Speed smoothing control

G411 654 Speed smoothing cutoff frequency

G420 679 Second droop gain

G421 680 Second droop filter time constant

G422 681 Second droop function activation selection

G423 682 Second droop break point gain

G424 683 Second droop break point torque

G601 1003 Notch filter frequency

G602 1004 Notch filter depth

G603 1005 Notch filter width

G932 89 Speed control gain (Advanced magnetic flux vector)

G942 569 Second motor speed control gain

Pr. group Pr. Name

Refer to

page

Dedicated function list

44 DANCER FEEDBACK SPEED CONTROL

3 DANCER FEEDBACK SPEED CONTROL Dancer feedback speed control is a control function to keep the line speed and the dancer roll position constant. To perform dancer feedback speed control on the winding/unwinding shaft of the system, the line speed and the dancer roll position can be kept constant in combination with the winding diameter calculation function.

3.1 Dedicated function list

Item Description

Dancer feedback speed control

Control method PID control, PI control, P control, and PD control can be selected. Gain switchover by dancer position is available. Gain switchover by external terminal input is available.

Dancer roll position setting Set a point with a parameter. Dancer roll position detection signal Use an analog terminal for the signal input. (Terminal 1, 2, 4, or 6 is selectable.) Line speed acceleration/deceleration function Available. Three patterns are selectable with external contact signal.

Additional function Material break detection function

Winding diameter compensation

Constant line speed control Available

Winding diameter calculation Calculation based on the line speed detection and the motor rotation speed and calculation based on the material thickness and the number of motor rotations are selectable.

Actual line speed detection Pulse train input (A/B phase, single phase) and analog input are selectable. Reduction ratio setting Available Maximum/minimum winding diameter setting Available. (Four patterns are selectable with external signal.)

Speed control proportional gain compensation function

Available. (Straight movement (with three break points) against the winding diameter can be performed.)

Winding diameter storage Available

Common

Dedicated input signal

Dancer/tension control selection, Winding diameter compensation selection, PID gain switchover, PID integral term reset (P control selection), Line speed acceleration/deceleration selection, Winding diameter selection, Stored winding diameter clear, Winding/unwinding selection, Two-way operation.

Dedicated output signal Upper limit, Lower limit, Dancer roll position, Break detection, Initial winding diameter calculation completion, Target winding diameter achieved, Winding/ unwinding completion

Dedicated monitor Set point, measured value, deviation, line speed command, roll diameter, actual line speed, compensation speed, winding length.

System configuration example

DANCER FEEDBACK SPEED CONTROL 45

3

3.2 System configuration example

FR-A800-R2R

Encoder

Line speed command

Potentiometer

Dancer roll

Dancer signal

Minimum diameter

Maximum diameter

AM

2

2 (Pr.361 = 3)

1 (Pr.363 = 5)

STF/STR

For winding roller (Pr.1230 = 0)

Start signal

Dancer/tension control selection X114 (Pr.180 = 114)

FR-A8AP

Encoder

Line speed command

Line speed command

FR-A800-R2R

FR-A8AP

M

M

STF/STR Start signal

Dancer/tension control selection X114

X117 (Pr.182 = 117)Winding length clear X109 (Pr.181 = 109)Stored winding diameter clear

Control block diagram

46 DANCER FEEDBACK SPEED CONTROL

3.3 Control block diagram

Winding diameter compensation

speed generation Conversion from

line speed to frequency

+

-

X116-OFF

X116-ON

X109-OFF

X109-ON

X115-OFF

X115-ON Held

Winding diameter clear

00 +

+

Speed control proportional gain compensation Pr.639 to Pr.644

M

Encoder

X114-ON

X114-OFF

Dancer signal / tension feedback

input selection Pr.363

PID action set point (Pr.133)

Dancer roll position

Actual line speed

Line speed command

Actual line speed input selection

Pr.362

Line speed command selection

Pr.361

Winding diameter calculation

Pr.1235, Pr.1236, Pr.1243, Pr.1244

Line speed command Acceleration /deceleration

Pr.394, Pr.395

PID operation Pr.129, Pr.130,

Pr.134

Pr.363 = 9999

Pr.363 = 9999

Pr.128 = 40, 41

Pr.128 = 0

Winding diameter compensation speed

Winding diameter

Motor speed

Speed control

Acceleration /deceleration Pr.7, Pr.8 = 0

Line speed command Winding diameter compensation speed =

Winding diameter Gear ratio

Frequency command

PID set point cushion time

Pr.1382

+

Pr.364 = 9999 and

Pr.430 = 9999

Pr.364 9999 or

Pr.430 9999

+

Dancer tension setting Pr.364, Pr.426, Pr.427, Pr.430

Analog signal for dancer tension control

Taper function Pr.1284 to Pr.1297

Pr.1236

Taper function Pr.1284 to Pr.1297

Pr.1236

Pr.1284 = 0

Pr.1284 0

+

After clearing, the value becomes the minimum winding diameter when Pr.1230 = "0" (winding), and the maximum winding diameter when Pr.1230 = "1" (unwinding).

The frequency command cannot be input using the terminal selected as the line speed command input terminal in Pr.361 Line speed command input selection. (For example, to input a frequency command while Pr.361 = "3", input the command from a terminal other than terminal 2.) Set "0" in Pr.361 to use the same terminal to input a line speed command and a frequency command. In this case, the bias and gain parameter settings must be consistent for both command types. Calibration parameters for frequency command input: Pr.125, Pr.126, C2 (Pr.902) to C7 (Pr.905), C12 (Pr.917) to C15 (Pr.918) Calibration parameters for line speed command input: Pr.350 to Pr.353

Control block diagram

DANCER FEEDBACK SPEED CONTROL 47

3

3.3.1 Analog input signals and pulse train input signals

Refer to the following table and set the parameters to input the signals. For analog input terminals, calibration is available with maximum and minimum input values. Use Pr.73 Analog input selection (Pr.267 Terminal 4 input selection) and the voltage/current input selection switch to

switch among input of 0 to 5 V, 0 to 10 V, and 0 to 20 mA. Always calibrate the input after changing the voltage/current input signal with Pr.73 (Pr.267) and the voltage/current input selection switch. (For details, refer to the FR-A800 Instruction Manual (Detailed).)

NOTE The Pr.361 to Pr.364 (dedicated function selection) and Pr.1285 settings have higher precedence over the other assigned

terminal settings such as Pr.868, Pr.858, and Pr.406. (Example: When Pr.363="5", and Pr.868="0", terminal 1 is set to the dancer signal input.)

The dedicated function parameters take the following precedence over each other. When two or more signals are assigned to a terminal, a signal with lower precedence is ineffective. Dancer signal input (Pr.363) > Actual line speed input (Pr.362) > Tension command input (Pr.804) > Line speed command input (Pr.3610) > Taper setting input (Pr.1285) > Dancer tension setting input (Pr.364) > Line speed command compensation input > Line speed command input (Pr.361=0) = Speed command during speed control

When Pr.361 Line speed command input selection="0" while tension sensorless torque control is valid, the line speed command is input in the same way as the frequency command.

Parameter Analog input

Refer to pageTerminal 1 (-10 to 10 V)

Terminal 2 (0 to 5 V)

Terminal 4 (4 to 20 mA)

Terminal 6 (-10 to 10 V)

Pr.363 Dancer / tension sensor feedback input selection 5 3 4 6 85

Pr.361 Line speed command input selection 5 3 4 6 67

Pr.362 Actual line speed input selection 5 3 4 6 199

Pr.1285 Taper setting analog input selection 5 3 4 6 108, 151

Pr.364 Dancer tension setting input selection / taper function enable/disable selection for tension sensor feedback speed control 1

5 3 4 6 108

Parameter Single-phase pulse train input Encoder pulse

train input Parameter

input (Pr.360) Refer to page Terminal JOG FR-A8AL

Pr.363 Dancer / tension sensor feedback input selection 85

Pr.361 Line speed command input selection 1 7 2 8 67

Pr.362 Actual line speed input selection 1 7 2 199

Pr.1285 Taper setting analog input selection 108, 151

Pr.364 Dancer tension setting input selection / taper function enable/disable selection for tension sensor feedback speed control 1

108

The parameter is invalid during tension sensorless torque control. When Pr.362 = "0" during tension sensorless torque control or tension sensor feedback torque control, the line

speed command value is used as the actual line speed. The line speed command setting is not used as it is. The actual line speed command output value in consideration of acceleration/deceleration is applied.

The parameter is invalid during tension sensorless torque control or tension sensor feedback torque control. The FR-A8AZ plug-in option is required.

: Setting not available

The FR-A8AP/FR-A8AL plug-in option or the FR-A8TP control terminal option is required. The setting is valid when Pr.291="1, 11, 21, or 100".

Parameter setting procedure for dancer feedback speed control

48 DANCER FEEDBACK SPEED CONTROL

3.4 Parameter setting procedure for dancer feedback speed control

The following procedure shows the parameter setting example for the dancer feedback speed control.

3.4.1 Parameter setting procedure 1 Wiring

Perform secure wiring.

NOTE Do not feed the workpiece through the machine.

2 Control method selection Select the control method according to the application and the motor.

For the control method, vector control is recommended. Setting is required for a motor other than a Mitsubishi Electric motor (the SF-PR, SF-JR, SF-HR, SF-JRCA, SF-HRCA, or SF-V5RU (1500 r/min

series) motor). For the FR-A820-03160(55K) or lower and FR-A840-01800(55K) or lower. For the FR-A820-03800(75K) or higher and FR-A840-02160(75K) or higher.

NOTE Select Vector control for regenerative driving in a low-speed range (about 10 Hz or lower). For the parameter details, refer to the FR-A800 Instruction Manual (Detailed).

3 Offline auto tuning Perform offline auto tuning as required. For offline auto tuning, refer to page 55.

After the offline auto tuning, perform the test run of the motor alone to make sure that no fault is found in the motor's behavior.

4 Speed control gain adjustment Adjust the speed control gain. Refer to page 59 for the speed control gain adjustment.

Pr. Name Setting range Minimum

setting increments

Initial value

71 Applied motor 0, 1, 3 to 6, 13 to 16, 20, 23, 24, 30, 33, 34, 40, 43, 44, 50, 53, 54, 70, 73, 74 1 0

9 Electronic thermal O/L relay 0 to 500 A 0.01 A Inverter rated

current0 to 3600 A 0.1 A

80 Motor capacity 0.4 to 55 kW, 9999 0.01 kW

9999 0 to 3600 kW, 9999 0.1 kW

81 Number of motor poles 2, 4, 6, 8, 10, 12, 9999 1 9999

83 Rated motor voltage 0 to 1000 V 0.1 V

200 V (200 V class) 400 V (400 V class)

84 Rated motor frequency 10 to 400 Hz, 9999 0.01 Hz 9999 800 Control method selection 0 to 2, 9 to 12, 20, 100 to 102, 109 to 112 1 20 810 Torque limit input method selection 0 to 2 1 0 359 Encoder rotation direction 0, 1, 100, 101 1 1 369 Number of encoder pulses 0 to 4096 1 1024 707 Motor inertia (integer) 10 to 999, 9999 1 9999 724 Motor inertia (exponent) 0 to 7, 9999 1 9999 862 Encoder option selection 0, 1 1 0

Pr. Name Setting range

Minimum setting

increments Initial value

96 Auto tuning setting/status 0, 1, 11, 101 1 0

Parameter setting procedure for dancer feedback speed control

DANCER FEEDBACK SPEED CONTROL 49

3

5 Mechanical specifications setting Set the following parameters according to the specifications of the machine used. Refer to 11.6 (Application examples) on page 243.

Set the parameter according to the specification of the machine used. The increment applies when Pr.21 = "0 (initial value)". The increment applies when Pr.358 = "0 (initial value)".

Pr. Name Setting Intermediate shaft

Winding/ unwinding

shaft Remarks

1235 Maximum winding diameter 1 For the intermediate shaft, set the roller (reel) diameter in millimeters (1 to 6553 mm) for both Pr.1235 and Pr.1236. 1236 Minimum winding diameter 1

178 to 189

Input terminal function selection

114 Set "114" for the X114 signal.

109 Set "109" for using the Stored winding diameter clear (X109) signal.

117 Set "117" for using the Winding length clear (X117) signal.

1230 Winding/unwinding selection 0: Winding shaft 1: Unwinding shaft

645 Winding diameter storage selection

0: Not stored. 1: The present roll diameter is stored.

1247 Winding diameter change increment amount limit

Set the maximum change in 0.001 mm increments (0 to 9.998 mm or 9999) per roll diameter calculation.

1243 Gear ratio numerator Set a gear ratio in 1 increments (1 to 65534) when the motor shaft has a reduction gear.1244 Gear ratio denominator

7 Acceleration time 0 s 0 to 3600 seconds, in 0.1 second increments8 Deceleration time 0 s

394 First acceleration time for line speed command

Setting is required in 0.1 second increments (0 to 3600 seconds) when the cushion time is not considered for the line speed command.

395 First deceleration time for line speed command

101 Second deceleration time for line speed command

Set the time in 0.1 second increments (0 to 3600 seconds) as required (for example, for rapid deceleration). Turn ON the X105 signal to enable the setting.

393 Line speed command acceleration/deceleration reference

Set the reference line speed (travel amount per minute) in 0.1 m/min increments (1 to 6553.4 m/min) for the acceleration/deceleration time for the line speed command.

1141 Line speed command acceleration/deceleration pattern

Set S-curve acceleration/deceleration to reduce shock during line speed acceleration/deceleration operation. (Refer to page 82.)

1142 Line speed command acceleration start S-curve time

1143 Line speed command acceleration completion S-curve time

1144 Line speed command deceleration start S-curve time

1145 Line speed command deceleration completion S-curve time

1231 Material thickness d1

Setting is required in 0.001 mm increments (0 to 20 mm or 9999) when thickness is used for winding diameter calculation.

1252 Dancer lower limit position

Setting is required when the initial winding diameter calculation is necessary for dancer feedback speed control (0.01% increments (400 to 600%) for Pr.1252, 1 mm increments (1 to 5000 mm, 8888, or 9999) for Pr.1255).

1255 Accumulated amount

Parameter setting procedure for dancer feedback speed control

50 DANCER FEEDBACK SPEED CONTROL

6 Dancer signal input setting Set the following parameter according to the dancer signal input method when the dancer roll is used.

The input specification in the initial setting is indicated. (Refer to page 47.)

The following table shows a setting example.

Pr. Name Setting Input method

363 Dancer / tension sensor feedback input selection

3 Terminal 2 (analog value: 0 to 100%) (0 to 5 VDC) 4 Terminal 4 (analog value: 20 to 100%) (4 to 20 mADC) 5 Terminal 1 (analog value: -100 to 100%) (0 to 10 VDC)

6 Terminal 6 (FR-A8AZ) (analog value: -100 to 100%) (0 to 10 VDC)

9 CC-Link or CC-Link IE Field Network Basic (-100 to 100%) 9999 (initial value) No function

Item Setting example

Dancer signal input method

Setting by analog voltage (-10 to 10 V) input through terminal 1 (Pr.363 = "5")

Parameter setting C13 (Pr.917) Terminal 1 bias (speed) = 0% C15 (Pr.918) Terminal 1 gain (speed) = 100%

100%

-100%

0 V C13 (Pr.917) (0%)

Analog input value10 V C15 (Pr.918) (100%)

-10 V

Dancer signal

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7 Line speed command input setting Set Pr.361 according to the line speed command value input method.

To perform Vector control, install the Vector control compatible option. The input specification in the initial setting is indicated. (Refer to page 47.) The frequency command cannot be input using the terminal selected as the line speed command input terminal in Pr.361 Line speed

command input selection. (For example, to input a frequency command while Pr.361 = "3", input the command from a terminal other than terminal 2.) Set "0" in Pr.361 to use the same terminal to input a line speed command and a frequency command. In this case, the bias and gain parameter settings must be consistent for both command types. Calibration parameters for frequency command input: Pr.125, Pr.126, C2 (Pr.902) to C7 (Pr.905), C12 (Pr.917) to C15 (Pr.918) Calibration parameters for line speed command input: Pr.350 to Pr.353

To feed paper or wire, turn ON all X114, X115, and X116 signals and disable winding diameter compensation and PID compensation so that the line speed command for tension control (dancer feedback speed control / tension sensor feedback speed control) is used for the feed operation.

The following table shows setting examples.

Set the pulse division scaling factor in Pr.384 for pulse train input through terminal JOG. Number of pulses calculated internally = Number of input pulses / Pr.384 setting value When inputting 50k pulses/s while Pr.351 = 0 m/min, Pr.353 = 100 m/min, Pr.354 = 0 pulses/s, Pr.355 = 50k pulses/s, and Pr.384 = "2", the line speed will be 50 m/min.

Pr. Name Setting Input method

361 Line speed command input selection

0 According to the priority of the speed command sources. (Refer to page 70)

1 Terminal JOG single-phase pulse train input (Refer to page 71)

2 FR-A8AP/FR-A8AL/FR-A8TP encoder pulse train input (complementary 12 V / differential 5 V (A-, B-phases)) (Refer to page 71)

3 Terminal 2 (analog value: 0 to 100%) (0 to 5 VDC) (Refer to page 73)

4 Terminal 4 (analog value: 20 to 100%) (4 to 20 mADC) (Refer to page 73)

5 Terminal 1 (analog value: -100 to 100%) (0 to 10 VDC) (Refer to page 73)

6 Terminal 6 (FR-A8AZ) (analog value: -100 to 100%) (0 to 10 VDC) (Refer to page 73)

7 FR-A8AL single-phase pulse train input (PP, NP) (Refer to page 71)

8 Line speed command according to the Pr.360 setting (Refer to page 73)

10 Inverter-to-inverter link function (Available only for the FR- A800-E-R2R. For details, refer to the Ethernet Function Manual.)

9999 (initial value) No function

Item Setting example 1 Setting example 2

Line speed command input method

Setting by analog voltage (0 to 5 V) input through terminal 2 (Pr.361 = "3")

Setting by pulse train input through terminal JOG (Pr.361 = "1")

Parameter setting

Pr.350 Line speed command voltage/current bias = 0% Pr.351 Line speed command bias = 0 m/min Pr.352 Line speed command voltage/current gain = 100% Pr.353 Line speed command gain = Maximum line speed Pr.73 Analog input selection= "1 (initial value)"

Pr.384 Input pulse division scaling factor = "1" Pr.351 Line speed command bias = 0 m/min Pr.354 Line speed command pulse input bias = "0" Pr.353 Line speed command gain = Maximum line speed Pr.355 Line speed command pulse input gain = Maximum number of pulses

Pr.353 (Maximum line speed)

Pr.351 (0 m/min)

0 V Pr.350 (0%)

Analog input value

5 V Pr.352 (100%)

Line speed command value

Pr.353 (Maximum line speed)

6553.4

Pr.351 (0 m/min)

Pr.354 (0 pulses/s)

Number of input pulses

Pr.355 (Maximum number of pulses)

Line speed command value

Parameter setting procedure for dancer feedback speed control

52 DANCER FEEDBACK SPEED CONTROL

8 Actual line speed input setting Set Pr.362 according to the line speed command value input method for calculating the winding diameter (actual line speed method). (Setting is not required for the intermediate shaft.)

To perform Vector control, install the Vector control compatible option. The input specification in the initial setting is indicated. (Refer to page 47.)

The following table shows setting examples.

Set the pulse division scaling factor in Pr.384 for pulse train input through terminal JOG. Number of pulses calculated internally = Number of input pulses / Pr.384 setting value When inputting 50k pulses/s while Pr.281 = 0 m/min, Pr.279 = 100 m/min, Pr.282 = 0 pulses/s, Pr.283 = 50k pulses/s, and Pr.384 = "2", the actual line speed will be 50 m/min.

Pr. Name Setting Input method

362 Actual line speed input selection

0 (initial value) V* (line speed command)

1 Terminal JOG single-phase pulse train input (Refer to page 200)

2 FR-A8AP/FR-A8AL/FR-A8TP encoder pulse train input (complementary 12 V / differential 5 V (A-, B-phases)) (Refer to page 200)

3 Terminal 2 (analog value: 0 to 100%) (0 to 5 VDC) (Refer to page 202)

4 Terminal 4 (analog value: 20 to 100%) (4 to 20 mADC) (Refer to page 202)

5 Terminal 1 (analog value: -100 to 100%) (0 to 10 VDC) (Refer to page 202)

6 Terminal 6 (FR-A8AZ) (analog value: -100 to 100%) (0 to 10 VDC) (Refer to page 202)

7 FR-A8AL single-phase pulse train input (PP, NP) (Refer to page 200)

9 CC-Link or CC-Link IE Field Network Basic (0 to 65534) 9999 No function

Item Setting example 1 Setting example 2

Actual line speed input method

Setting by analog current (4 to 20 mA) input through terminal 4 (Pr.362 = "4")

Setting by pulse train input through terminal JOG (Pr.362 = "1")

Parameter setting

Pr.280 Actual line speed voltage/current bias = 20% Pr.281 Actual line speed bias = 0 m/min Pr.278 Actual line speed voltage/current gain = 100% Pr.279 Actual line speed gain = Maximum line speed

Pr.384 Input pulse division scaling factor = "1" Pr.281 Actual line speed bias = 0 m/min Pr.282 Actual line speed pulse input bias = 0 pulses/s Pr.279 Actual line speed gain = Maximum line speed Pr.283 Actual line speed pulse input gain = Maximum number of pulses

Pr.279 (Maximum line speed)

Pr.281 (0 m/min)

4 mA Pr.280 (20%) Analog input value

20 mA Pr.278 (100%)

Actual line speed

Pr.279 (Maximum line speed)

6553.4

Pr.281 (0 m/min)

Pr.282 (0 pulses/s)

Number of input pulses

Pr.283 (Maximum number of pulses)

Actual line speed

Parameter setting procedure for dancer feedback speed control

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3

9 PID control action setting Set the following parameters for PID control.

Set the parameter according to the specification of the machine used.

The following table shows setting examples.

The reference value for the offset setting is 1000% for the voltage (monitored in percentage) input through terminal 1, and 500% for the Pr.133 setting. Therefore, 500% is subtracted from the monitored value.

NOTE The setting unit for manipulated amount of PID control is initially set to Hz (frequency). To change the unit to m/min (line

speed), set the amount using Pr.1148 and Pr.1149. (Refer to page 104.)

Pr. Name Setting Remarks

128 PID action selection 40 or 41 40: Dancer feedback speed control (reverse action) 41: Dancer feedback speed control (forward action)

131 PID upper limit Set the value in 0.1% increments (400 to 600% or 9999) for outputting the PID upper limit (FUP) signal.

132 PID lower limit Set the value in 0.1% increments (400 to 600% or 9999) for outputting the PID lower limit (FDN) signal.

133 PID action set point Set the set point in 0.01% increments (400 to 600%) for the dancer roll control.

1382 PID set point cushion time Set the cushion time for the PID set point. (Refer to page 85.)

Item Setting example 1 Setting example 2 Target position setting method

Setting the target position in the middle between the upper and lower limits Setting the target position directly

Parameter setting

Set Pr.52 = "86" (terminal 1 input voltage monitor in %) and record the value when the dancer position is at the lower limit (% at lower limit) and the value when the dancer position is at the upper limit (% at upper limit). Set the value obtained from:

Move the dancer roll to the middle position and monitor the percentage of the voltage input through terminal 1. Subtract 500 from the monitored value, and set the remaining value in Pr.133.

Pr.133 = Upper limit % - Lower limit %

+ % at lower limit - 500% 2

Dancer roll upper limit

Dancer roll lower limit

Dancer roll target position

Pr.133

Lower limit %

Upper limit %

Parameter setting procedure for dancer feedback speed control

54 DANCER FEEDBACK SPEED CONTROL

10 PID control action check (example) Set the dancer roll approximately around the target position. Input a line speed command of 0 m/min. Input the X114 signal and start command. Start the motor without feeding the workpiece. Change the dancer roll position during motor operation, and check that the following motor speed conditions. If any inconsistency is found, check the Pr.128 setting.

11 PID control gain adjustment Feed the workpiece through the system and adjust the tension PI gain. Refer to page 63 for the tension PI gain adjustment.

12 Test run Operate the system starting from the maximum-diameter roll to the minimum-diameter roll and vice versa and check that no fault is found in the system behavior.

Winding/ unwinding Dancer roll position Motor speed

Winding Current position > Target position Deceleration Current position < Target position Acceleration

Unwinding Current position > Target position Acceleration Current position < Target position Deceleration

Parameter setting procedure for dancer feedback speed control

DANCER FEEDBACK SPEED CONTROL 55

3

3.4.2 Offline auto tuning Before performing offline auto tuning Check the following points before performing offline auto tuning: A value other than "9999" is set in Pr.80 and Pr.81, and Advanced magnetic flux vector control, Real sensorless vector

control or vector control is selected (with Pr.800). A motor is connected. (Check that the motor is not rotated by an external force during tuning.) The motor capacity is equal to or one rank lower than the inverter capacity. (It must be 0.4 kW or higher.)

Using a motor with the rated current substantially lower than the rated inverter current will cause torque ripples, etc. and degrade the speed and torque accuracies. As a reference, select the motor with the rated motor current that is 40% or higher of the inverter rated current.

The target motor is other than a high-slip motor, a high-speed motor, or a special motor. The highest frequency is 400 Hz. The motor may rotate slightly even if the offline auto tuning without motor rotation (Pr.96 Auto tuning setting/status = "1")

is selected. (The slight motor rotation does not affect the tuning performance.) Fix the motor securely with a mechanical brake, or before tuning, make sure that it is safe even if the motor rotates.

Check the following points for the offline auto tuning with motor rotation (Pr.96 Auto tuning setting/status = "101"). Torque is not sufficient during tuning. The motor can be rotated up to the speed close to the rated speed. The mechanical brake is released.

Offline auto tuning is not performed correctly when the surge voltage suppression filter (FR-ASF-H/FR-BMF-H) is inserted between the inverter and motor. Be sure to remove them before performing tuning.

Make sure to connect the encoder to the motor without coaxial misalignment during vector control. Set the speed ratio to 1:1.

Setting To perform tuning, set the following parameters about the motor.

Differs according to the voltage class. (200 V/400 V) For the details to set SF-V5RU, refer to the FR-A800 Instruction Manual (Detailed). Set Pr.71 Applied motor according to the motor to be used and the motor constant setting range. According to the Pr.71 setting, the range of

the motor constant parameter setting values and units can be changed.

First motor

Pr.

Second motor

Pr. Name Initial value Description

80 453 Motor capacity 9999 (V/F control) Set the motor capacity (kW). 81 454 Number of motor poles 9999 (V/F control) Set the number of motor poles (2 to 12).

800 451 Control method selection 20 Set this parameter when using vector control or Real sensorless vector control.

9 51 Electronic thermal O/L relay Inverter rated current Set the rated motor current (A).

83 456 Rated motor voltage 200 V/400 V Set the rated motor voltage (V) printed on the motor's rating plate.

84 457 Rated motor frequency 9999 Set the rated motor frequency (Hz). When the setting is "9999", the Pr.3 Base frequency setting is used.

71 450 Applied motor 0 (standard motor) Set this parameter according to the motor. Three types of motor constant setting ranges, units and tuning data can be stored according to settings.

96 463 Auto tuning setting/ status 0

Set "1" or "101". 1: Performs tuning without rotating the motor. (Excitation noise occurs at this point.) 101: Performs tuning by rotating the motor. The motor can rotate up to the speed near the rated motor frequency.

Parameter setting procedure for dancer feedback speed control

56 DANCER FEEDBACK SPEED CONTROL

NOTE If the SF-V5RU (other than the 1500 r/min series) is used, be sure to perform auto tuning after setting "1, 13, or 14" in Pr.71

and setting Pr.83 and Pr.84. If Pr.11 DC injection brake operation time = "0" or Pr.12 DC injection brake operation voltage = "0", offline auto tuning is

performed considering Pr.11 or Pr.12 is set to the initial value. If the star connection or delta connection is incorrectly selected in Pr.71 , Advanced magnetic flux vector control, Real

sensorless vector control and vector control are not performed normally.

For tuning accuracy improvement, set the following parameters when the motor constants are known in advance.

The setting is valid only when a value other than "9999" is set in both Pr.707 (Pr.744) and Pr.724 (Pr.745).

Motor

Pr.71 setting Motor constant

parameter mH, %, and A unit setting

Motor constant parameter internal

data setting

Motor constant parameter , m, and A unit setting

Mitsubishi Electric standard motor Mitsubishi Electric high- efficiency motor

SF-JR, SF-TH 0 (initial value) 3 (4) SF-JR 4P 1.5 kW or lower 20 23 (24) SF-HR 40 43 (44) Others 0 (initial value) 3 (4)

Mitsubishi Electric constant- torque motor

SF-JRCA 4P, SF-TH (constant-torque) 1 13 (14)

SF-HRCA 50 53 (54) Other (SF-JRC, etc.) 1 13 (14)

Mitsubishi Electric high- performance energy-saving motor with encoder

SF-PR-SC 70 73 (74)

Vector control dedicated motor

SF-V5RU (1500 r/min series) SF-THY 30 33 (34)

SF-V5RU (other than the 1500 r/min series) 1 13 (14)

Other manufacturer's standard motor 0 (initial value) 3 (4)

5 (star connection motor) 6 (delta connection motor)

Other manufacturer's constant-torque motor 1 13 (14)

15 (star connection motor) 16 (delta connection motor)

First motor Pr.

Second motor Pr. Name

Mitsubishi Electric motor (SF-JR, SF-HR, SF-JRCA,

SF-HRCA, SF-V5RU) Other motors

707 744 Motor inertia (integer) 9999 (initial value)

Motor inertia Jm = Pr.707 10^(-Pr.724) (kgm2)724 745 Motor inertia (exponent)

Parameter setting procedure for dancer feedback speed control

DANCER FEEDBACK SPEED CONTROL 57

3

Performing tuning POINT

Before performing tuning, check the monitor display of the operation panel or parameter unit if the inverter is in the state ready for tuning. Turning ON the start command while tuning is unavailable starts the motor.

In the PU operation mode, press the FWD or REV key on the operation panel. For External operation, turn ON the start command (STF signal or STR signal). Tuning will start.

NOTE Satisfy the required inverter start conditions to start offline auto tuning. For example, stop input of the MRS signal. To force tuning to end, use the MRS or RES signal or press the STOP/RESET key on the operation panel.

(Turning the start signal (STF signal or STR signal) OFF also ends tuning.) During offline auto tuning, only the following I/O signals are valid. (initial value)

Input terminals : STP (STOP), OH, MRS, RT, RES, STF, STR, S1, and S2 Output terminals: RUN, OL, IPF, FM/CA, AM, A1B1C1, and SO

When the rotation speed and the output frequency are selected for terminals FM/CA and AM, the progress status of offline auto tuning is output in fifteen steps from FM/CA and AM.

Do not perform ON/OFF switching of the Second function selection (RT) signal during offline auto tuning. Auto tuning will not be performed properly.

Setting offline auto tuning (Pr.96 Auto tuning setting/status = "1 or 101") will make pre-excitation invalid. When the offline auto tuning is selected (Pr.96 Auto tuning setting/status = "101"), the motor rotates. Take caution and

ensure the safety. Since the Inverter running (RUN) signal turns ON when tuning is started, pay close attention especially when a sequence

which releases a mechanical brake by the RUN signal has been designed. When executing offline auto tuning, input the operation command after switching ON the main circuit power (R/L1, S/L2, T/

L3) of the inverter. While Pr.79 Operation mode selection = "7", turn the PU operation external interlock (X12) signal ON to tune in the PU

operation mode.

During tuning, the monitor is displayed on the operation panel as follows.

Pr.96 setting 1 101 1 101

(1) Setting

Operation panel (FR-DU08) display LCD operation panel (FR-LU08) display

(2) During tuning

(3) Normal completion

AutoTune 12:34 TUNE

1 --- STOP PU PREV NEXT

AutoTune 12:34 TUNE

101 --- STOP PU PREV NEXT

AutoTune 12:34 TUNE

2 STF FWD PU PREV NEXT

AutoTune 12:34 TUNE

102 STF FWD PU PREV NEXT

Blinking Blinking

AutoTune 12:34 TUNE

Completed 3 STF STOP PU PREV NEXT

AutoTune 12:34 TUNE

Completed 103 STF STOP PU PREV NEXT

Parameter setting procedure for dancer feedback speed control

58 DANCER FEEDBACK SPEED CONTROL

Note: Offline auto tuning time (with the initial setting)

When offline auto tuning ends, press the STOP/RESET key on the operation panel during PU operation. For External operation, turn OFF the start signal (STF or STR signal). This operation resets the offline auto tuning, and the PU's monitor display returns to the normal indication. (Without this operation, next operation cannot be started.)

NOTE The motor constants measured once in the offline auto tuning are stored as parameters and their data are held until the

offline auto tuning is performed again. However, performing all parameter clear resets the tuning data. Changing Pr.71 (Pr.450) after tuning completion will change the motor constant. For example, if Pr.71 = "3" is set after tuning

is performed with Pr.71 ="0", the tuning data becomes invalid. Set Pr.71 = "0" again for using the tuning data.

If offline auto tuning has ended in error (see the table below), motor constants are not set. Perform an inverter reset and restart tuning.

When offline auto tuning with motor rotation is performed under vector control, the protective function (E.EPS) may be activated.

The data code is used for checking the fault detail via communication or for setting Pr.997 Fault initiation. (Refer to the Instruction Manual (Detailed) of the FR-A800 inverter.)

When tuning is ended forcibly by pressing the STOP/RESET key or turning OFF the start signal (STF or STR signal) during tuning, offline auto tuning does not end properly. (The motor constants have not been set.) Perform an inverter reset and restart tuning.

Offline auto tuning setting Time

No motor rotation (Pr.96 = "1") Approx. 25 to 120 s (The time depends on the inverter capacity and motor type.)

With motor rotation (Pr.96 = "101")

Approx. 40 s (The following offline auto tuning time is set according to the acceleration/ deceleration time setting. Offline auto tuning time = Acceleration time + Deceleration time + Approx. 30 s)

Error display Error cause Countermeasures 8 Forced end Set Pr.96 = "1 or 101" and try again. 9 Inverter protective function operation Make the setting again.

91 The current limit (stall prevention) function is activated. Set the acceleration/deceleration time longer. Set Pr.156 Stall prevention operation selection = "1".

92 The converter output voltage fell to 75% of the rated voltage.

Check for the power supply voltage fluctuation. Check the Pr.84 Rated motor frequency setting.

93 Calculation error The motor is not connected.

Check the Pr.83 and Pr.84 settings. Check the motor wiring and make the setting again.

94

Rotation tuning frequency setting error (The frequency command for the tuning was given to exceed the maximum frequency setting, or to be in the frequency jump range.)

Check the Pr.1 Maximum frequency and Pr.31 to Pr.36 Frequency jump settings.

Operation panel indication

E.EPS FR-LU08 indication Fault 15

Name Encoder pulse number setting error (Data code: 255 (HFF))

Description When the rotation speed deviates from the command value range while auto tuning with motor rotation is performed under vector control, the inverter trips.

Check point Check the encoder setting (Pr.369, Pr.851, differential line driver / complementary) and wiring. The external power supply for the encoder is not wired correctly. Load inertia is too high, or the acceleration time is too short. Check that the load is not too large.

Corrective action Check the encoder setting and wiring. Wire an external power supply. Set the acceleration time longer. Reduce the load.

Vector

Parameter setting procedure for dancer feedback speed control

DANCER FEEDBACK SPEED CONTROL 59

3

If using a motor falling under the following conditions, set the value of Pr.9 Electronic thermal O/L relay as shown below after tuning is complete.

a) If the rated power supply of the motor is 200/220 V (400/440 V) 60 Hz, set the rated motor current multiplied by 1.1 in Pr.9.

b) If using a motor with a temperature detector such as PTC thermistor and Klixon and performs motor overheat protection, set Pr.9 = "0" (disables the motor overheat protection feature of the inverter).

NOTE An instantaneous power failure occurring during tuning will result in a tuning error. After power is restored, the inverter starts

normal operation. Therefore, when the STF (STR) signal is ON, the motor runs in the forward (reverse) rotation. Any alarm occurring during tuning is handled as in the normal operation. Note that even if a retry operation has been set,

retry is not performed. The set frequency monitor displayed during the offline auto tuning is 0 Hz.

3.4.3 Speed control gain adjustment The load inertia ratio (load moment of inertia) for the motor is calculated from the torque command and rotation speed

during motor driving by the vector control. Because the optimum gain for speed control of dancer feedback / tension sensor feedback is calculated automatically from the load inertia ratio and the response level, the work required for gain adjustment is reduced (Easy gain tuning).

By manually entering the load inertia ratio (if known), the control gain is set automatically. Manual gain adjustment is useful for achieving optimum machine performance or improving unfavorable conditions, such

as vibration and acoustic noise during operation with high load inertia. For gain adjustment, rolls of minimum, medium, and maximum diameters are used.

POINT If a roll of medium diameter is not available, refer to the procedure for the case where the medium-diameter roll is not

available ("No medium-diameter roll").

Adjustment by easy gain tuning (recommended) 1 Installation of the minimum-diameter roll

Install the minimum-diameter roll.

2 Motor inertia setting Set an accurate motor inertia value using Pr.707 and Pr.724.

3 Easy gain tuning response level setting (tuning with the minimum-diameter roll) Set the response level in Pr.818 Easy gain tuning response level setting. Setting this parameter higher improves the trackability for commands, but setting it too high causes vibration. Set the value measured shortly before vibration occurs in Pr.818.

Caution Note that the motor may start running suddenly. For the offline auto tuning in vertical lift applications, etc., caution is required to avoid falling due to

insufficient torque.

Pr.818 setting

Estimated mechanical resonance frequency (Hz)

Response level Slow response Fast responseMedium response

8 10 12 15 18 22 28 34 42 52 64 79 98 122 150

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Parameter setting procedure for dancer feedback speed control

60 DANCER FEEDBACK SPEED CONTROL

4 Easy gain tuning (tuning with the minimum diameter-roll)

NOTE When Pr.819 = "1 or 2" is set, even if the Pr.819 setting value is returned to "0" after tuning is performed, the data that was set

in each parameter is retained in the tuning results. If good precision cannot be obtained even after executing easy gain tuning, because of external disturbances or other

reasons, perform fine adjustment manually. At this time, set the Pr.819 setting to "0" (no easy gain tuning). The calculation of the load inertia ratio may take excessive time or otherwise not be performed properly if the following

conditions are not satisfied. - The time in acceleration/deceleration driving until 1500 r/min is reached in 5 s or less. - The rotation speed in driving is 150 r/min or higher. - The acceleration/deceleration torque is 10% or higher. - No sudden external disturbances during acceleration/deceleration. - The load inertia ratio is about 30-fold or lower. - No gear backlash or belt sagging.

If the load inertia ratio is known in advance during vector control, the tuning procedure for Real sensorless vector control operation is applicable by setting "2" in Pr.819.

5 Gain adjustment (tuning with the minimum diameter-roll) After the easy gain tuning, increase the Pr.818 setting and perform easy gain tuning again. Gradually increase the Pr.818 setting and repeat the procedure. In the end, set the value measured shortly before vibration occurs in Pr.818. Then, perform easy gain tuning again, and set the automatically set final Pr.820 value in Pr.641 Speed control proportional gain 1.

6 Installation of the maximum-diameter roll Install the maximum-diameter roll.

7 Tuning with the maximum-diameter roll Perform easy gain tuning in the same way used for the tuning with the minimum-diameter roll. Take a note of the Pr.820 value and set it in Pr.644 Speed control proportional gain 4.

Vector control Real sensorless vector control Vector control with the load inertia ratio manual input

1

When Pr.819 Easy gain tuning selection = "1", the load inertia ratio is estimated during acceleration/deceleration, and the gain for each control is set automatically from this value and the value of Pr.818 Easy gain tuning response level setting. Use Pr.880 Load inertia ratio as the initial value for tuning. During tuning, the estimated value is set in Pr.880.

Set the load inertia ratio for the motor in Pr.880 Load inertia ratio.

2

Press the FWD or REV key to calculate the continuous load inertia ratio, or calculate the gain. (The operation command during External operation is the STF or STR signal.)

Set "2" (easy gain tuning enabled) in Pr.819 Easy gain tuning selection. When set, Pr.820 Speed control P gain 1 and Pr.821 Speed control integral time 1 are set automatically. Operation is performed with the adjusted gain from the next operation.

3 Start and stop the inverter repeatedly until the Pr.820 and Pr.880 settings are stabilized.

Perform a test run, and set the response level in Pr.818 Easy gain tuning response level setting. Setting this parameter higher improves the trackability for commands, but setting it too high causes vibration. (The response level can be adjusted during operation when Pr.77 Parameter write selection = "2" (parameters can be written during operation).)

Parameter setting procedure for dancer feedback speed control

DANCER FEEDBACK SPEED CONTROL 61

3

8 Calculation of the medium diameter gain

9 Tuning completion Set Pr.819 back to "0" to complete the easy gain tuning.

10 Speed control integral time setting Set "0" in Pr.821 Speed control integral time 1.

With medium-diameter roll No medium-diameter roll

1

Tuning with the medium-diameter roll 1 Perform easy gain tuning in the same way used for the tuning with the minimum-diameter roll. Then, set the Pr.820 value in Pr.642.

Set the result of the following calculation in Pr.642 Speed control proportional gain 2.

2

Tuning with the medium-diameter roll 2 Perform easy gain tuning in the same way used for the tuning with the minimum-diameter roll. Then, set the Pr.820 value in Pr.643.

Set the result of the following calculation in Pr.643 Speed control proportional gain 3.

3

Set the diameters of the medium-diameter rolls. Medium-diameter roll 1 Pr.639 Speed control proportional term applied diameter 1 = (Medium diameter 1 - Minimum diameter)/(Maximum diameter -

Minimum diameter) 100 (%) Medium-diameter roll 2 Pr.640 Speed control proportional term applied diameter 2 = (Medium diameter 2 - Minimum diameter)/(Maximum diameter -

Minimum diameter) 100 (%)

Set "9999" (initial value) in Pr.639 and Pr.640.

X1 = ((Maximum winding diameter - Minimum winding diameter) Pr.639/100) + Minimum winding diameter

X2 = ((Maximum winding diameter - Minimum winding diameter) Pr.640/100) + Minimum winding diameter

+5 Pr.644 Pr.641

Pr.642 = Pr.641

+15 Pr.644 Pr.641

Pr.643 = 8 Pr.641

Pr.1236 (Pr.1238, Pr.1240, Pr.1242)

Minimum diameter

Pr.1235 (Pr.1237, Pr.1239, Pr.1241)

Maximum diameter Small LargeMedium

Pr.644 (Proportional gain 4)

Speed control proportional (P) gain (%)

Pr.643 (Proportional gain 3)

Pr.642 (Proportional gain 2)

Pr.641 (Proportional gain 1)

Winding diameter (mm) X1 X2

Parameter setting procedure for dancer feedback speed control

62 DANCER FEEDBACK SPEED CONTROL

Manual adjustment 1 Installation of the minimum-diameter roll

Install the minimum-diameter roll.

2 Speed control integral time setting Set "0" in Pr.821 Speed control integral time 1. (The initial value is 0.333 s.)

3 Adjustment with the minimum-diameter roll Increase Pr.820 Speed control P gain 1 by 10%, and adjust the gain to a 80 to 90 % value of the setting immediately before vibration/noise starts in the range from the minimum number of rotations to the maximum number of rotations. Then, set the Pr.820 value in Pr.641.

4 Installation of the maximum-diameter roll Install the maximum-diameter roll.

NOTE If the maximum-diameter roll is not available, perform the "PID gain adjustment" (refer to page 63), and wind the material up

to the maximum diameter while adjusting Pr.820 Speed control P gain 1.

5 Adjustment with the maximum-diameter roll Adjust the Pr.820 setting in the same way used for the tuning with the minimum-diameter roll. Then, set the Pr.820 value in Pr.644.

6 Calculation of the medium diameter gain With medium-diameter roll No medium-diameter roll

1

Tuning with the medium-diameter roll 1 Adjust the Pr.820 setting in the same way used for the tuning with the minimum-diameter roll. Then, set the Pr.820 value in Pr.642.

Set the result of the following calculation in Pr.642 Speed control proportional gain 2.

2

Tuning with the medium-diameter roll 2 Adjust the Pr.820 setting in the same way used for the tuning with the minimum-diameter roll. Then, set the Pr.820 value in Pr.643.

Set the result of the following calculation in Pr.643 Speed control proportional gain 3.

3

Set the diameters of the medium-diameter rolls. Medium-diameter roll 1 Pr.639 Speed control proportional term applied diameter 1 = (Medium diameter 1 - Minimum diameter)/(Maximum diameter -

Minimum diameter) 100 (%) Medium-diameter roll 2 Pr.640 Speed control proportional term applied diameter 2 = (Medium diameter 2 - Minimum diameter)/(Maximum diameter -

Minimum diameter) 100 (%)

Set "9999" (initial value) in Pr.639 and Pr.640.

+5 Pr.644 Pr.641

Pr.642 = Pr.641

+15 Pr.644 Pr.641

Pr.643 = 8 Pr.641

Parameter setting procedure for dancer feedback speed control

DANCER FEEDBACK SPEED CONTROL 63

3

3.4.4 PID gain adjustment Adjust the PID gain of dancer feedback speed control.

Adjustment by tension PI gain tuning (recommended) The PID gain is adjusted by tension PI gain tuning (refer to page 91). Tension PI gain tuning is recommended for PID gain adjustment.

Manual adjustment Set the minimum-diameter roll for winding and the maximum-diameter roll for unwinding. Connect the material from the

beginning to the end of the machine, and increase the line speed gradually while observing the movement of the dancer roll. Adjust the line speed so that the dancer roll moves properly.

Adjust the PID gain so that the dancer roll works without problems at acceleration, constant speed, deceleration, and sudden deceleration.

It is important to adjust the dancer PI gain as high as possible for the minimum-diameter roll. Normally, adjust the gain with Pr.129 PID proportional band and Pr.130 PID integral time.

POINT Adjust the gain so that overshooting occurs once or so before the dancer roll returns to the set position.

Refer to the following according to the dancer roll condition.

NOTE Set Pr.134 PID differential time only when it is necessary as it causes hunting. However, set a small value in Pr.134 to

cease fluctuation of the dancer roll by disturbance and such at an early point. (Set 0.01 s at first and gradually increase the value.)

Status Adjustment method

When the response is slow (the dancer roll position is too low)

Decrease Pr.129 PID proportional band by 10%. Decrease Pr.130 PID integral time by 0.1 s. Repeat the adjustment procedure in the range from the minimum diameter to the maximum diameter so that the dancer roll moves properly at acceleration, constant speed, deceleration, and sudden deceleration.

When the response is fast (hunting occurs too frequently)

Increase Pr.129 PID proportional band by 10%. Increase Pr.130 PID integral time by 0.1 s. Repeat the adjustment procedure in the range from the minimum diameter to the maximum diameter so that the dancer roll moves properly at acceleration, constant speed, deceleration, and sudden deceleration.

Slow response (the dancer roll position is too low)

Fast response (hunting occurs too frequently)

Proper condition

Dancer feedback speed control details

64 DANCER FEEDBACK SPEED CONTROL

3.5 Dancer feedback speed control details

POINT To enable the dancer feedback speed control and the winding diameter compensation function, turn ON the X114 signal and

set "40 or 41" in Pr.128 PID action selection. (When the X114 signal is OFF or "0" is set in Pr.128, the dancer feedback speed control and the winding diameter compensation function are disabled.)

Dancer feedback speed control may be performed without using the winding diameter compensation (with the winding diameter retained) for example for the intermediate shafts. In such cases, turn ON the X114 signal while the X115 signal is ON or Pr.1247 Winding diameter change increment amount limit = "9999" (no winding diameter calculation).

For the X114 and X115 signals, assign the function by setting "114 (X114)" or "115 (X115)" in any of Pr.178 to Pr.189 (input terminal function selection).

Purpose Parameter to set Refer to page

To select forward/reverse action for PID control PID action selection P.R100 Pr.128 65

To select winding or unwinding for a shaft

Winding/unwinding selection P.R002 Pr.1230 67

To select the line speed command input method

Line speed command input selection P.R200 Pr.361 67

To select a unit of the line speed Line speed unit P.R201 Pr.358 67 To set a draw rate for the line speed command value Draw control P.R203 Pr.398 67

To set a filter time for pulse train input

Line speed command input filter P.R224 Pr.1146 67

To set the maximum value for the line speed command

Line speed command maximum value P.R205 Pr.1147 67

To input the line speed command using multi-speed setting

Line multi-speed setting P.R230 to P.R244 Pr.1265 to Pr.1279 67

To calibrate the line speed command value

Line speed command bias/gain

P.R210 to P.R213, P.R220 to P.R223 Pr.350 to Pr.357 67

To set the line speed command to start operation

Line speed command for starting P.R204 Pr.622 67

To calibrate the compensation value added to the line speed command value

Line speed command added compensation value bias/gain

P.R214 to P.R217 Pr.635 to Pr.638 76

To set acceleration/deceleration time to increase/decrease the line speed command value

Acceleration/ deceleration time selection for line speed command

P.R253 to P.R256, P.R250 to P.R252

Pr.100 to Pr.103, Pr.393 to Pr.395 79

To set the acceleration/deceleration pattern suitable for an application

Line speed command acceleration/ deceleration pattern

P.R290 to P.R294 Pr.1141 to Pr.1145 82

To detect malposition of the dancer roll due to a fault such as a break

Dancer roll malposition detection (break detection)

P.A601 to P.A604, P.R160, P.R163

Pr.131, Pr.132, Pr.137, Pr.425, Pr.553, Pr.554

89

To enable automatic tuning for complex PI gain calculation Tension PI gain tuning P.R170 to P.R176

Pr.1211, Pr.1215, Pr.1217, Pr.1219, Pr.1222, Pr.1223, Pr.1226

91

To enable manual input of gains for PID control PID control gain setting P.R110 to P.R112 Pr.129, Pr.130,

Pr.134 99

To set the upper and lower limits of the PID compensation amount

PID compensation amount upper/lower limit setting

P.A605, P.A606 Pr.1134, Pr.1135 104

Dancer feedback speed control details

DANCER FEEDBACK SPEED CONTROL 65

3

3.5.1 Dancer feedback speed control function selection

Select forward/reverse action for dancer feedback speed control.

PID action selection (Pr.128) Set forward or reverse action according to the control target. The following table shows the input method for the set point, dancer signal, and line speed command for the dancer

feedback speed control function (Pr.128 = "40 or 41").

NOTE The automatic restart after instantaneous power failure function is not activated while dancer feedback speed control is valid

(Pr.128 = "40 or 41"). To perform dancer feedback speed control, set Pr.127 PID control automatic switchover frequency = "9999" (initial value).

(If the Pr.127 setting is other than "9999", a sudden speed change may occur.)

Tension control selection signal (X114 signal) To enable the dancer feedback speed control, turn ON the Tension control selection (X114) signal and set "40 or 41" in

Pr.128 PID action selection. Ensure the motor has stopped before switching between normal operation and dancer feedback speed control operation. To input the X114 signal, set "114" in any of Pr.178 to Pr.189 (input terminal function selection) to assign the function. After turning ON the X114 signal, wait 20 ms or longer to input a start command (STF/STR).

Pr. Name Initial value Setting range Description

128 R100 (A610)

PID action selection 0 0 Dancer feedback speed control invalid 40

Dancer feedback speed control valid Reverse action

41 Forward action

Pr.128 setting

Forward /reverse action setting

Operation status Set point input

Dancer signal input

Line speed command

input

0 (initial value) Dancer feedback speed control invalid

40 Reverse action

When deviation X (set point subtracted by measured value) is a plus value, the manipulated amount is increased, and when the deviation is a minus value, the manipulated amount is decreased.

Set in Pr.133. Set in Pr.363. Set in Pr.361.

41 Forward action

When deviation X (set point subtracted by measured value) is a minus value, the manipulated amount is increased, and when the deviation is a plus value, the manipulated amount is decreased.

STF

X114

20 ms or more

ON

ON

Dancer feedback speed control details

66 DANCER FEEDBACK SPEED CONTROL

PID compensation disabled signal (X116 signal) PID compensation can be disabled by turning ON the X116 signal. To input the X18 signal, set "116" in any of Pr.178 to

Pr.189 (input terminal function selection) to assign the function. When the line speed command becomes 0 m/min while the output frequency is not 0 Hz, operation is decelerated to stop in

the deceleration time set for the line speed command. When the X116 signal is turned ON at this time, the frequency command is regarded as 0 Hz and the deceleration time is regarded as 0 s, and operation is decelerated to stop.

Frequency command (= Winding diameter compensation speed +

PID manipulated amount)

Frequency

Time

PID manipulated amount

Winding diameter compensation speed ( Line speed command)

X116

STF

Turning ON the X116 signal after the winding diameter compensation speed becomes 0

When the line speed command becomes 0, deceleration starts according to Pr.364, with PID control interrupted. (Turning ON the X116 signal decelerates operation to stop, regarding the deceleration time as 0 s.)

OFF

ON

Frequency command (= Winding diameter compensation speed +

PID manipulated amount)

Frequency

PID manipulated amount

Winding diameter compensation speed ( Line speed command)

X116

STF

When the X116 signal is turned ON, the PID manipulated amount becomes 0.

OFF

ON

Turning ON the X116 signal before the winding diameter compensation speed becomes 0

Dancer feedback speed control details

DANCER FEEDBACK SPEED CONTROL 67

3

3.5.2 Winding/unwinding shaft selection Select whether the target roll is a winding shaft or unwinding shaft.

Winding/unwinding selection (Pr.1230) Use Pr.1230 Winding/unwinding selection to select whether the target roll is a winding shaft or unwinding shaft. The initial diameter of the winding shaft is selected according to whether the operation is winding or unwinding.

3.5.3 Line speed command input Set the line speed command input method. The selectable input methods include the following: parameter setting, analog input, multi-speed setting input, and pulse input.

Pr. Name Initial value Setting range Description

1230 R002 Winding/unwinding selection 0

0 Winding 1 Unwinding

Pr.1230 setting Winding/unwinding selection Initial roll diameter 0 Winding Minimum roll diameter 1 Unwinding Maximum roll diameter

Pr. Name Initial value Setting range Description 350 R210

Line speed command voltage/current bias 0% 0 to 100% Set the converted % of the bias voltage (current) for

analog input.

351 R211 Line speed command bias 0 m/min 0 to 6553.4 m/min Set the bias line speed for analog input.

352 R212

Line speed command voltage/current gain 50% 0 to 100% Set the converted % of the gain voltage (current) for

analog input.

353 R213 Line speed command gain 0 m/min 0 to 6553.4 m/min,

9999 Set the gain line speed command value for analog input.

354 R220

Line speed command pulse input bias 0 pulses/s 0 to 500k pulses/s Set the number of bias input pulses for pulse train

input.

355 R221

Line speed command pulse input gain 100k pulses/s 0 to 500k pulses/s Set the bias line speed command value for pulse train

input.

356 R222

Line speed command digital input bias 0 0 to 65535 Set the number of gain input pulses for pulse train

input.

357 R223

Line speed command digital input gain 65535 0 to 65535 Set the gain line speed command value for pulse train

input.

358 R201 Line speed unit 0

0 m/min 1 m/s 2 mm/min 3 mm/s

360 R202

Line speed command value 0 m/min 0 to 6553.4 m/min Set the line speed command value.

361 R200

Line speed command input selection 9999

0 According to the priority of the speed command sources.

1 Terminal JOG single-phase pulse train input

2 FR-A8AP/FR-A8AL/FR-A8TP encoder pulse train input

3 Terminal 2 (0 to 100%) 4 Terminal 4 (20 to 100%) 5 Terminal 1 (-100 to 100%) 6 Terminal 6 (FR-A8AZ) (-100 to 100%) 7 FR-A8AL single-phase pulse train input 8 Line speed command according to the Pr.360 setting

10 Inverter-to-inverter link function (Available only for the FR-A800-E-R2R. For details, refer to the Ethernet Function Manual.)

9999 No function

Dancer feedback speed control details

68 DANCER FEEDBACK SPEED CONTROL

The increment varies depending on the Pr.358 setting.

384 D101

Input pulse division scaling factor 0 0 to 250 Set the pulse division scaling factor for pulse train

input through terminal JOG.

398 R203 Draw rate 100% 0 to 200%

Set a draw rate to be multiplied to the line speed command value or the line speed command acceleration/deceleration reference.

428 B009 Command pulse selection 0

0 Forward/Reverse pulse train Negative logic1 Pulse train + rotation direction sign

2 A/B phase pulse train 3 Forward/Reverse pulse train

Positive logic4 Pulse train + rotation direction sign 5 A/B phase pulse train

622 R204

Line speed command for starting 0 m/min 0 to 6553.4 m/min Set the line speed command to start operation.

1146 R224

Line speed command input filter time constant 0 s 0 to 5 s Set the time constant of the primary delay filter

relative to the pulse input value.

1147 R205

Line speed command maximum value

6553.4 m/ min 0 to 6553.4 m/min Set the maximum value for the line speed command.

1265 R230

Line multi-speed setting (high-speed) 0 m/min 0 to 6553.4 m/min Set the line speed command value when the RH

signal is ON.

1266 R231

Line multi-speed setting (middle-speed) 0 m/min 0 to 6553.4 m/min Set the line speed command value when the RM

signal is ON.

1267 R232

Line multi-speed setting (low-speed) 0 m/min 0 to 6553.4 m/min Set the line speed command value when the RL

signal is ON.

1268 R233

Line multi-speed setting (speed 4) 0 m/min 0 to 6553.4 m/min

The line speed from 4th speed to 15th speed can be set according to the combination of the RH, RM, RL and REX signals.

1269 R234

Line multi-speed setting (speed 5) 0 m/min 0 to 6553.4 m/min

1270 R235

Line multi-speed setting (speed 6) 0 m/min 0 to 6553.4 m/min

1271 R236

Line multi-speed setting (speed 7) 0 m/min 0 to 6553.4 m/min

1272 R237

Line multi-speed setting (speed 8) 0 m/min 0 to 6553.4 m/min

1273 R238

Line multi-speed setting (speed 9) 0 m/min 0 to 6553.4 m/min

1274 R239

Line multi-speed setting (speed 10) 0 m/min 0 to 6553.4 m/min

1275 R240

Line multi-speed setting (speed 11) 0 m/min 0 to 6553.4 m/min

1276 R241

Line multi-speed setting (speed 12) 0 m/min 0 to 6553.4 m/min

1277 R242

Line multi-speed setting (speed 13) 0 m/min 0 to 6553.4 m/min

1278 R243

Line multi-speed setting (speed 14) 0 m/min 0 to 6553.4 m/min

1279 R244

Line multi-speed setting (speed 15) 0 m/min 0 to 6553.4 m/min

Pr. Name Initial value Setting range Description

Dancer feedback speed control details

DANCER FEEDBACK SPEED CONTROL 69

3

Block diagram

NOTE The plug-in option used to input a line speed command or the actual line speed (selected according to the Pr.862 setting) is

not the one used for the motor encoder input (selected by turning ON/OFF of the RT signal). For the details, refer to page 234.

Line speed command input selection (Pr.361) Use Pr.361 Line speed command input selection to select the input method for the line speed command value.

The input specification in the initial setting is indicated. The frequency command cannot be input using the terminal selected as the line speed command input terminal in Pr.361 Line speed

command input selection. (For example, to input a frequency command while Pr.361 = "3", input the command from a terminal other than terminal 2.) Set "0" in Pr.361 to use the same terminal to input a line speed command and a frequency command. In this case, the bias and gain parameter settings must be consistent for both command types. Calibration parameters for frequency command input: Pr.125, Pr.126, C2 (Pr.902) to C7 (Pr.905), C12 (Pr.917) to C15 (Pr.918) Calibration parameters for line speed command input: Pr.350 to Pr.353

To feed paper or wire, turn ON all X114, X115, and X116 signals and disable winding diameter compensation and PID compensation so that the line speed command for tension control (dancer feedback speed control / tension sensor feedback speed control) is used for the feed operation.

Pr.361 setting Input method for line speed command value 0 According to the priority of the speed command sources. (Refer to page 70) 1 Terminal JOG single-phase pulse train input (Refer to page 71)

2 FR-A8AP/FR-A8AL/FR-A8TP encoder pulse train input (complementary 12 V / differential 5 V (A-, B-phases)) (Refer to page 71)

3 Terminal 2 (analog value: 0 to 100%) (0 to 5 VDC) (Refer to page 73) 4 Terminal 4 (analog value: 20 to 100%) (4 to 20 mADC) (Refer to page 73) 5 Terminal 1 (analog value: -100 to 100%) (0 to 10 VDC) (Refer to page 73) 6 Terminal 6 (FR-A8AZ) (analog value: -100 to 100%) (0 to 10 VDC) (Refer to page 73) 7 FR-A8AL single-phase pulse train input (PP, NP) (Refer to page 71) 8 Line speed command according to the Pr.360 setting (Refer to page 73)

10 Line speed command according to the inverter-to-inverter link function (Available only for the FR-A800-E-R2R. For details, refer to the Ethernet Function Manual.)

9999 (initial value) No function

Pr.361

Pr.360 setting

Terminal 4

Terminal 2

Multi-speed operation (Pr.1265 to Pr.1279) JOG single-phase pulse train input digital command using the FR-A8AX, analog input (terminal 1, 2, 4, 6), etc.

Encoder pulse train input (FR-A8TP)

Encoder pulse train input (FR-A8AP/FR-A8AL)

Terminal JOG single-phase pulse train input

Terminal 6

Terminal 1

4

3

0

1

6

5

Pr.291 = 0, 10, 20

Pr.291 = 1, 11, 21, 100

Pr.622 Line speed command

Pr.622 > Line speed command

Pr.862 = 1

Pr.1146

Pr.361

Pr.862 = 0

Input pulse Pr.384

Pulse train calibration

Pr.354, Pr.355, Pr.356, Pr.357

Pulse train calibration

Pr.354, Pr.355, Pr.356, Pr.357

Pulse train calibration

Pr.354, Pr.355, Pr.356, Pr.357

Primary delay filter

Pr.1146

Primary delay filter

Pr.1146

Primary delay filter

2

7

Analog calibration

Pr.350, Pr.351, Pr.352, Pr.353

Pr.74, Pr.822, Pr.832

Primary delay filter 3 to 6

8

FR-A8AL pulse train input (PP, NP)

Line speed command

Unit switchover

Pr.358

0

0

9999

Inverter-to-inverter link function 10

Communication Other than 9999

0

Dancer feedback speed control details

70 DANCER FEEDBACK SPEED CONTROL

Line speed unit (Pr.358) Use Pr.358 Line speed unit to select the unit of the line speed.

Line speed command input according to the priority of the speed command sources (Pr.361 = "0")

The line speed is determined according to the frequency command. In the External operation mode, the priorities of the line speed commands are defined as follows:

Multi-speed setting signal (RL/RM/RH/REX signal) > single-phase pulse train input (terminal JOG) > digital command input (FR-A8AX) > analog input (terminals 1, 2, 4)

In the Network operation mode, the priorities of the line speed commands are defined as follows: Multi-speed setting signal (RL/RM/RH/REX) (communication or external input) > single-phase pulse train input (terminal JOG) > digital command input (FR-A8AX) > command input via communication or analog input (terminals 1, 2, 4)

The setting of Pr.339 Communication speed command source will be applied to the selection of communication or external input for multi- speed operation, or the selection of command input via communication or analog input.

When the line speed command is input according to the multi-speed operation, set the line speed command values in Pr.1265 to Pr.1279.

When Pr.361 = "0", the following calibration parameters are used for calibrating the line speed command according to the input method.

NOTE For the frequency command input method, refer to the Instruction Manual (Detailed) of the FR-A800 inverter.

Pr.358 setting Commanded line speed monitoring

Actual line speed monitoring

Line speed setting in parameters

0 m/min m/min m/min 1 m/s m/s m/s 2 mm/min mm/min mm/min 3 mm/s mm/s mm/s

Input method Calibration parameter Analog terminal input Pr.350 to Pr.353 Terminal JOG single-phase pulse train input Pr.351, Pr.353 to Pr.355 Digital input through the FR-A8AX Pr.351, Pr.353, Pr.356, Pr.357

Time

Speed 8

Speed 9

Speed 10 Speed 11

Speed 12 Speed 13

Speed 14 Speed 15

ONON ON ON ON ON ON ON

ON ON ON ON

ON ON ON ON

ON ON ON ON

REX

Line speed command (m/min)

ON ON

ON ON

ONON

ON

Speed 4

Speed 5

Speed 6

Speed 7

ON

ON

ON

ON

Speed 1 (High speed)

Speed 2 (Middle speed)

Speed 3 (Low speed)

RH

RM

RL

Dancer feedback speed control details

DANCER FEEDBACK SPEED CONTROL 71

3

Line speed command input by pulse train input (Pr.361 = "1, 2, 7") The line speed can be commanded using single phase pulse train input through terminal JOG, encoder pulse train input

through FR-A8AP/FR-A8AL/FR-A8TP, or pulse train input through FR-A8AL (PP, NP). The number of pulses is calculated internally as follows.

To perform Vector control, install the Vector control compatible option.

NOTE To input the line speed command by the pulse train input to the plug-in option or control terminal option under vector control,

setting of Pr.862 Encoder option selection is required. (Refer to page 234.) When the single-phase pulse train input using the FR-A8AL is selected, the command pulse train type can be switched by

changing the setting of Pr.428 Command pulse selection as shown in the following table. The number of pulses is recognized as an absolute value regardless of the sign setting.

The line speed commanded by pulse train input is calibrated with Pr.351 Line speed command bias, Pr.353 Line speed command gain, Pr.354 Line speed command pulse input bias, and Pr.355 Line speed command pulse input gain. The calculation result is applied as the line speed command value (lower limit: 0 m/min, upper limit: 6553.4 m/min). When Pr.353 = "9999", the calculation result is invalid (line speed command value: 0).

Pr.361 setting Pulse train input Number of pulses calculated internally

1 Terminal JOG single-phase pulse train input

Set the pulse division scaling factor in Pr.384 for pulse train input through terminal JOG. Number of pulses calculated internally = Number of input pulses / Pr.384 setting value

2 FR-A8AP/FR-A8AL/FR-A8TP encoder pulse input Time-averaged number of input pulses using Pr.1245 Sampling time for winding diameter calculation. (When Pr.1245 = "9999", the sampling time is fixed to about 5 ms.)7 Single-phase pulse train input through FR-A8AL (PP,

NP)

Command pulse train type During forward rotation During reverse rotation Setting of Pr.428

Negative logic

Forward pulse train Reverse pulse train 0 (initial value)

Pulse train + sign 1

A phase pulse train B phase pulse train 2

Positive logic

Forward pulse train Reverse pulse train 3

Pulse train + sign 4

A phase pulse train B phase pulse train 5

PP NP

PP

NP HL

PP NP

PP NP

PP NP H L

PP NP

Dancer feedback speed control details

72 DANCER FEEDBACK SPEED CONTROL

To calibrate the line speed when Pr.361 = "2" or when Pr.361 = "7" and Pr.428 = "2 or 5", set the number of pulses multiplied by four in Pr.354 and Pr.355. A calculation example is as follows.

Use Pr.1146 Line speed command input filter time constant to set a filter time for the pulse train input. When Pr.1146 = "0 (initial value)", the filter time is not set.

Pr.1146 setting Description 0 (initial value) None 0.01 to 5 s Set a filter time constant.

System specifications Roll diameter: 80 mm Encoder resolution: 1024 Pulse/Rev Line speed range: 5 to 50 m/min

Theoretical formula V [m/min] = D [m] n [r/min]

When the line speed is 5 m/min:

When the line speed is 50 m/min:

5 [m/min] 19.89 [r/min]

1.36 [k pulses/s]

13.58 [k pulses/s]

0.08 [m] n [r/min] =

19.89 [r/min] 1024 [Pulse/Rev] 4

60 [s] Input pulse [k pulses/s] =

50 [m/min] 198.9 [r/min]

0.08 [m] n [r/min] =

198.9 [r/min] 1024 [Pulse/Rev] 4

60 [s] Input pulse [k pulses/s] =

50 (Pr.353)

5 (Pr.351)

Line speed command [m/min]

Input pulse [k pulses/s]

13.58 (Pr.355)

1.36 (Pr.354)

6553.4

0

Pr.353

Pr.351

Line speed command (m/min)

Line speed command (m/min)

Line speed command (m/min)

Line speed command (m/min)

Input pulse (k pulses/s)

Input pulse (k pulses/s)

Input pulse (k pulses/s)

Input pulse (k pulses/s)

Pr.355

Pr.355

Pr.355Pr.354

Pr.354 Pr.355 Pr.354

Pr.354

6553.4

Pr.353

Pr.351

6553.4

Pr.353

Pr.351

6553.4

Pr.353

Pr.351

6553.4

0 0

0 0

Pr.351 < Pr.353, and Pr.354 < Pr.355 Pr.351 > Pr.353, and Pr.354 < Pr.355

Pr.351 < Pr.353, and Pr.354 > Pr.355 Pr.351 > Pr.353, and Pr.354 > Pr.355

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3

Line speed command analog input (Pr.361 = "3 to 6") The line speed can be commanded by analog input. The line speed commanded by analog input is calibrated with Pr.350 Line speed command voltage/current bias, Pr.351

Line speed command bias, Pr.352 Line speed command voltage/current gain, and Pr.353 Line speed command gain. The calculation result is applied as the line speed command value (lower limit: 0 m/min, upper limit: 6553.4 m/min). When Pr.353 = "9999", the calculation result is invalid (line speed command value: 0).

When the line speed is commanded by analog input, the input value can be filtered using Pr.74 Input filter time constant, Pr.822 Speed setting filter 1, and Pr.832 Speed setting filter 2.

NOTE The difference between the setting values of Pr.350 and Pr.352 can be set within 5%. (Even if the difference is 5% or less,

Er3 (calibration error) does not occur.) The Pr.350 setting can be larger than the Pr.352 setting. Also, the Pr.351 setting can be larger than the Pr.353 setting. Specifications differ depending on the settings of Pr.73 (terminal 2) or Pr.267 (terminal 4) and the voltage/current input

selection switch. For details, refer to the Instruction Manual (Detailed) of the FR-A800 inverter. The frequency command cannot be input using the terminal selected as the line speed command input terminal in Pr.361

Line speed command input selection. (For example, to input a frequency command while Pr.361 = "3", input the command from a terminal other than terminal 2.) Set "0" in Pr.361 to use the same terminal to input a line speed command and a frequency command. In this case, the bias and gain parameter settings must be consistent for both command types. Calibration parameters for frequency command input: Pr.125, Pr.126, C2 (Pr.902) to C7 (Pr.905), C12 (Pr.917) to C15 (Pr.918) Calibration parameters for line speed command input: Pr.350 to Pr.353

To feed paper or wire, turn ON all X114, X115, and X116 signals and disable winding diameter compensation and PID compensation so that the line speed command for tension control (dancer feedback speed control / tension sensor feedback speed control) is used for the feed operation.

The range for the PID manipulated amount can be set using the line speed command. (Refer to page 104)

Line speed command input by parameter setting (Pr.361 = "8") The value set in Pr.360 Line speed command value is used for the line speed command. (Setting range: 0 to 6553.4 m/

min)

Line speed command input through RS-485/Ethernet or using a communication option (except for the FR-A8ND) (Pr.361 "9999")

Use the read/write procedure for the set frequency to read/write the line speed command value through RS-485 / Ethernet (CC-Link IE Field Network Basic) or using a communication option (FR-A8NC/FR-A8NCE/FR-A8NP). The frequency set for normal speed control is used as the line speed command value for dancer feedback speed control. (The setting is used as the set frequency when the X114 signal is OFF, and used as the line speed command value when the X114 signal is ON.)

The setting range is H0000 to HFFFE (0 to 6553.4), and the setting increment is 0.1.

NOTE For the details of RS-485 communication, refer to the FR-A800 Instruction Manual (Detailed). For the details of CC-Link IE

Field Network Basic, refer to the Ethernet Function Manual. For the details of communication options, refer to the Instruction Manual of each option.

Pr.350 Pr.352

Pr.351

Pr.353

Analog input value (%)

Line speed command (m/min)

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74 DANCER FEEDBACK SPEED CONTROL

Line speed command input using the FR-A8ND (Pr.361 "9999") The line speed command value is read/written as follows.

The line speed command value is written through I/O communication (output instance 127) as follows.

The message communication (instance 1 in class 0x2A) related to the line speed command value is defined as follows.

NOTE Output instances 20, 21, and 126 and input instances 70, 71, and 176 are not available for the line speed command.

Line speed command input signal (X125 signal) During speed control, turning ON the Line speed / tension command input (X125) signal enables write and read of the line

speed command value through communication regardless of whether the dancer feedback speed control is valid or invalid. The signal is useful for inputting the line speed command value while dancer feedback speed control is invalid, or switching

validity of the dancer feedback speed control without accidentally changing the frequency command value. The following table shows the ON/OFF status of the X125 signal and the validity of the available commands.

(: Valid through communication, : Invalid through communication)

Read/write Reading/writing method for line speed command Setting range Setting increments

Read Read the Pr.360 setting. H0000 to HFFFE (0 to 6553.4) 0.1 m/min

Write Writing through I/O communication (Output instance 127). Write through message communication. Write in Pr.360.

H0000 to HFFFE (0 to 6553.4) 0.1 m/min

Byte Bit Function Setting method Remarks

1

5 Write Attr 0: The values set in bytes 2 and 3 are used as the speed/frequency setting value.

1: The values set in bytes 2 and 3 are used as the writing data to the attributes specified in bytes 6 and 7, respectively.

6 Hz 1: 0.01 Hz increment

0: An unexpected value is written. (The value written in byte 2 and byte 3 is recognized as a number of rotations. Then, the value is converted into a frequency value and written as the line speed command value.)

7 32-bit format

0: The format for 16-bit data is being selected. (Bytes 2 and 3 are used.) 1: The format for 32-bit data is being selected. (Bytes 2 to 5 are used.)

2, 3 Speed setting The line speed command value is written. According to the setting of bit 7 in byte 1, the format

is selected for 16-bit data or 32-bit data.

Attribute ID Access Data type

Number of data bytes

Range Description

112 Set UINT 2 0 to 0xFFFE (0 to 6553.4)

The line speed command value is written in RAM. (0.1 increments)

113 Set UINT 2 0 to 0xFFFE (0 to 6553.4)

The line speed command value is written in EEPROM. (0.1 increments)

Dancer feedback speed control

X125 signal status

Validity of setting through communication Line speed command Frequency command

Valid

ON OFF

Not assigned to a terminal

Invalid

ON OFF

Not assigned to a terminal

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The X125 signal affects the input methods as follows.

To input the X125 signal, set "125" in any of Pr.178 to Pr.189 (input terminal function selection) to assign the function.

NOTE If the X125 or X114 signal is used to switch the command from frequency to line speed while the Frequency setting screen is

displayed on the FR-LU08/FR-PU07, the setting screen remains the same. However, when a frequency value is written, the value is set as a line speed value. For example, if 60.00 Hz is entered in the Frequency setting screen of the FR-LU08 while the X125 signal is OFF and then the X125 signal is turned ON before pressing the WRITE key, the Frequency setting screen is still displayed. When the WRITE key is pressed under this condition, "600.0" is written as a line speed command value.

Line speed command for starting (Pr.622) Use Pr.622 Line speed command for starting to set the line speed command for starting operation. The line speed command is regarded as zero while the line speed command input value is less than the Pr.622 setting. When the line speed command input value reaches or exceeds the Pr.622 setting, the commanded line speed is applied for

operation.

Draw control (Pr.398) Use Pr.398 Draw rate to set a draw rate to be multiplied to the line speed command value or the line speed command

acceleration/deceleration reference. Line speed command value after the multiplication = line speed command value (Pr.398) / 100 Line speed command acceleration/deceleration reference after the multiplication = Pr.393 (Pr.398) / 100

As the line speed command acceleration/deceleration reference changes in accordance with the draw rate, the actual acceleration/deceleration time is the same when the same settings are used for the parameters related to acceleration/ deceleration.

Line speed command maximum value (Pr.1147) Use Pr.1147 Line speed command maximum value to set the maximum value for the line speed command.

Input method affected by the X125 signal Input method not affected by the X125 signal

Operation panel RS-485 communication (Mitsubishi inverter protocol, MODBUS RTU) Communication option (FR-A8NC, FR-A8ND, FR-A8NCE, FR-A8NP) PLC function

Pulse train input Analog input Multi-speed input FR-A8AX Parameter

Inverter for the intermediate shaft

Inverter for the winding shaft

Line speed command 1000 m/min

Line speed command 1000 m/min

Pr.393 = "1000 m/min" Pr.394 = "15 s"

Pr.398 = "100%"

Pr.393 = "1000 m/min" Pr.394 = "15 s" Pr.398 = "80%"

Line speed = "1000 m/min" Line speed command acceleration/

deceleration reference = "1000 m/min" Time to reach the line speed = "15 s"

Line speed = "800 m/min" Line speed command acceleration/

deceleration reference = "800 m/min" Time to reach the line speed = "15 s"

Parameter setting

Actual operation

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76 DANCER FEEDBACK SPEED CONTROL

3.5.4 Compensation for line speed command input Set the following parameters for setting added compensation or override compensation for the line speed command.

The increment varies depending on the Pr.358 setting. (Refer to page 67.)

Pr. Name Initial value Setting range Description 252 T050 Override bias 50% 0 to 1000% Set the bias compensation value for the override

function.

253 T051 Override gain 150% 0 to 1000% Set the gain compensation value for the override

function.

635 R214

Line speed command added compensation value voltage/ current bias

9999 0 to 100%, 9999 Set the converted % of the bias voltage (current) for analog input.

636 R215

Line speed command added compensation value bias 9999 0 to 6553.4 m/min,

9999 Set the bias line speed compensation value for analog input.

637 R216

Line speed command added compensation value voltage/ current gain

9999 0 to 100%, 9999 Set the converted % of the gain voltage (current) for analog input.

638 R217

Line speed command added compensation value gain 9999 0 to 6553.4 m/min,

9999 Set the gain line speed compensation value for analog input.

650 R270

Terminal 4 input compensation selection 0

0 The compensation input through terminal 4 is disabled.

1 The compensation value is input through terminal 4.

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Added compensation through terminal 1 or 4 (Pr.73, Pr.635 to Pr.638, Pr.650, Pr.868)

Use terminal 1 or 4 for adding compensation for the line speed command. The terminal used for compensation is determined by the settings of Pr.73 Analog input selection, Pr.650 Terminal 4

input compensation selection, and Pr.868 Terminal 1 function assignment.

Set Pr.28 Multi-speed input compensation selection = "1" to enable analog input compensation while the line speed is commanded according to the multi-speed operation.

Set Pr.304 Digital input and analog input compensation enable/disable selection = "2, 3, 12, or 13" to enable analog input compensation while the line speed is commanded using the FR-A8AX.

The analog input value of the line speed compensation value is calibrated with Pr.635 Line speed command added compensation value voltage/current bias, Pr.636 Line speed command added compensation value bias, Pr.637 Line speed command added compensation value voltage/current gain, and Pr.638 Line speed command added compensation value gain. The settings are applied to the line speed command compensation value (lower limit: 0 m/min, upper limit: 6553.4 m/min).

When "9999" is set in any of Pr.635 to Pr.638, all the settings in Pr.635 to Pr.638 are invalid. Instead, the settings in Pr.350 to Pr.353 are applied for calibrating the compensation value. (Refer to page 73.)

NOTE The difference between the setting values of Pr.635 and Pr.637 can be set within 5%. (Even if the difference is 5% or less,

Er3 (calibration error) does not occur.) The Pr.635 setting can be larger than the Pr.637 setting. Also, the Pr.636 setting can be larger than the Pr.638 setting. The compensation is invalid when it is input through the terminal specified for the line speed command input.

Line speed command input method

Add compensation signal input terminal

Add compensation signal input terminal selection Pr.73 setting Pr.650 setting Pr.868 setting

Analog input Multi-speed (NET operation (terminal)) FR-A8AX

Terminal 4 Other than 4, 5, 14, 15

1

Terminal 1 Other than 1 0

Pr.635 Pr.637

Pr.636

Pr.638

Analog input value (%)

Line speed command compensation input (m/min)

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78 DANCER FEEDBACK SPEED CONTROL

Override compensation through terminal 2, 4, or 6 (Pr.73, Pr.406, Pr.252, Pr.253, Pr.650)

Use terminal 2, 4, or 6 (FR-A8AZ) for override compensation of the line speed command value. The terminal used for compensation is determined by the settings of Pr.73 Analog input selection, Pr.406 High

resolution analog input selection, and Pr.650 Terminal 4 input compensation selection.

When any function is assigned to a terminal by setting Pr.361 to Pr.364, Pr.804, or Pr.1285, the terminal cannot be used for the override compensation signal.

Set Pr.28 Multi-speed input compensation selection = "1" to enable analog input compensation while the line speed is commanded according to the multi-speed operation.

Set Pr.304 Digital input and analog input compensation enable/disable selection = "2, 3, 12, or 13" to enable analog input compensation while the line speed is commanded using the FR-A8AX.

Use Pr.252 Override bias and Pr.253 Override gain to set the override compensation amount.

NOTE When any function is assigned to terminal 1 using Pr.361 to Pr.364, Pr.804, or Pr.1285, the override compensation is invalid.

Line speed command input method

Override compensation signal

input terminal

Parameter setting for selecting the override compensation input terminal

Pr.73 setting Pr.406 setting Pr.650 setting Pulse train input Analog input Multi-speed (NET operation (terminal)) FR-A8AX

Terminal 6 (FR-A8AZ)

4, 5, 14, 15

0 Terminal 4

Other than 0 1

Terminal 2 0

Pr.252

0 V (0 V) (0 mA)

2.5 V (5 V)

(10 mA)

5 V (10 V) (20 mA)

0

50

100

150

1000

Initial value (50% to 150%)

Analog input

Pr.253

Override amount (%)

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3.5.5 Acceleration/deceleration time setting for line speed command

Set the acceleration/deceleration time for the line speed command.

The increment varies depending on the Pr.358 setting. (Refer to page 67.)

Block diagram

Pr. Name Initial value Setting range Description 394 R251

First acceleration time for line speed command 15 s 0 to 3600 s Set the acceleration time (from a stop to Pr.393) for

the line speed command.

395 R252

First deceleration time for line speed command 15 s 0 to 3600 s Set the deceleration time (from Pr.393 to a stop) for

the line speed command.

100 R253

Second acceleration time for line speed command 15 s 0 to 3600 s Set the second acceleration time for the line speed

command.

101 R254

Second deceleration time for line speed command 15 s 0 to 3600 s Set the second deceleration time for the line speed

command.

102 R255

Third acceleration time for line speed command 15 s 0 to 3600 s Set the third acceleration time for the line speed

command.

103 R256

Third deceleration time for line speed command 15 s 0 to 3600 s Set the third deceleration time for the line speed

command.

393 R250

Line speed command acceleration/deceleration reference

1000 m/min 1 to 6553.4 m/min Set the reference line speed for the acceleration/ deceleration time for the line speed.

621 R423

Allowable deviation from target line speed 0 m/min 0 to 6553.4 m/min The Y237/Y238 signal output range can be set for the

target line speed command.

Unit switchover Pr.21

Line speed command

Line speed command value in consideration of acceleration/deceleration

Pr.394 Pr.395

Pr.100 Pr.101

Pr.102 Pr.103

X105-OFF

X105-ON

X106-OFF

X106-ON

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Acceleration/deceleration time setting (Pr.100 to Pr.103, Pr.393 to Pr.395, X105 signal, X106 signal)

Settings of acceleration/deceleration time for line speed command are used in the command for accelerating/decelerating the line speed.

Use Pr.393 Line speed command acceleration/deceleration reference for setting time in each parameter. Use Pr.21 Acceleration/deceleration time increments to set the minimum increment of the acceleration/deceleration

time.

The acceleration/deceleration time for the line speed command can be switched using the Acceleration/deceleration time selection signals for line speed command (X105 and X106). For the X105 and X106 signals, assign the function by setting "105 (X105)" or "106 (X106)" in any of Pr.178 to Pr.189 (input terminal function selection).

NOTE Normally set "0" in Pr.7 Acceleration time and Pr.8 Deceleration time.

Pr.21 setting Minimum increment 0 0.1 s 1 0.01 s

Signal state Acceleration/deceleration time Acceleration/deceleration time

setting parameterX105 signal X106 signal OFF OFF First acceleration/deceleration time Pr.394/Pr.395 ON OFF Second acceleration/deceleration time Pr.100/Pr.101 ON Third acceleration/deceleration time Pr.102/Pr.103

Line speed command value

Acceleration time for line speed command Pr.394 (Pr.100, Pr.102)

Acceleration/deceleration reference line speed command

(Pr.393)

Line speed command (m/min)

Deceleration time for line speed command Pr.395 (Pr.101, Pr.103)

Line speed command value in consideration of acceleration/deceleration

Time

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DANCER FEEDBACK SPEED CONTROL 81

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Line speed command acceleration/deceleration signal (Pr.621, Y237 signal, Y238 signal)

The Y237 signal is output while the line speed command value increases. When S-curve acceleration/deceleration is selected for the line speed command (Pr.1141 = "1"), the signal is output when acceleration is started by the S-curve acceleration/deceleration command or during linear acceleration.

The Y238 signal is output while the line speed command value decreases. When S-curve acceleration/deceleration is selected for the line speed command (Pr.1141 = "1"), the signal is output when deceleration is started by the S-curve acceleration/deceleration command or during linear deceleration.

When using the Y237 and Y238 signals, refer to the following and assign the functions by Pr.190 to Pr.196 (output terminal function selection).

NOTE When the line speed signal value fluctuates while analog input, etc. is used for the command, the Y237/Y238 signal may

repeat ON/OFF. Pr.621 Allowable deviation from target line speed can be used to prevent the repetitive ON/OFF operation.

When the command value for the target line speed and the setting in Pr.622 Line speed command for starting are close to each other, the line speed increases and decreases repeatedly and the Y237/Y238 signal may repeat ON/OFF.

Output signal Pr.190 to Pr.196 setting

Positive logic Negative logic Y237 237 337 Y238 238 338

Line speed command value

Y237

Y238

Line speed command (m/min)

Line speed command value in consideration of acceleration/deceleration

Time

ON

Pr.621

Pr.621

Pr.621

ON

Pr.1141 = "0" (Linear acceleration/deceleration)

Line speed command value

Acceleration start

Linear acceleration

Line speed command (m/min)

Time

Line speed command value in consideration of acceleration/deceleration

Pr.621

Pr.621

Deceleration start

Pr.621

Y237

Y238 ON

ON

Pr.1141 = "1" (S-curve acceleration/deceleration)

Linear deceleration

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82 DANCER FEEDBACK SPEED CONTROL

3.5.6 Line speed command acceleration/deceleration pattern

The acceleration/deceleration pattern can be set according to the application.

Use Pr.1142 to Pr.1145 to set times for S-curve acceleration/deceleration. Set times to start acceleration (Pr.1142), complete acceleration (Pr.1143), start deceleration (Pr.1144), and complete

deceleration (Pr.1145) for S-curve acceleration/deceleration. When the S-curve acceleration/deceleration is set, the acceleration/deceleration time becomes longer, as shown below.

The set acceleration/deceleration time T1 indicates the actual time taken for linear acceleration/deceleration as calculated based on Pr.394, Pr.395, and Pr.100 to Pr.103.

NOTE Even if the start signal is turned OFF during acceleration, the inverter does not decelerate immediately to avoid sudden

frequency change. (Likewise, the inverter does not immediately accelerate when deceleration is changed to re-acceleration by turning ON the start signal during deceleration, etc.)

Pr. Name Initial value Setting range Description

1141 R290

Line speed command acceleration/deceleration pattern

0 0 Linear acceleration/deceleration

1 S-curve acceleration/deceleration

1142 R291

Line speed command acceleration start S-curve time

0.1 s 0.1 to 2.5 s

Set times for S-curve acceleration/deceleration. The settings are also used for the inertia compensation cushion time. The settings are valid for S-curve acceleration/deceleration (Pr.1141 = "1"). Refer to page 157 for the inertia compensation function.

1143 R292

Line speed command acceleration completion S- curve time

0.1 s 0.1 to 2.5 s

1144 R293

Line speed command deceleration start S-curve time

0.1 s 0.1 to 2.5 s

1145 R294

Line speed command deceleration completion S- curve time

0.1 s 0.1 to 2.5 s

Actual acceleration time T2 = set acceleration time T1 + (acceleration start S-curve time + acceleration completion S-curve time) / 2

Actual deceleration time T2 = set deceleration time T1 + (deceleration start S-curve time + deceleration completion S-curve time) / 2

Pr.1142

Time

Line speed command

ONStart signal

Pr.1143 Pr.1144 Pr.1145

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The following section shows the actual acceleration time required to start the inverter by selecting S-curve acceleration/ deceleration from a stop to the target line speed command value in the conditions shown in the setting example.

[Setting example] Target line speed command = 1000 m/min Pr.1142 = 0.1 s Pr.1143 = 0.1 s Pr.393 = 1000 m/min Pr.394 = 15 s Pr.622 = 0 m/min

T2

Line speed command acceleration/deceleration reference (Pr.393)

T1 Line speed command for starting (Pr.622)

Pr.1143/2

Pr.1143

Pr.1142

Pr.1142/2 Linear acceleration Slope set by Pr.394, Pr.100, or Pr.102

Set acceleration time T1 = (target line speed command - Pr.622) Pr.394 / Pr.393 = (1000 m/min - 0 m/min) 15 s / 1000 m/min = 15 s (actual acceleration time for linear acceleration)

Actual acceleration time T2 = set acceleration time T1 + (Pr.1142 + Pr.1143 ) / 2 = 15 s + (0.1 s 0.1 s) / 2 = 15.1 s (acceleration time for S-curve acceleration)

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84 DANCER FEEDBACK SPEED CONTROL

The following section shows the actual deceleration time required to stop the inverter by selecting S-curve acceleration/ deceleration from the target line speed command value to 0 m/min in the conditions shown in the setting example.

[Setting example] Target line speed command = 1000 m/min Pr.1142 = 0.1 s Pr.1143 = 0.1 s Pr.393 = 1000 m/min Pr.394 = 15 s Pr.10 = 0 Hz

T2

Line speed command acceleration/deceleration reference (Pr.393)

T1

DC injection brake operation frequency (Pr.10)

Pr.1144/2

Pr.1144

Pr.1145

Pr.1145/2

Linear deceleration Slope set by Pr.395, Pr.101, or Pr.103

Set deceleration time T1 = (target line speed command - Pr.10) Pr.395 / Pr.393 = (1000 m/min - 0 Hz) 15 s / 1000 m/min = 15 s (actual deceleration time for linear deceleration)

Actual deceleration time T2 = set deceleration time T1 + (Pr.1144 + Pr.1145) / 2 = 15 s + (0.1 s 0.1 s) / 2 = 15.1 s (deceleration time for S-curve deceleration)

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3.5.7 Dancer roll setting Set the target position for the dancer roll control. Select the input method to the inverter (analog input terminal) for dancer signal input.

Block diagram

PID set point (Pr.133) Set the target position (neutral position) of the dancer roll in Pr.133 PID action set point.

If the position signal input from the dancer roll through terminal 1 is 10 V at the upper limit position, -10 V at the lower limit position, and 0 V at the neutral position (target position), set 500% in Pr.133. If the signal is -5 V at the neutral position (target position), set 450% in Pr.133. A voltage from -10 V to 10 V can be input through terminal 1.

NOTE Set "86" in Pr.52 to monitor the dancer roll position in %. When the negative indication is invalid, the monitored value is

indicated as an offset from 1000%.

Pr. Name Initial value

Setting range Description

133 R101 (A611)

PID action set point 500% 400 to 600% Set the set point for the dancer roll control.

363 R102

Dancer / tension sensor feedback input selection 9999

3 The measured value is input through terminal 2. 4 The measured value is input through terminal 4. 5 The measured value is input through terminal 1. 6 The measured value is input through terminal 6 (FR-A8AZ).

9 The measured value is input via CC-Link / CC-Link IE Field Network Basic communication.

9999 No function

1227 R103

Dancer / tension sensor feedback input filter time constant

0 0 Without filter

0.01 to 5 s Set the primary delay filter for the dancer signal input value.

1382 R150 PID set point cushion time 0s 0 to 360s Set the cushion time required to reach the PID set point.

Pr.133 setting Actual set point 600% +100% 500% (initial setting) 0% 400% -100%

Pr.1227 Pr.363

Dancer roll positionTerminal 4

Terminal 2

Terminal 6

Terminal 1

4

3

6

5

Primary delay filter Clamping

100% -100%

0 (500%)

Dancer roll position signal (Pr.133 (dancer roll center))

Dancer signal input through terminal 1, terminal 6

10 V (600%)

Dancer roll upper limit position

Dancer roll lower limit position

5 V (550%)

-5 V (450%)

-10 V (400%)

5 V/12 mA (500%)

Dancer roll position signal (Pr.133 (dancer roll center))

10 V/20 mA (600%)

Dancer roll upper limit position

7.5 V/16 mA (550%)

2.5 V/8 mA (450%)

0 V/4 mA (400%)

Dancer signal input through terminal 2, terminal 4

Dancer roll lower limit position

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86 DANCER FEEDBACK SPEED CONTROL

PID set point cushion time (Pr.1382) Use Pr.1382 PID set point cushion time to set the time required for the PID set point to reach 100% (-100%) from 0%.

Taper function for the PID set point FTP can be replaced with the PID set point after taper control, and F* with the PID set point after the cushion time. (For

details on FTP and F*, refer to page 151.) The taper ratio is the reduction ratio against 100% (the PID set point set in Pr.133 is regarded as 100%). When the taper

ratio setting is 20% in the example of linear taper control, the PID set point after taper control is 80% of the original value. When the taper function is used for the set point, set Pr.1284 Taper mode selection "0", Pr.364 Dancer tension setting

input selection / taper function enable/disable selection for tension sensor feedback speed control 1 = "9999", and Pr.430 Dancer tension setting / taper function enable/disable selection for tension sensor feedback speed control 2 = "9999".

When the PID set point after the cushion time is negative, the limit is set at 0%. When the taper function is used for the set point, calibrate the settings so that 0% is equivalent to 0 N.

NOTE When the analog signal output for dancer tension setting is enabled (Pr.364 "9999" or Pr.430 "9999"), the taper function

is enabled for the analog signal output for dancer tension setting. (Refer to page 108.)

Dancer signal input selection (Pr.363) Use Pr.363 Dancer / tension sensor feedback input selection to select the input terminal for the dancer signal

(measured value).

The input specification in the initial setting is indicated. When Pr.363 = "9", dancer / tension sensor feedback can be input via CC-Link or CC-Link IE Field Network Basic

communication. The 16-bit feedback signal input via communication is recognized as a signed signal. The input data range is from -10000

(-100.00%) to +10000 (+100.00%). When out-of-range values are input, the limit is set at 10000 (100.00%).

Pr.363 setting Input terminal 3 Terminal 2 (0 to 100%) (0 to 5 V) 4 Terminal 4 (20 to 100%) (4 to 20 mA) 5 (initial value) Terminal 1 (-100 to 100%) (-10 to 10 V) 6 Terminal 6 (FR-A8AZ) (-100 to 100%) (-10 to 10 V) 9 CC-Link or CC-Link IE Field Network Basic (-100 to 100%)

Cushion time reference PID set point (= 100%)

0

PID set point (%)

Time

PID set point (%)

PID set point cushion time Pr.1382

PID set point cushion time Pr.1382

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Dancer signal calibration example The following parameters are used for calibrating the dancer signal according to the input terminal. The dancer signal

analog input values at both 0% and 100% can be calibrated.

The initial input range is 20 to 100%.

In the following example, a potentiometer with the output range of -10 to 10 V is used for inputting the dancer signal to terminal 1 (input range: -10 to 10 V). The neutral position is defined as 0% for the calibration. C13 (Pr.917) Terminal 1 bias (speed) and C15 (Pr.918) Terminal 1 gain (speed) are used for calibration.

In the following example, a potentiometer with the output range of 1 to 7 V is used for inputting the dancer signal to terminal 2 (input range: 0 to 10 V). The neutral position is defined as 0% for the calibration. C3 (Pr.902) Terminal 2 frequency setting bias and C4 (Pr.903) Terminal 2 frequency setting gain are used for calibration.

NOTE The dancer signal is clamped at 100%. For the details of C3 (Pr.902), C4 (Pr.903), C6 (Pr.904), C7 (Pr.905), C13 (Pr.917), and C15 (Pr.918), refer to the FR-A800

Instruction Manual (Detailed).

Dancer signal input filter (Pr.1227) Use Pr.1227 Dancer / tension sensor feedback input filter time constant to set the primary delay filter for the dancer

signal input value. When Pr.1227 = "0", the filter is not set.

Input terminal Calibration parameter Terminal 2 (0 to 100%) C3 (Pr.902), C4 (Pr.903) Terminal 4 (0 to 100%) C6 (Pr.904), C7 (Pr.905) Terminal 1 (-100 to 100%) C13 (Pr.917), C15 (Pr.918) Terminal 6 (FR-A8AZ) (-100 to 100%) C31 (Pr.926), C33 (Pr.927) CC-Link, CC-Link IE Field Network Basic

Potentiometer

-10 to 10 V

Terminal 1 calibration example

100%

-100%

0 C13 (Pr.917)

Analog input value

10 V C15 (Pr.918)

Calibration example (initial value)

-10 V

Dancer signal

Potentiometer

1 to 7 V

Terminal 2 calibration example

Calibration example

100%

-100%

Dancer signal

0

1 V Analog input value10 V7 V

C4 (Pr.903) 4 V

C3 (Pr.902)

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88 DANCER FEEDBACK SPEED CONTROL

3.5.8 Dancer roll position detection A signal is output while the dancer roll position value maintains the specified normal level.

Dancer roll position detection (Pr.423, Y235 signal) The Dancer / tension sensor feedback detection level (Y235) signal is output when the dancer roll, which is viewed from the

target position, is within the range set in Pr.423 Dancer position / tension feedback detection. For the Y235 signal, set "235 (positive logic) or 335 (negative logic)" in one of Pr.190 to Pr.196 (output terminal function

selection) to assign the function to the output terminal.

3.5.9 PID offset displacement Pr.424 is used to calibrate the reference value of the dancer roll position (PID measured value).

PID offset displacement (Pr.424, X102 signal) When the dancer roll is in the user-specified position (set as the reference value), an offset can be added to the PID

measured value by turning on the X102 signal. The dancer roll position can also be set to 0% by turning on the X102 signal. At the ON edge of the X102 signal, the present input value (-100 to 100%) is written in Pr.424 Dancer / tension sensor

feedback input offset. A value within the range from 400 to 600% is written in Pr.424, considering the measured value of 0% as 500%.

Measured value (after the offset) = Measured value (before the offset) - Pr.424 (offset value)

NOTE The measured value (after the offset) is limited within the range of 100%.

Pr. Name Initial value Setting range Description

423 R422

Dancer / tension sensor feedback detection level 10% 0 to 100%

Set the normal position range of the dancer roll. Define the percentage of deviation with respect to the target position.

Pr. Name Initial value Setting range Description

424 R104

Dancer / tension sensor feedback input offset 500% 400 to 600% The offset displacement input value is written.

Neutral position (target position)

Upper limit

Lower limit

Pr.423

Pr.423

Dancer position detection level Y235 is ON while the dancer roll

stays within this range.

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3.5.10 Dancer roll malposition detection When a break occurs and the dancer roll falls, dancer feedback speed control is used to prevent the motor speed from increasing.

Dancer roll malposition detection (break detection) (Pr.131, Pr.132, Pr.425) Set the upper limit of the dancer roll position in Pr.131 PID upper limit. Set the lower limit of the dancer roll position in

Pr.132 PID lower limit. When the dancer roll position goes higher than the position set in Pr.131, the FUP signal is output. When the position goes

lower than the position set in Pr.132, the FDN signal is output. When the dancer roll position remains higher than the position set in Pr.131 or lower than the position set in Pr.132 for the

time set in Pr.425 Break detection waiting time or longer, the condition is determined as the dancer roll malposition (break), and compensation by PID control becomes 0. The winding diameter at the time of malposition detection is retained.

When the dancer roll malposition (break) is detected, the Break detection (Y231) signal can be output. When the following two conditions are both met, dancer feedback speed control (PID calculation) is resumed.

- The motor is stopped or output is shutoff. - The start signal is OFF.

For using each signal, use Pr.190 and Pr.196 (output terminal function selection) to assign the function referring to the following table.

Pr. Name Initial value Setting range Description

131 A601 PID upper limit 9999

400 to 600% Set the value for outputting the PID upper limit (FUP) signal. 9999 No function

132 A602 PID lower limit 9999

400 to 600% Set the value for outputting the PID lower limit (FDN) signal. 9999 No function

137 R163

PID upper/lower limit hysteresis width 9999

0 to 100% Set the hysteresis width for the FUP and FDN signals. 9999 No function

425 R160 Break detection waiting time 9999

0 to 100 s Set the time until the dancer roll malposition is determined. 9999 Break detection disabled

553 A603 PID deviation limit 9999

0 to 100% The Y48 signal is output when the absolute value of the deviation exceeds the deviation limit value.

9999 No function

554 A604

PID signal operation selection 0 0 to 3

The action when the upper or lower limit for a measured value input is detected or when a limit for the deviation is detected can be selected.

Output signal

Pr.190 to Pr.196 setting Positive logic Negative logic

FDN 14 114 FUP 15 115 Y231 231 331

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90 DANCER FEEDBACK SPEED CONTROL

PID upper/lower limit hysteresis width (Pr.137) When the dancer roll position fluctuates, the FUP/FDN signal may chatter (turn ON and OFF repeatedly), depending on the position. To prevent the signal chattering, configure Pr.137 PID upper/lower limit hysteresis width to set a hysteresis for the FUP and FDN signals.

NOTE Pr.137 setting does not affect the operation of the Y231 signal. (Refer to page 89 for the details of the Y231 signal.) When a value other than "9999" is set in Pr.137, depending on fluctuation of the dancer roll position, the FUP/FDN signal may

not be turned ON even if the dancer roll position exceeds the Pr.131 setting or falls below the Pr.132 setting.

Operation selection when a limit is detected (Pr.554, FUP signal, FDN signal, Y48 signal)

Using Pr.554 PID signal operation selection, set the action when the measured value input exceeds the upper limit (Pr.131 PID upper limit) or lower limit (Pr.132 PID lower limit), or when the deviation input exceeds the permissible value (Pr.553 PID deviation limit).

Choose whether to output the signals (FUP, FDN, Y48) only or to activate the protective function to output the inverter shutoff.

NOTE When each of Pr.131, Pr.132 and Pr.553 settings corresponding to each of the FUP, FDN and Y48 signals is "9999" (no

function), signal output and protective function are not available.

Pr.554 setting Inverter operation

FUP, FDN Y48 0 (initial value) Signal output only

Signal output only 1 Signal output + output shutoff (E.PID) 2 Signal output only

Signal output + output shutoff (E.PID) 3 Signal output + output shutoff (E.PID)

Winding diameter compensation amount

Break detection

Start command ON OFF

OFF OFFONY231

Pr.425 (Break detection waiting time)

PID compensation amount = 0

Normal operation Dancer roll falling to the lower limit

Dancer roll neutral position

Turns OFF when the motor stops running and the start command turns OFF.

Line speed command

Motor speed

Dancer lower limit position (Pr.132)

Dancer roll position

Pr.137 Pr.131

ON ON

ONFUP

Example of the PID upper limit (FUP) signal

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3.5.11 Tension PI gain tuning During dancer/tension feedback speed control, the PI gain is automatically set by changing the PID manipulated amount and measuring the PID response. PI gain automatic tuning facilitates setting of PID gain. The tension PI gain tuning can be performed either while the system is stopped or in operation.

System configuration example

Pr. Name Initial value Setting range Description

554 A604

PID signal operation selection 0 0 to 3

The action when the upper or lower limit for a measured value input is detected or when a limit for the deviation is detected can be selected.

1211 R171

Tension PI gain tuning timeout time 50 s 1 to 9999 s Set the timeout time.

1215 R172 Limit cycle output upper limit 0% 0 to 100% Set the output upper limit for the amount of positive

manipulation.

1217 R173 Limit cycle hysteresis 1% 0.1 to 10% Set the hysteresis of the set point.

1219 R170

Tension PI gain tuning start/ status 0

0 Tension PI gain tuning is not performed. (Read only) 1 Tension PI gain tuning starts. 8 Tension PI gain tuning is forcibly terminated. 2, 3, 9, 12, 13, 90 to 96 Tuning status is indicated. (Read only)

1222 R175 Target amplitude 9999

0 to 100% Set the target amplitude for the limit cycle. 9999 Tension PI gain tuning during a stop is disabled.

1223 R174

Manipulated amount for operation 1% 0 to 10% Set the amount for manipulation to fit the value to the

set point.

1226 R176

Tension PI gain tuning response level setting 2 1 to 7 Set the response level.

FR-A800-R2R

Encoder

Potentiometer Lock the rolls.

Dancer roll

Dancer signal

Minimum diameter

Maximum diameter

1

STF/STR

PID upper limit

PID lower limit

Start signal

FUP

FDN

Dancer/tension control selection X114

FR-A8AP

M

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92 DANCER FEEDBACK SPEED CONTROL

Tension PI gain tuning The limit cycle method is used to perform tension PI gain tuning. In the limit cycle method, the manipulated amount is output ten times in square waves using the actual system. Gain is

calculated from the commanded amplitude (M), vibration amplitude (Xc), and vibration cycle (Tc). The PI gain calculation result is automatically applied to the relevant parameter.

Before performing tension PI gain tuning Tension PI gain tuning can be performed when the system is stopped, or while the system is in operation. Tension PI gain tuning while the system is in operation is performed if the response is still slow after the tension PI gain

tuning at a system stop is performed.

NOTE Tension PI gain tuning during stopping is not available under Real sensorless vector control. Perform the operation under the

control method other than Real sensorless vector control. After tension PID gain tuning is completed normally, the settings of the PID constant parameters (Pr.129 and Pr.130) are

automatically changed. Before performing tension PI gain tuning, save the PID constant parameter settings as required. During tension PI gain tuning, set Pr.131 PID upper limit, Pr.132 PID lower limit, Pr.553 PID deviation limit according to

the system. The tuning result varies depending on the winding diameter because of the different inertia. If the PID control gain response

level is slow when the winding diameter and the inertia values are large, set a large value in Pr.820 Speed control P gain 1. When offline auto tuning and tension PI gain tuning are attempted at the same time, offline auto tuning is performed. A setting

error occurs for tension PI gain tuning. When online auto tuning at startup and offline auto tuning are attempted at the same time, online auto tuning at startup is

performed first, and then offline auto tuning is performed.

Tension PI gain tuning procedure (system stopped) 1 Tuning preparation

Fix the shafts other than the target shaft for tension PI gain tuning so that the workpiece does not move. Check that forward/reverse operation of the target shaft causes no problem.

2 Parameter setting Set the following parameters for tension PI gain tuning. Start the setting of Pr.1222 with a small value (about 1%) and then gradually increase the setting value as required.

3 Tuning Enter the start command to start the test operation. Check the behavior of the workpiece and the motor. The inverter output is shut off after the tuning is complete. If tuning completes normally, "3" will be displayed in Pr.1219. As required, perform tension PI gain tuning while the system is in operation. Check the accelerating/decelerating operation or the operation with different winding diameters, and adjust the response level as required.

Tuning method Purpose Tension PI gain tuning during stopping Automatic tuning of the PI gain

Tension PI gain tuning during operation Tuning for increasing the accuracy, to be performed if the response is still slow after the PI gain tuning during stopping is performed.

Pr. Name Setting

73 Analog input selection 10 to 17 (Polarity reversible operation enabled.) (For the details of Pr.73, refer to the FR-A800 Instruction Manual (Detailed).)

646 Stored winding diameter When the initial winding diameter calculation is invalid, set the winding diameter value.

1219 Tension PI gain tuning start/status 1 (Tension PI gain tuning starts.) 1222 Target amplitude 1%

Pr. Name 1226 Tension PI gain tuning response level setting

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DANCER FEEDBACK SPEED CONTROL 93

3

4 Finishing tuning Turn OFF the start command to finish tuning. When the polarity reversal operation is not required, set Pr.73 back to the previous value.

NOTE To forcibly finish tuning, perform any of the following:

Set "8" in Pr.1219. Turn OFF the start signal. Inverter reset Turn ON the MRS signal.

Tension PI gain tuning procedure (during operation) POINT

Perform tension PI gain tuning during stopping first, and then perform tension PI gain tuning during operation as required.

1 Parameter setting Set the following parameter.

2 Operation Start the inverter normally.

3 Tuning Set "1" in Pr.1219 Tension PI gain tuning start/status or turn ON the Tension PI gain tuning start / forced end (PGT) signal during operation to start tuning. To input the PGT signal, set "81" in any of Pr.178 to Pr.189 (input terminal function selection) to assign the function. The inverter returns to normal operation after the tuning is complete. If tuning completes normally, "13" will be displayed in Pr.1219.

NOTE To finish tuning forcibly, perform any of the following:

Set "8" in Pr.1219. Turn OFF the Tension PI gain tuning start / forced end (PGT) signal. Turn OFF the start signal. Inverter reset Turn ON the MRS signal.

If "1" is already set in Pr.1219 or the PGT signal is ON when the power is supplied to the inverter, tuning does not start by starting the start command.

CAUTION When tension PI gain tuning is started, the motor is automatically started and the dancer roll starts

moving. If the value set in Pr.1222 under dancer feedback control is too large, the dancer roll may hit against the system and cause damage.

Pr. Name Setting

646 Stored winding diameter When the initial winding diameter calculation is invalid, set the winding diameter value.

CAUTION If the value set in Pr.1222 under dancer feedback control is too large, the dancer roll may hit against

the system and cause damage.

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94 DANCER FEEDBACK SPEED CONTROL

Tension PI gain tuning adjustment parameter Before performing tension PI gain tuning, adjust the following parameters as required.

: Setting required, : Setting not required The setting can be adjusted. Adjust the setting as required. After the tuning, the result is set automatically. If the approximate setting value is unknown, use the result of the PI gain tuning during stopping. The PGT signal can be also used for starting or terminating the tuning.

Pr. Name

Necessity of parameter setting

DescriptionTension PI gain tuning at

a stop

Tension PI gain tuning during

operation

1211 Tension PI gain tuning timeout time Set the timeout time for tension PI gain tuning.

1215 Limit cycle output upper limit Set the output upper limit for the amount of positive manipulation for tension PI gain tuning.

1217 Limit cycle hysteresis Set the hysteresis of the set point to perform tension PI gain tuning.

1219 Tension PI gain tuning start/ status

Set to indicate the condition of tension PI gain tuning, or start/terminate the tuning.

1222 Target amplitude Set the target amplitude for the limit cycle. Start tuning with a small value and gradually increase the value while making sure that tuning causes no problem.

1223 Manipulated amount for operation Set the amount for manipulation to fit the value to the

set point.

1226 Tension PI gain tuning response level setting

Set the response level of tension PI gain tuning in the range from "1" (slow) to "7" (fast).

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DANCER FEEDBACK SPEED CONTROL 95

3

Tension PI gain tuning during stopping

The tuning results are applied to the following parameters.

Status Tuning operation

a Operate as per the amount set in Pr.1223 Manipulated amount for operation, to fit PID value to the setting of Pr.133 PID action set point.

b When the PID value reaches the Pr.1222 setting, tension PI gain tuning starts. c Tension PI gain tuning is in progress.

d Calculate PI gain. The PI gain response level can be set with Pr.1226 Tension PI gain tuning response level setting.

e Operate as per the amount set in Pr.1223 to lower the PID measured value.

Pr. Name 129 PID proportional band 130 PID integral time 1215 Limit cycle output upper limit 1217 Limit cycle hysteresis

0

Pr.133

Pr.1223

Measured value

Pr.1222

Manipulated amount

a b

Pr.1222

Pr.1215

c

- Pr.1215

Pr.1219

Tension PI gain tuning in progress

Vibration amplitude

During stop

Pr.1217

Pr.1217

d

During stop

Output shutoff

1 (Setting)

2 (Tuning in progress)

3 (Completed)

Start command

ON

Pr.1217

Pr.1223

e

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96 DANCER FEEDBACK SPEED CONTROL

Tension PI gain tuning during operation

The tuning results are applied to the following parameters.

Status Tuning operation

a Tension PI gain tuning is in progress. Refer to the manipulated amount when the tuning is started, and use the setting in Pr.1215 Limit cycle output upper limit to increase/decrease the manipulated amount to adjust the amplitude of the measured value.

b Calculate PI gain. The PI gain response level can be set with Pr.1226 Tension PI gain tuning response level setting.

Pr. Name 129 PID proportional band 130 PID integral time

0

Pr.133

Measured value

Manipulated amount

Pr.1215

Pr.1215

PGT

Start command

Tension PI gain tuning in progress

Vibration amplitude

Pr.1217

Pr.1217

ON

ON

ON ONPID

During PID control activated

During PID control activated

Pr.1219

12 (Tuning in progress)

13 (Completed)

a b

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Tension PI gain tuning status indicator The tension PI tuning status can be checked by reading the Pr.1219 setting. Alternatively, check the tension PI gain tuning

monitor, which is displayed instead of the output voltage monitor. The monitor is displayed on the operation panel as shown below.

NOTE When the tuning is forcibly terminated or a tuning error is displayed, tension PI gain tuning has not been properly completed.

Tuning error causes and corrective actions If a tuning error occurs, refer to the following for corrective actions.

Status Monitor readout of Pr.1219 Tension PI gain tuning status

Tuning during stopping Tuning during operation Not performed 0 Tuning start 1 Tuning in progress 2 12 Tuning completed 3 13 Forced end 8 Tuning error 9, 90 to 96

Error indication Name Possible cause Corrective action

8 Forced end

The start signal has been turned OFF. The PGT signal has been turned OFF. The inverter has been reset. An output shutoff has occurred.

9 Protective function activation An inverter protective function has been activated.

Refer to the FR-A800 Instruction Manual (Detailed) to identify the cause and take corrective actions.

90 Input upper limit error

A value higher than the Pr.131 PID upper limit setting is measured while Pr.554 PID signal operation selection = "1 or 3".

Check the Pr.131 and Pr.554 settings.

91 Input lower limit error

A value lower than the Pr.132 PID lower limit setting is measured while Pr.554 PID signal operation selection = "1 or 3".

Check the Pr.132 and Pr.554 settings.

92 Deviation limit error The deviation is higher than the Pr.553 PID deviation limit setting while Pr.554 PID signal operation selection = "2 or 3".

Check the Pr.553 and Pr.554 settings.

93 Timeout error Tension PI gain tuning is not terminated within the time set in Pr.1211 Tension PI gain tuning timeout time. Set a larger value in Pr.1211.

94 Calculation error

The tuning calculation is inconsistent. Vibration amplitude Xc is equal to or lower than the amount of hysteresis. Pr.1222 Target amplitude is lower than the amount of hysteresis.

Tuning during stopping The dancer signal may include noise. Set a larger value in Pr.1222 or take countermeasures against noise to reduce the dancer signal noise. Tuning during operation Check the settings of Pr.1222 and Pr.1217 Limit cycle hysteresis. The Pr.1222 setting must be higher than the Pr.1217 setting.

95 Setting error PID control is disabled during tension PI gain tuning. The PID control setting has been changed during tension PI gain tuning.

Check that PID control can be performed normally.

96 PID mode error

The switchover frequency is not reached while Pr.127 PID control automatic switchover frequency is set. The stall prevention or regeneration avoidance function is activated. Frequency fluctuation occurred because of the frequency jump, maximum frequency, or minimum frequency.

Set "9999" in Pr.127. Refer to the FR-A800 Instruction Manual (Detailed) to check the setting.

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98 DANCER FEEDBACK SPEED CONTROL

Fine adjustment after tension PI gain tuning If fine adjustment is required after completion of tension PI gain tuning, adjust the proportional band (Pr.129), integral time

(Pr.130), and differential time (Pr.134).

NOTE During the differential operation is used, adjust the differential time (Pr.134) while checking the stability and the response

level. (Increasing the differential time makes the differential effect larger, and decreasing the differential time makes the differential effect smaller.)

Status of measurement values Adjustment method The response is fast, but vibrations are observed.

Increase the proportional band (Pr.129). (Smaller proportional effect)

Increase the integral time (Pr.130). (Smaller integral effect)

Optimal

Response is slow.

Decrease the proportional band (Pr.129). (Larger proportional effect)

Decrease the integral time (Pr.130). (Larger integral effect)

Time

Measured value (%)

Set point (%)

Time

Measured value (%)

Set point (%)

Time

Measured value (%)

Set point (%)

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3.5.12 PID control gain setting Set the proportional band, integral time, and differential time for PID control.

Block diagram

PID control proportional band (Pr.129) If a narrow proportional band is set (small parameter setting value), the manipulated amount changes considerably by

slight changes in the dancer signal.

PID control integral time (Pr.130) Ti is the time required for integral (I) action alone to provide the same manipulated amount as is the case with proportional

(P) action. The set point is reached earlier when the integral time setting is shorter.

PID control differential time (Pr.134) Set the differential time for differential (D) action. Td is the time required to provide the same manipulated amount as is the

case with proportional (P) action. Response to changes in deviation increase greatly as the differential time increases.

Pr. Name Initial value Setting range Description

129 R110 (A613)

PID proportional band 100% 0.1 to 1000%

If a narrow proportional band is set (small parameter setting value), the manipulated amount changes considerably by slight changes in the measured value. As a result, response improves as the proportional band becomes narrower, though stability worsens as shown by the occurrence of hunting. Gain Kp=1/proportional band

9999 Without proportional band

130 R111 (A614)

PID integral time 1 s 0.1 to 3600 s

With deviation step input, this is the time (Ti) used for obtaining the same manipulated amount as proportional band (P) by only integral (I) action. Arrival to the set point becomes quicker the shorter an integral time is set, though hunting is more likely to occur.

9999 Without integral control

134 R112 (A615)

PID differential time 9999 0.01 to 10 s

With deviation ramp input, this is the time (Td) used for obtaining the manipulated amount only by proportional action (P). Response to changes in deviation increase greatly as the differential time increases.

9999 Without differential control

PID control formula: GKp (1 + 1

+ TdS) TiS

Gain Kp = 1/proportional band

Ti = Integral time

Td = Differential time

Gain G = PID gain selection function: Refer to page 104.

PID control gain selection

Tension PI gain tuning result

Gain G switching

Pr.486 to Pr.494

Pr.486 to Pr.494

Pr.486 to Pr.494

Pr.135, Pr.136

Gain G switching Clamping

Deviation

Gain G switching

Clamping

Manipulated amount

Held

Pr.485

Integral action selection

Tension PI gain tuning not performed

Tension PI gain tuning performed

Tension PI gain tuning not performed

Tension PI gain tuning performed

X100-OFF

X100-ON

X103-OFF +

+ +

X103-ON Tds

1 Tis

Kp

100% -100%

0

0

Kp

Kp

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100 DANCER FEEDBACK SPEED CONTROL

3.5.13 Integral control action setting The manipulated amount for PID integral action can be limited by setting parameters. The integral control action can be enabled or disabled (the integral term is held) according to the PID control deviation. Integral control can be disabled by the signal input. (The integral term value is cleared.)

Integral action limit (Pr.135, Pr.136) Use Pr.135 Integral clamp (positive polarity) or Pr.136 Integral clamp (negative polarity) to limit the manipulated

amount for PID integral action.

Integral control action selection (Pr.485) The integral control action can be selected according to the PID control deviation. Use Pr.486 to Pr.489 to set the deviation, and use Pr.485 Integral control activation to select the action. In the holding period, the integral of the deviation is stopped and the integral term is retained as it is. The manipulated

amount is calculated using the kept integral term value.

The integral of the deviation is valid when "9999" is set in Pr.488 or Pr.489.

Pr. Name Initial value Setting range Description

135 R161

Integral clamp (positive polarity) 9999

0 to 100% Set the limit level for integral action. 9999 The limit level is 100%.

136 R162

Integral clamp (negative polarity) 9999

0 to 100% Set the limit level for integral action (negative polarity). 9999 As set in Pr.135.

485 R149 Integral control activation 0 0 to 3 Select the action for integral control.

486 R140 Deviation A 600% 400.1 to 600%

Set the reference deviation for the integral control action set in Pr.485. 9999: Integral control is valid.

487 R141 Deviation B 400% 400 to 599.9%

488 R142 Deviation C1 9999

400.1 to 599.9% 9999

489 R143 Deviation C2 9999

400.1 to 599.9% 9999

1015 A607

Integral stop selection at limited manipulated amount 0

0 The integral stops when the manipulated amount is limited.

1 The integral does not stop when the manipulated amount is limited.

Pr.135 setting Pr.136 setting Integral action limit level (positive polarity)

Integral action limit level (negative polarity)

9999 9999 100% 100% 9999 0 to 100% 100% Pr.136 setting 0 to 100% 9999 Pr.135 setting Pr.135 setting 0 to 100% 0 to 100% Pr.135 setting Pr.136 setting

+100% 0% -100% Deviation input

Deviation C1 (Pr.488)

Deviation A (Pr.486)

Deviation C2 (Pr.489)

Deviation B (Pr.487)

Enabled

Enabled Enabled

Held Held1 HeldEnabled Enabled

Held HeldEnabled

Held1

Pr.485="0"

Pr.485="1"

Pr.485="2"

Pr.485="3"

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Integral stop selection at limited manipulated amount (Pr.1015) The operation for the integral term can be selected when the manipulated amount is limited during PID control.

Integral control action selection using input signal (X100 signal, X103 signal)

Turn ON the PID integral term reset input (X100) signal to disable the integral control. (The integral term value is cleared.) To input the X100 signal, set "100" in any of Pr.178 to Pr.189 (input terminal function selection) to assign the function. Turn ON the Integral term activation selection (X103) signal to keep the integral term value. The manipulated amount is

calculated using the kept integral term value. To input the X103 signal, set "103" in any of Pr.178 to Pr.189 (input terminal function selection) to assign the function.

NOTE Changing the terminal assignment using Pr.178 to Pr.189 (input terminal function selection) may affect the other

functions. Set parameters after confirming the function of each terminal.

3.5.14 Differential control action setting Differential control can be disabled by the signal input. (The differential term value is cleared.)

Differential control action selection using input signal (X101 signal) Turn ON the PI control switchover (X101) signal to disable the differential control. (The differential term value is cleared.) To input the X101 signal, set "101" in any of Pr.178 to Pr.189 (input terminal function selection) to assign the function.

NOTE Changing the terminal assignment using Pr.178 to Pr.189 (input terminal function selection) may affect the other

functions. Set parameters after confirming the function of each terminal.

3.5.15 PID control gain selection PID gain (proportional band, integral time, differential time) can be set individually according to the polarity of the deviation. First to fourth PID gain (proportional band, integral time, differential time) can be selected by the signal input.

Pr.1015 setting Operation at limited manipulated amount

0 (initial value) Integral stops. 1 Integral does not stop.

Pr. Name Initial value Setting range Description

464 R113

PID proportional band for values below set point 9999

0.1 to 1000% Set the proportional band for negative deviations. 9999 As set in Pr.129 also for negative deviations.

465 R114

PID integral time for values below set point 9999

0.1 to 3600 s Set the integral time for negative deviations. 9999 As set in Pr.130 also for negative deviations.

466 R115

PID differential time for values below set point 9999

0.01 to 10 s Set the differential time for negative deviations. 9999 As set in Pr.134 also for negative deviations.

467 R116

Second PID proportional band 9999

0.1 to 1000% Set the second PID proportional band. 9999 As set in Pr.129/Pr.464.

468 R117 Second PID integral time 9999

0.1 to 3600 s Set the second PID integral time. 9999 As set in Pr.130/Pr.465.

469 R118 Second PID differential time 9999

0.01 to 10 s Set the second PID differential time. 9999 As set in Pr.134/Pr.466.

470 R119

Second PID proportional band for values below set point

9999 0.1 to 1000% Set the second PID proportional band for values below

set point. 9999 As set in Pr.467.

471 R120

Second PID integral time for values below set point 9999

0.1 to 3600 s Set the second PID integral time for values below set point.

9999 As set in Pr.468.

Dancer feedback speed control details

102 DANCER FEEDBACK SPEED CONTROL

472 R121

Second PID differential time for values below set point 9999

0.01 to 10 s Set the second PID differential time for values below set point.

9999 As set in Pr.469. 473 R122 Third PID proportional band 9999

0.1 to 1000% Set the third PID proportional band. 9999 As set in Pr.129/Pr.464.

474 R123 Third PID integral time 9999

0.1 to 3600 s Set the third PID integral time. 9999 As set in Pr.130/Pr.465.

475 R124 Third PID differential time 9999

0.01 to 10 s Set the third PID differential time. 9999 As set in Pr.134/Pr.466.

476 R125

Third PID proportional band for values below set point 9999

0.1 to 1000% Set the third PID proportional band for values below set point.

9999 As set in Pr.473.

477 R126

Third PID integral time for values below set point 9999

0.1 to 3600 s Set the third PID integral time for values below set point.

9999 As set in Pr.474.

478 R127

Third PID differential time for values below set point 9999

0.01 to 10 s Set the third PID differential time for values below set point.

9999 As set in Pr.475. 479 R128 Fourth PID proportional band 9999

0.1 to 1000% Set the fourth PID proportional band. 9999 As set in Pr.129/Pr.464.

480 R129 Fourth PID integral time 9999

0.1 to 3600 s Set the fourth PID integral time. 9999 As set in Pr.130/Pr.465.

481 R130 Fourth PID differential time 9999

0.01 to 10 s Set the fourth PID differential time. 9999 As set in Pr.134/Pr.466.

482 R131

Fourth PID proportional band for values below set point 9999

0.1 to 1000% Set the fourth PID proportional band for values below set point.

9999 As set in Pr.479.

483 R132

Fourth PID integral time for values below set point 9999

0.1 to 3600 s Set the fourth PID integral time for values below set point.

9999 As set in Pr.480.

484 R133

Fourth PID differential time for values below set point 9999

0.01 to 10 s Set the fourth PID differential time for values below set point.

9999 As set in Pr.481. 486 R140 Deviation A 600% 400.1 to 600% Set the deviation used for selecting PID gain A.

487 R141 Deviation B 400% 400 to 599.9% Set the deviation used for selecting PID gain B.

488 R142 Deviation C1 9999

400.1 to 599.9% Set the deviation used for selecting PID gain C1.

9999 The PID gain is 100%.

489 R143 Deviation C2 9999

400.1 to 599.9% Set the deviation used for selecting PID gain C2.

9999 The PID gain is 100%. 490 R144 PID gain A 9999

0.1 to 1000% Set the gain for the deviation A. 9999 The PID gain is 100%.

491 R145 PID gain B 9999

0.1 to 1000% Set the gain for the deviation B. 9999 The PID gain is 100%.

492 R146 PID gain C1 9999

0.1 to 1000% Set the gain for the deviation C1. 9999 The PID gain is 100%.

493 R147 PID gain C2 9999

0.1 to 1000% Set the gain for the deviation C2. 9999 The PID gain is 100%.

494 R148 PID gain D 9999

0.1 to 1000% Set the gain for the deviation in the C1 to C2 range. 9999 The PID gain is 100%.

Pr. Name Initial value Setting range Description

Dancer feedback speed control details

DANCER FEEDBACK SPEED CONTROL 103

3

Block diagram

PID gain setting for negative deviations (values below set point) (Pr.464 to Pr.466)

PID gain can be set individually when the measured value (dancer feedback signal) has a negative deviation from the set point. When the setting is 9999, settings in Pr.129, Pr.130, and Pr.134 are applied regardless of the polarity of deviation.

Switchover to the second to fourth PID gain (Pr.464 to Pr.484, X120 signal, X121 signal)

Use the PID gain switchover (X120/X121) signal to switch the PID gain. To assign the X120 signal, set "120" in any of Pr.178 to Pr.189 (input terminal function selection). To assign the X121

signal, set "121" in any of Pr.178 to Pr.189 (input terminal function selection).

As set in Pr.129, Pr.130, or Pr.134 respectively when "9999" is set. When "9999" is set, the parameter setting for the first PID control gain (or the first PID control gain for values below set point) is applied. For

example, when Pr.468 = "9999", the PID integral time is as set in Pr.130, and the PID integral time for values below set point is as set in Pr.465. When "9999" is set, the PID control gain for positive deviations is applied. For example, when Pr.478 = "9999" and Pr.475 "9999", the Pr.475

setting is applied to the both.

Item Parameter for PID control gain

Positive deviation Negative deviation PID proportional band Pr.129 Pr.464 (Pr.129 when Pr.464 = "9999") PID integral time Pr.130 Pr.465 (Pr.130 when Pr.465 = "9999") PID differential time Pr.134 Pr.466 (Pr.134 when Pr.466 = "9999")

Signal

PID control gain

Parameter for PID control gain

X121 X120 PID proportional band / PID integral time / PID differential time

PID proportional band / PID integral time / PID differential time

(negative deviation)

OFF OFF (First) PID control gain Pr.129/Pr.130/Pr.134 Pr.464/Pr.465/Pr.466 ON Second PID control gain Pr.467/Pr.468/Pr.469 Pr.470/Pr.471/Pr.472

ON OFF Third PID control gain Pr.473/Pr.474/Pr.475 Pr.476/Pr.477/Pr.478 ON Fourth PID control gain Pr.479/Pr.480/Pr.481 Pr.482/Pr.483/Pr.484

X120-OFF X121-OFF Tension PI gain tuning

not performed

Tension PI gain tuning performed

Deviation < 0

Deviation 0

X121-OFF

X121-ON

X121-ON

X120-ON X120-OFF

X120-ON X120-OFF

X120-ON X120-OFF

X120-ON

First PID control gain Pr.129, Pr.130, Pr.134

Second PID control gain Pr.467 to Pr.469

Third PID control gain Pr.473 to Pr.475

Fourth PID control gain Pr.479 to Pr.481

First PID control gain Pr.464 to Pr.466

Second PID control gain Pr.470 to Pr.472

Third PID control gain Pr.476 to Pr.478

Fourth PID control gain Pr.482 to Pr.484 Tension PI gain

tuning result Pr.129, Pr.130

PID control gain

Dancer feedback speed control details

104 DANCER FEEDBACK SPEED CONTROL

Gain switchover according to the PID deviation (Pr.486 to Pr.494) Gain can be switched according to the amount of the deviation from the set point included in the measured value (dancer

feedback signal). Value G in the PID control formula can be changed according to the deviation of the PID control input.

When "9999" is set in Pr.490 to Pr.494, the gain is 100%. To use the gain switchover function, set a value other than "9999" in both Pr.488 and Pr.489. If "9999" is set in either or

both of the parameters, "9999" is applied to all gains (A to D). Set Pr.486 to Pr.489 so that A>C1C2>B is true. Otherwise, a write error occurs. When C1 = C2, larger gain between gain

C1 and C2 becomes valid.

3.5.16 PID manipulated amount

PID control formula: GKp (1 + 1

+ TdS) TiS

Gain Kp = 1/proportional band

Ti = Integral time

Td = Differential time

Gain G = PID gain selection function

Pr. Name Initial value Setting range Description 1134 A605

PID upper limit manipulated value 100% 0 to 100% Set the upper limit of PID action.

1135 A606

PID lower limit manipulated value 100% 0 to 100% Set the lower limit of PID action.

1148 R105

PID manipulated line speed bias 0 m/min 0 to 6553.4 m/min Convert the PID manipulated amount to a frequency

value (Hz) or a line speed (m/min). 9999: No function1149

R106 PID manipulated line speed gain 9999 0 to 6553.4 m/min,

9999

+100% 0% -100% Deviation input

Deviation C1 (Pr.488)

Deviation A (Pr.486)

Deviation C2 (Pr.489)

Deviation B (Pr.487)

Gain A (Pr.490) Gain B (Pr.491)

Gain C1 (Pr.492)

Gain G

Gain C2 (Pr.493)

Gain D (Pr.494)

Dancer feedback speed control details

DANCER FEEDBACK SPEED CONTROL 105

3

Setting the upper and lower limits of the PID manipulated amount Set the upper and lower limits of the PID manipulated amount. The upper limit of the manipulated amount is the frequency obtained by adding the value resulting from the frequency

conversion by Pr.1134 to the line speed frequency. The lower limit of the manipulated amount is the frequency obtained by subtracting the value resulting from the frequency conversion by Pr.1135 from the line speed frequency.

Converting the PID manipulated amount to values in different units (Pr.1148, Pr.1149)

The PID manipulated amount (%) can be converted to values in different units (Hz or m/min). When Pr.1149 = "9999 (initial value)", the amount is converted as shown in the following diagram.

When Pr.1149 = "9999", the amount is converted as shown in the following diagram.

Line speed

Upper limit of PID manipulated amount (Pr.1134)

Lower limit of PID manipulated amount (Pr.1135)

Output frequency considering upper/lower limit of PID manipulated amount

Output frequency

Time

Output frequency (Hz)

C2 (Pr.902)

Pr.125 (Pr.903)

PID manipulated amount (%)1000

Line speed (m/min)

Pr.1149

Pr.1148

PID manipulated amount (%)1000

Dancer feedback speed control details

106 DANCER FEEDBACK SPEED CONTROL

3.5.17 Reel change function Before starting control with a standby shaft, the line speed command can be fit to the target line speed. Also, a speed bias can be set.

The increment varies depending on the Pr.358 setting. (Refer to page 67.)

Reel change function setting The reel change function is activated when the following conditions are satisfied.

- Dancer feedback speed control valid - When Pr.361 Line speed command input selection "9999" - The Reel change (X104) signal is ON.

Turning ON of the Reel change (X104) signal enables the reel change function. To input the X104 signal, set "104" in any of Pr.178 to Pr.189 (input terminal function selection) to assign the function.

Line speed bias for reel change (Pr.620) When the reel change function is valid (the X104 signal is ON), a speed bias can be set with Pr.620 Line speed bias for

reel change. The reel change speed bias can be set as an offset from 1000 m/min.

Use Pr.358 Line speed unit to change the unit. When the commanded line speed reaches the target line speed after the cushion time while the reel change function is

activated, the Reel change ready (Y236) signal is output. For the Y236 signal, set "236 (positive logic) or 336 (negative logic)" in one of Pr.190 to Pr.196 (output terminal function

selection) to assign the function to the output terminal.

NOTE The target line speed command is limited in the range of 0 to Pr.1147 (maximum value for the line speed command) after the

reel change line speed bias is added. The reel change speed bias is added after the analog input compensation. When the reel change function is invalid (the X104 signal is OFF), the target line speed command value (after reel change

speed bias is added) and the line speed command value after the cushion time are fit to the target line speed command value before reel change speed bias is added.

Pr. Name Initial value Setting range Description 620 R570

Line speed bias for reel change 1000 m/min 0 to 2000 m/min Reel change line speed bias can be set for the target

line speed.

621 R423

Allowable deviation from target line speed 0 m/min 0 to 6553.4 m/min The Y236 signal output range can be set for the target

line speed command.

Pr.620 setting Speed bias for reel change 2000 m/min 1000 m/min 1000 m/min 0 m/min 0 m/min -1000 m/min

Dancer feedback speed control details

DANCER FEEDBACK SPEED CONTROL 107

3

Allowable deviation from target line speed (Pr.621) An allowable deviation range can be set to the Y236 output condition.

NOTE The sum of the target line speed command and Pr.621 values is limited at the value set in Pr.1147 Line speed command

maximum value.

Overview of the reel change operation

While the reel change function is activated, PID control and winding diameter calculation are disabled.

Function Condition during reel change PID control Disabled (P, I, and D term values are cleared) Winding diameter calculation Disabled (winding diameter is held)

Target line speed command setting

Line speed command (after cushioning)

Line speed (m/min)

Y236

Pr.621

Pr.621

ON

Time

Start command

Y236

Line speed

X104 ON

ON

ON

Time

Line speed command (after cushioning)

Target line speed command setting Pr.620

PID control Invalid Valid

Winding diameter calculation Invalid (winding diameter is held) Valid

Fit to the originally set target line speed

Dancer feedback speed control details

108 DANCER FEEDBACK SPEED CONTROL

3.5.18 Analog output signal function for dancer tension setting

The dancer tension command can be used for controlling the dancer roll using an air cylinder. The dancer tension command can be output through terminal FM/CA or terminal AM. The dancer tension setting can be input by setting parameters or through an analog input terminal. By setting the dancer tension, taper ratio, and winding diameter at taper start, the analog output signal for dancer tension control can be calculated based on the winding diameter determined by winding diameter calculation.

Pr. Name Initial value Setting range Description

74 T002 Input filter time constant 1 0 to 8

The primary delay filter time constant to the analog input is selectable. A larger setting results in slower response.

364 R411

Dancer tension setting input selection / taper function enable/disable selection for tension sensor feedback speed control 1

9999

3 The tension setting is input through terminal 2. 4 The tension setting is input through terminal 4. 5 The tension setting is input through terminal 1.

6 The tension setting is input through terminal 6 (FR- A8AZ).

9999 No function 426 R412 Dancer tension setting bias 0% 0 to 200% Set the bias tension.

427 R413 Dancer tension setting gain 100% 0 to 200% Set the gain tension.

430 R410

Dancer tension setting / taper function enable/disable selection for tension sensor feedback speed control 2

100

1 to 100 Set the maximum value for dancer tension setting.

9999 Tension setting through analog input terminal

826 T004 Torque setting filter 1 9999

0 to 5 s Set the primary delay filter time constant to the analog input.

9999 As set in Pr.74.

836 T006 Torque setting filter 2 9999

0 to 5 s Second function of Pr.826 (enabled when the RT signal is ON)

9999 As set in Pr.826 or Pr.74.

1284 R500 Taper mode selection 0

0 No taper 1 Linear taper profile 2 Hyperbolic taper profile 1 3 Hyperbolic taper profile 2 4 Data table profile

1285 R501

Taper setting analog input selection 9999

3 The taper ratio is input through terminal 2. 4 The taper ratio is input through terminal 4. 5 The taper ratio is input through terminal 1. 6 The taper ratio is input through terminal 6 (FR-A8AZ). 9999 No function

1286 R503

Winding diameter at taper start 9999

0 to 6553 mm Set the winding diameter to start taper control.

9999 Taper control is started at the minimum winding diameter.

1287 R502 Taper ratio setting 0

0 to 100% Set the taper ratio. 9999 The taper ratio is set through the analog input terminal.

Dancer feedback speed control details

DANCER FEEDBACK SPEED CONTROL 109

3

Block diagram

Connection diagram

Terminal 6 is equipped to the plug-in option FR-A8AZ.

1288 R510 Data table winding diameter 1 9999 0 to 6553 mm,

9999

Set the data table profile for the taper mode selection.

1289 R511 Data table taper ratio 1 0% 0 to 100%

1290 R512 Data table winding diameter 2 9999 0 to 6553 mm,

9999

1291 R513 Data table taper ratio 2 0% 0 to 100%

1292 R514 Data table winding diameter 3 9999 0 to 6553 mm,

9999

1293 R515 Data table taper ratio 3 0% 0 to 100%

1294 R516 Data table winding diameter 4 9999 0 to 6553 mm,

9999

1295 R517 Data table taper ratio 4 0% 0 to 100%

1296 R518 Data table winding diameter 5 9999 0 to 6553 mm,

9999

1297 R519 Data table taper ratio 5 0% 0 to 100%

Pr. Name Initial value Setting range Description

Dancer tension setting Pr.430

Analog terminal input Pr.364

Pr.430=9999

Pr.430=9999 Pr.426

Pr.427

Dancer tension setting (%)

Dancer tension setting (after calibration) (%)

0% 100%

Taper control Analog output signal for dancer tension control

Taper ratio setting Pr.1287

Analog terminal input Pr.1285

Pr.1287=9999

Pr.1287=9999

Dancer tension setting Taper functionDancer tension setting calibration

Clamping

FR-A800-R2R 2 (0 to 10 V)

Line speed command

1 (10 V) Dancer signal

10E Tension setting

AM

5

Taper ratio setting

1 W 2 k

1 W 2 k

Electro-pneumatic converter4

5

6 1 FR-A8AZ

Input with the potentiometer

Pr.1285="4" Pr.1287="9999" Pr.158="19"

Dancer feedback speed control details

110 DANCER FEEDBACK SPEED CONTROL

Tension command output setting For outputting the tension command, assign the dancer tension command to terminal FM/CA or terminal AM.

Use C0 (Pr.900) for terminal FM/CA calibration and use C1 (Pr.901) for terminal AM calibration. The dancer tension command is dependent on the winding diameter. Set Pr.645 Winding diameter storage selection =

"1" to enable the winding diameter storage function.

NOTE When the X114 signal is turned OFF while Pr.645 = "0" (winding diameter storage function disabled), the winding diameter is

initialized, which may cause a sudden change in the analog signal output for dancer tension control. The dancer tension command and the dancer tension command 2 are clamped at 100%.

Dancer tension setting input selection (Pr.364, Pr.430) Use Pr.364 Dancer tension setting input selection / taper function enable/disable selection for tension sensor

feedback speed control 1 or Pr.430 Dancer tension setting / taper function enable/disable selection for tension sensor feedback speed control 2 to set the dancer tension setting input method.

The input specification in the initial setting is indicated. The dancer tension command is 0%.

NOTE If two or more functions are assigned to one terminal, the priorities of the functions are defined as follows.

Dancer signal input (Pr.363) > Actual line speed input (Pr.362) > Tension command input (Pr.804) > Line speed command input (Pr.3610) > Taper setting input (Pr.1285) > Dancer tension setting input (Pr.364) > Line speed command compensation input > Line speed command input (Pr.361=0)

Dancer tension setting input adjustment (Pr.74, Pr.822, Pr.833, Pr.902 to Pr.905, Pr.917, Pr.918, Pr.926, Pr.927)

When analog input is used for setting the dancer tension, use the following parameters to calibrate the input value of each terminal. The tension setting analog input values at both 0% and 100% can be calibrated.

The input specification in the initial setting is indicated.

Signal type Minimum increment

Pr.54 (FM/CA) Pr.158 (AM) setting

Terminal FM/CA/AM full-scale value Remarks

Dancer tension command 1% 19 100% Output even while dancer feedback speed control is invalid

Dancer tension command 2 1% 30 100% Zero output while dancer feedback speed control is invalid

Pr.430 setting Pr.364 setting Dancer tension setting method 1 to 100% As set in Pr.430

9999

3 Terminal 2 (analog value: 0 to 100%) (0 to 5 VDC) 4 Terminal 4 (analog value: 20 to 100%) (4 to 20 mADC) 5 Terminal 1 (analog value: -100 to 100%) (0 to 10 VDC) 6 Terminal 6 (FR-A8AZ) (analog value: -100 to 100%) (0 to 10 VDC) 9999 No function

Input terminal Calibration parameter Terminal 2 (analog value: 0 to 100%) (0 to 5 VDC) C3 (Pr.902), C4 (Pr.903) Terminal 4 (analog value: 20 to 100%) (4 to 20 mADC) C6 (Pr.904), C7 (Pr.905) Terminal 1 (analog value: -100 to 100%) (0 to 10 VDC) C13 (Pr.917), C15 (Pr.918) Terminal 6 (FR-A8AZ) (analog value: -100 to 100%) (0 to 10 VDC) C31 (Pr.926), C33 (Pr.927)

Dancer tension setting (%)

100

0 C3 (Pr.902) C6 (Pr.904) C13 (Pr.917) C31 (Pr.926)

Analog input value 10 V C4 (Pr.903) C7 (Pr.905) C15 (Pr.918) C33 (Pr.927)

-10 V

Dancer feedback speed control details

DANCER FEEDBACK SPEED CONTROL 111

3

When the dancer tension setting is input using analog input, the input value can be filtered using Pr.74 Input filter time constant, Pr.826 Torque setting filter 1, and Pr.836 Torque setting filter 2.

NOTE The dancer tension setting input is clamped at 100%.

Dancer tension setting adjustment (Pr.426, Pr.427) Use Pr.426 Dancer tension setting / taper function enable/disable selection for tension sensor feedback speed

control 2 and Pr.427 Dancer tension setting input selection / taper function enable/disable selection for tension sensor feedback speed control 1 to calibrate the dancer tension setting (Pr.430 Dancer tension setting bias setting or input value through terminal set in Pr.364 Dancer tension setting gain).

Use Pr.426 to set the value when the dancer tension setting is 0%, and use Pr.427 to set the value when the dancer tension setting is 100%.

Taper function (Pr.1284 to Pr.1297) By setting the dancer tension, taper ratio, and winding diameter at taper start, the analog output signal for dancer tension

control can be calculated based on the winding diameter determined by winding diameter calculation. The following example shows the relation between the winding diameter and analog output signal for dancer tension

control when Pr.1284 Taper mode selection = "1" (taper mode selection: linear taper profile)

For the details of the operation using taper function, refer to the description of taper function for tension sensorless torque control. (Refer to page 151.) The differences from the taper function for tension sensorless torque control are as follows.

Function Input Output Taper function for analog output signal for dancer tension control

Dancer tension setting (Pr.430, or analog input according to Pr.364) Analog output signal for dancer tension control

Taper function for tension sensorless torque control / tension sensor feedback torque control

Tension command (Tension command according to Pr.804) Taper control tension command FTP

Taper function for the PID action set point (tension command percentage)

PID action set point (tension command percentage)

PID action set point after taper control (tension command percentage)

100%0%

Pr.426 (Dancer tension setting bias)

Pr.427 (Dancer tension setting gain)

Pr.430 setting or analog input

Dancer tension setting (%)

For dancer tension control Analog output signal (%)

Winding diameter Pr.1286

(Winding diameter at taper start)

Minimum winding diameter

Maximum winding diameter

Dancer tension setting for taper control

Taper ratio setting

Taper ratio setting (Pr.1287 or analog terminal input)

Taper ratio = 100%

Dancer tension setting (after calibration)

Dancer feedback speed control details

112 DANCER FEEDBACK SPEED CONTROL

Dancer tension setting example This example assumes an air cylinder for which the dancer tension is 0 N when the input voltage is 0 V, and the dancer tension is 20 N when the input voltage is 10 V. In the example, the setting method is described to input the analog output signal for dancer tension control to the air cylinder so that the dancer tension becomes 10 N when the winding diameter has the minimum value.

1 Checking the air cylinder specifications Check the air cylinder specifications (relation between the input voltage and the tension). It is assumed that the dancer tension is 0 N when the input voltage is 0 V, and the dancer tension is 20 N when the input voltage is 10 V for the air cylinder in this example.

2 Finding the voltage based on the target tension setting When the target tension value is 10 N, the input voltage is 5 V.

3 Finding the analog output signal value for dancer tension control In order to output the voltage of 5 V through terminal AM to achieve the target tension, set the analog output signal for dancer tension control to 50%. Assign the analog output signal for dancer tension control to terminal AM. (Pr.158="19")

4 Setting the tension Set the tension so that the value calibrated using Pr.426 Dancer tension setting bias and Pr.427 Dancer tension setting gain matches the value determined in step 3. When the Pr.426 and Pr.427 settings are initial values, set Pr.430 or input an analog value through the terminal set in Pr.364 so that the tension setting becomes 50%.

10 V

20 N

0 N

Tension (N)

Voltage (V) 0 V 5 V

10 N

Air cylinder specification

100%

10 V

0 V

Terminal AM voltage (V)

Analog output signal for dancer tension control (%)0% 50%

5 V

Analog output signal for dancer tension control

Dedicated function list

TENSION SENSOR FEEDBACK SPEED CONTROL 113

4

4 TENSION SENSOR FEEDBACK SPEED CONTROL

Tension sensor feedback speed control is a control function to keep the tension constant using feedback from the tension sensor, instead of the dancer roll position.

4.1 Dedicated function list

Item Description

Tension sensor feedback speed control

Control method PID control, PI control, P control, and PD control can be selected. Gain switchover by tension feedback is available. Gain switchover by external terminal input is available.

Tension command Set a point with a parameter. Tension detection signal Use an analog terminal for the signal input. (Terminal 1, 2, 4, or 6 is selectable.) Line speed acceleration/deceleration function Available Three patterns are selectable with external contact signal.

Additional function Material break detection function

Winding diameter compensation

Constant line speed control Available

Winding diameter calculation Calculation based on the line speed detection and the motor rotation speed and calculation based on the material thickness and the number of motor rotations are selectable.

Actual line speed detection Pulse train input (A/B phase, single phase) and analog input are selectable. Reduction ratio setting Available Maximum/minimum winding diameter setting Available. (Four patterns are selectable with external signal.)

Speed control proportional gain compensation function

Available. (Straight movement (with three break points) against the winding diameter can be performed.)

Winding diameter storage Available

Common

Dedicated input signal

Dancer/tension control selection, Winding diameter compensation selection, PID gain switchover, PID integral term reset (P control selection), Line speed acceleration/deceleration selection, Winding diameter selection, Stored winding diameter clear, Winding/unwinding selection

Dedicated output signal Upper limit, Lower limit, Tension feedback detection, Break detection, Initial winding diameter calculation completion, Target winding diameter achieved, Winding/unwinding completion

Dedicated monitor Set point, measured value, deviation, line speed command, winding diameter, actual line speed, compensation speed, winding length.

System configuration example

114 TENSION SENSOR FEEDBACK SPEED CONTROL

4.2 System configuration example

FR-A800-R2R

For winding roller (Pr.1230 = 0)

Encoder

Line speed command

Tension sensor

Tension feedback

Minimum diameter

Maximum diameter

AM

2 (Pr.361 = 3) 1 (Pr.363 = 5)

STF/STR Start signal

Dancer/tension control selection X114 (Pr.180 = 114)

FR-A8AP

Encoder

Line speed command

FR-A800-R2R

FR-A8AP

M

M

X117 (Pr.182 = 117)Winding length clear X109 (Pr.181 = 109)Stored winding diameter clear

2

Line speed command

STF/STR Start signal

Dancer/tension control selection X114

Control block diagram

TENSION SENSOR FEEDBACK SPEED CONTROL 115

4

4.3 Control block diagram

Pr.363 = 9999

Actual line speed

Line speed command

Frequency setting

Winding diameter compensation

speed generation Conversion from line speed to frequency

Winding diameter compensation speed

Winding diameter

Motor speed

+

-

PID operation Pr.129, Pr.130,

Pr.134

X116-OFF

X116-ON

X109-OFF

X109-ON

X115-OFF

X115-ON Held

Winding diameter clear

00 +

+

Speed control proportional gain compensation Pr.639 to Pr.644

Speed control

Acceleration /deceleration Pr.7, Pr.8 = 0

M

Encoder

Pr.128 = 40, 41 X114-ON

X114-OFF

Pr.128 = 0

Dancer signal / tension feedback

input selection Pr.363

Line speed command selection

Pr.361

Actual line speed input selection

Pr.362

Winding diameter calculation

Pr.1235, Pr.1236, Pr.1243, Pr.1244

Line speed command Acceleration /deceleration

Pr.394, Pr.395

Tension feedback

Pr.363 = 9999

Line speed command Winding diameter compensation speed =

Winding diameter Gear ratio

PID action set point (Pr.133)

PID set point cushion time

Pr.363

+

Pr.364 = 9999 and

Pr.430 = 9999

Pr.364 9999 or

Pr.430 9999

+

Dancer tension setting

Pr.364, Pr.426, Pr.427, Pr.430

Analog signal for dancer tension control

Taper function Pr.1284 to Pr.1297

Pr.1236

Taper function Pr.1284 to Pr.1297

Pr.1236

Pr.1284 0

Pr.1284 0

+

After clearing, the value becomes the minimum winding diameter when Pr.1230 = "0" (winding), and the maximum winding diameter when Pr.1230 = "1" (unwinding).

The frequency command cannot be input using the terminal selected as the line speed command input terminal in Pr.361 Line speed command input selection. (For example, to input a frequency command while Pr.361 = "3", input the command from a terminal other than terminal 2.) Set "0" in Pr.361 to use the same terminal to input a line speed command and a frequency command. In this case, the bias and gain parameter settings must be consistent for both command types. Calibration parameters for frequency command input: Pr.125, Pr.126, C2 (Pr.902) to C7 (Pr.905), C12 (Pr.917) to C15 (Pr.918) Calibration parameters for line speed command input: Pr.350 to Pr.353

Parameter setting procedure for tension sensor feedback speed control

116 TENSION SENSOR FEEDBACK SPEED CONTROL

4.4 Parameter setting procedure for tension sensor feedback speed control

The following procedure shows the parameter setting example for the tension sensor feedback speed control.

4.4.1 Parameter setting procedure 1 Wiring

Perform secure wiring.

NOTE Do not feed the workpiece through the machine.

2 Control method selection Select the control method according to the application and the motor.

For the control method, vector control is recommended. Setting is required for a motor other than a Mitsubishi Electric motor (the SF-PR, SF-JR, SF-HR, SF-JRCA, SF-HRCA, or SF-V5RU (1500 r/min

series) motor). For the FR-A820-03160(55K) or lower and FR-A840-01800(55K) or lower. For the FR-A820-03800(75K) or higher and FR-A840-02160(75K) or higher.

NOTE Select Vector control for regenerative driving in a low-speed range (about 10 Hz or lower). For the parameter details, refer to the FR-A800 Instruction Manual (Detailed).

3 Offline auto tuning Perform offline auto tuning as required. For offline auto tuning, refer to page 55.

After the offline auto tuning, perform the test run of the motor alone to make sure that no fault is found in the motor's behavior.

4 Speed control gain adjustment Adjust the speed control gain. Refer to page 59 for the speed control gain adjustment.

Pr. Name Setting range Minimum setting

increments Initial value

71 Applied motor 0, 1, 3 to 6, 13 to 16, 20, 23, 24, 30, 33, 34, 40, 43, 44, 50, 53, 54, 70, 73, 74 1 0

9 Electronic thermal O/L relay 0 to 500 A 0.01 A Inverter rated

current0 to 3600 A 0.1 A

80 Motor capacity 0.4 to 55 kW, 9999 0.01 kW

9999 0 to 3600 kW, 9999 0.1 kW

81 Number of motor poles 2, 4, 6, 8, 10, 12, 9999 1 9999

83 Rated motor voltage 0 to 1000 V 0.1 V

200 V (200 V class) 400 V (400 V class)

84 Rated motor frequency 10 to 400 Hz, 9999 0.01 Hz 9999 800 Control method selection 0 to 2, 9 to 12, 20, 100 to 102, 109 to 112 1 20 810 Torque limit input method selection 0 to 2 1 0 359 Encoder rotation direction 0, 1, 100, 101 1 1 369 Number of encoder pulses 0 to 4096 1 1024 707 Motor inertia (integer) 10 to 999, 9999 1 9999 724 Motor inertia (exponent) 0 to 7, 9999 1 9999 862 Encoder option selection 0, 1 1 0

Pr. Name Setting range

Minimum setting

increments

Initial value

96 Auto tuning setting/status 0, 1, 11, 101 1 0

Parameter setting procedure for tension sensor feedback speed control

TENSION SENSOR FEEDBACK SPEED CONTROL 117

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5 Mechanical specifications setting Set the following parameters according to the specifications of the machine used. Refer to 11.6 (Application examples) on page 243.

Set the parameter according to the specification of the machine used. The increment applies when Pr.21 = "0 (initial value)". The increment applies when Pr.358 = "0 (initial value)".

Pr. Name Setting Intermediate shaft

Winding/ unwinding

shaft Remarks

1235 Maximum winding diameter 1 For the intermediate shaft, set the

roller (reel) diameter in millimeters (1 to 6553 mm) for both Pr.1235 and Pr.1236.1236 Minimum winding diameter

1

178 to 189

Input terminal function selection

114 Set "114" for the X114 signal.

109 Set "109" to use the Stored winding diameter clear (X109) signal.

117 Set "117" to use the Winding length clear (X117) signal.

1230 Winding/unwinding selection 0: Winding shaft 1: Unwinding shaft

645 Winding diameter storage selection

0: Not stored. 1: The present roll diameter is stored.

1247 Winding diameter change increment amount limit

Set the maximum change in 0.001 mm increments (0 to 9.998 mm or 9999) per roll diameter calculation.

1243 Gear ratio numerator Set a gear ratio in 1 increments (1 to 65534) when the motor shaft has a reduction gear.1244 Gear ratio denominator

7 Acceleration time 0 s 0 to 3600 seconds, in 0.1 second increments8 Deceleration time 0 s

394 First acceleration time for line speed command

Setting is required in 0.1 second increments (0 to 3600 seconds) when the cushion time is not considered for the line speed command.

395 First deceleration time for line speed command

101 Second deceleration time for line speed command

Set the time in 0.1 second increments (0 to 3600 seconds) as required (for example, for rapid deceleration). Turn ON the X105 signal to enable the setting.

393 Line speed command acceleration/deceleration reference

Set the reference line speed (travel amount per minute) in 0.1 m/min increments (1 to 6553.4 m/min) for the acceleration/deceleration time for the line speed command.

1141 Line speed command acceleration/deceleration pattern

Set S-curve acceleration/deceleration to reduce shock during line speed acceleration/deceleration operation. (Refer to page 82.)

1142 Line speed command acceleration start S-curve time

1143 Line speed command acceleration completion S- curve time

1144 Line speed command deceleration start S-curve time

1145 Line speed command deceleration completion S- curve time

1231 Material thickness d1

Setting is required in 0.001 mm increments (0 to 20 mm or 9999) when thickness is used for winding diameter calculation.

Parameter setting procedure for tension sensor feedback speed control

118 TENSION SENSOR FEEDBACK SPEED CONTROL

6 Tension feedback setting Set the following parameters according to the tension feedback input method when the tension sensor is used.

The input specification in the initial setting is indicated. (Refer to page 47.)

The following table shows a setting example.

Pr. Name Setting Input method

363 Dancer / tension sensor feedback input selection

3 Terminal 2 (analog value: 0 to 100%) (0 to 5 VDC) 4 Terminal 4 (analog value: 20 to 100%) (4 to 20 mADC) 5 Terminal 1 (analog value: -100 to 100%) (0 to 10 VDC)

6 Terminal 6 (FR-A8AZ) (analog value: -100 to 100%) (0 to 10 VDC)

9 CC-Link or CC-Link IE Field Network Basic (-100 to 100%) 9999 (initial value) No function

Item Setting example

Tension feedback input method

Setting by analog voltage (0 to 10 V) input through terminal 1 (Pr.363 = "5")

Parameter setting C13 (Pr.917) Terminal 1 bias (speed) = 0% C15 (Pr.918) Terminal 1 gain (speed) = 100%

100%

0 V C13(Pr.917) (0%)

Analog input value10 V C15(Pr.918) (100%)

Tension feedback

Parameter setting procedure for tension sensor feedback speed control

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7 Line speed command input setting Set Pr.361 according to the line speed command value input method.

To perform Vector control, install the Vector control compatible option. The input specification in the initial setting is indicated. (Refer to page 47.) The frequency command cannot be input using the terminal selected as the line speed command input terminal in Pr.361 Line speed

command input selection. (For example, to input a frequency command while Pr.361 = "3", input the command from a terminal other than terminal 2.) Set "0" in Pr.361 to use the same terminal to input a line speed command and a frequency command. In this case, the bias and gain parameter settings must be consistent for both command types. Calibration parameters for frequency command input: Pr.125, Pr.126, C2 (Pr.902) to C7 (Pr.905), C12 (Pr.917) to C15 (Pr.918) Calibration parameters for line speed command input: Pr.350 to Pr.353

To feed paper or wire, turn ON all X114, X115, and X116 signals and disable winding diameter compensation and PID compensation so that the line speed command for tension control (dancer feedback speed control / tension sensor feedback speed control) is used for the feed operation.

The following table shows setting examples.

Set the pulse division scaling factor in Pr.384 for pulse train input through terminal JOG. Number of pulses calculated internally = Number of input pulses / Pr.384 setting value When inputting 50k pulses/s while Pr.351 = 0 m/min, Pr.353 = 100 m/min, Pr.354 = 0 pulses/s, Pr.355 = 50k pulses/s, and Pr.384 = "2", the line speed will be 50 m/min.

Pr. Name Setting Input method

361 Line speed command input selection

0 According to the priority of the speed command sources. (Refer to page 70)

1 Terminal JOG single-phase pulse train input (Refer to page 71)

2 FR-A8AP/FR-A8AL/FR-A8TP encoder pulse train input (complementary 12 V / differential 5 V (A-, B-phases)) (Refer to page 71)

3 Terminal 2 (analog value: 0 to 100%) (0 to 5 VDC) (Refer to page 73)

4 Terminal 4 (analog value: 20 to 100%) (4 to 20 mADC) (Refer to page 73)

5 Terminal 1 (analog value: -100 to 100%) (0 to 10 VDC) (Refer to page 73)

6 Terminal 6 (FR-A8AZ) (analog value: -100 to 100%) (0 to 10 VDC) (Refer to page 73)

7 FR-A8AL single-phase pulse train input (PP, NP) (Refer to page 71)

8 Line speed command according to the Pr.360 setting (Refer to page 73)

10 Inverter-to-inverter link function (Available only for the FR- A800-E-R2R. For details, refer to the Ethernet Function Manual.)

9999 (initial value) No function

Item Setting example 1 Setting example 2

Line speed command input method

Setting by analog voltage (0 to 5 V) input through terminal 2 (Pr.361 = "3")

Setting by pulse train input through terminal JOG (Pr.361 = "1")

Parameter setting

Pr.350 Line speed command voltage/current bias = 0% Pr.351 Line speed command bias = 0 m/min Pr.352 Line speed command voltage/current gain = 100% Pr.353 Line speed command gain = Maximum line speed

Pr.384 Input pulse division scaling factor = "1" Pr.351 Line speed command bias = 0 m/min Pr.354 Line speed command pulse input bias = "0" Pr.353 Line speed command gain = Maximum line speed Pr.355 Line speed command pulse input gain = Maximum number of pulses

Pr.353 (Maximum line speed)

Pr.351 (0 m/min)

0 V Pr.350 (0%)

Analog input value

5 V Pr.352 (100%)

Line speed command value

Pr.353 (Maximum line speed)

6553.4

Pr.351 (0 m/min)

Pr.354 (0 pulses/s)

Number of input pulses

Pr.355 (Maximum number of pulses)

Line speed command value

Parameter setting procedure for tension sensor feedback speed control

120 TENSION SENSOR FEEDBACK SPEED CONTROL

8 Actual line speed input setting Set Pr.362 according to the line speed command value input method for calculating the winding diameter (actual line speed method). (Setting is not required for the intermediate shaft.)

To perform Vector control, install the Vector control compatible option. The input specification in the initial setting is indicated. (Refer to page 47.)

The following table shows setting examples.

Set the pulse division scaling factor in Pr.384 for pulse train input through terminal JOG. Number of pulses calculated internally = Number of input pulses / Pr.384 setting value When inputting 50k pulses/s while Pr.281 = 0 m/min, Pr.279 = 100 m/min, Pr.282 = 0 pulses/s, Pr.283 = 50k pulses/s, and Pr.384 = "2", the actual line speed will be 50 m/min.

Pr. Name Setting Input method

362 Actual line speed input selection

0 (initial value) V* (line speed command) 1 Terminal JOG single-phase pulse train input (Refer to page 200)

2 FR-A8AP/FR-A8AL/FR-A8TP encoder pulse train input (complementary 12 V / differential 5 V (A-, B-phases)) (Refer to page 200)

3 Terminal 2 (analog value: 0 to 100%) (0 to 5 VDC) (Refer to page 202)

4 Terminal 4 (analog value: 20 to 100%) (4 to 20 mADC) (Refer to page 202)

5 Terminal 1 (analog value: -100 to 100%) (0 to 10 VDC) (Refer to page 202)

6 Terminal 6 (FR-A8AZ) (analog value: -100 to 100%) (0 to 10 VDC) (Refer to page 202)

7 FR-A8AL single-phase pulse train input (PP, NP) (Refer to page 200)

9 CC-Link or CC-Link IE Field Network Basic (0 to 65534) 9999 No function

Item Setting example 1 Setting example 2

Actual line speed input method

Setting by analog current (4 to 20 mA) input through terminal 4 (Pr.362 = "4")

Setting by pulse train input through terminal JOG (Pr.362 = "1")

Parameter setting

Pr.280 Actual line speed voltage/current bias = 20% Pr.281 Actual line speed bias = 0 m/min Pr.278 Actual line speed voltage/current gain = 100% Pr.279 Actual line speed gain = Maximum line speed

Pr.384 Input pulse division scaling factor = "1" Pr.281 Actual line speed bias = 0 m/min Pr.282 Actual line speed pulse input bias = 0 pulses/s Pr.279 Actual line speed gain = Maximum line speed Pr.283 Actual line speed pulse input gain = Maximum number of pulses

Pr.279 (Maximum line speed)

Pr.281 (0 m/min)

4 mA Pr.280 (20%) Analog input value

20 mA Pr.278 (100%)

Actual line speed

Pr.279 (Maximum line speed)

6553.4

Pr.281 (0 m/min)

Pr.282 (0 pulses/s)

Number of input pulses

Pr.283 (Maximum number of pulses)

Actual line speed

Parameter setting procedure for tension sensor feedback speed control

TENSION SENSOR FEEDBACK SPEED CONTROL 121

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9 PID control action setting Set the following parameters for PID control.

Set the parameter according to the specification of the machine used.

The following table shows a setting example.

NOTE The setting unit for manipulated amount of PID control is initially set to Hz (frequency). To change the unit to m/min (line

speed), set the amount using Pr.1148 and Pr.1149. (Refer to page 104.)

10 PID control action check (example) Apply tension force corresponding to the tension command to the tension sensor. Input a line speed command of 0 m/min. Input the X114 signal and start command. Start the motor without feeding the workpiece. Change the tension during motor operation, and check that the following motor speed conditions. If any inconsistency is found, check the Pr.128 setting.

11 PID control gain adjustment Feed the workpiece through the system and adjust the tension PI gain. Refer to page 122 for the tension PI gain adjustment.

12 Test run Operate the system starting from the maximum-diameter roll to the minimum-diameter roll and vice versa and check that no fault is found in the system behavior.

Pr. Name Setting Remarks

128 PID action selection 40 or 41 40: Tension sensor feedback speed control (reverse action) 41: Tension sensor feedback speed control (forward action)

131 PID upper limit Set the value in 0.1% increments (400 to 600% or 9999) for outputting the PID upper limit (FUP) signal.

132 PID lower limit Set the value in 0.1% increments (400 to 600% or 9999) for outputting the PID lower limit (FDN) signal.

133 PID action set point Set the tension command value in 0.01% increments (400 to 600%).

1382 PID set point cushion time Set the cushion time for the PID set point. (Refer to page 85.) 1284 Taper mode selection Set the taper function for the PID set point. (Refer to page 124.)

Item Setting example Tension command setting method Setting the tension command directly

Parameter setting

Perform calculation to convert the output voltage sent from the tension sensor when an intended tension command is applied. Convert the output voltage of the tension sensor to a percentage. Here 5 V corresponds to 100%. Set the output voltage value (in %) plus 500% in Pr.133.

Winding/unwinding Tension feedback Motor speed

Winding Tension feedback Tension command Deceleration Tension feedback < Tension command Acceleration

Unwinding Tension feedback Tension command Acceleration Tension feedback < Tension command Deceleration

Parameter setting procedure for tension sensor feedback speed control

122 TENSION SENSOR FEEDBACK SPEED CONTROL

4.4.2 PID gain adjustment Adjust the PID gain for tension sensor feedback speed control.

Adjustment by tension PI gain tuning (recommended) The PID gain is adjusted by tension PI gain tuning (refer to page 91). Tension PI gain tuning is recommended for PID gain adjustment.

Manual adjustment Set the minimum-diameter roll for winding and the maximum-diameter roll for unwinding. Connect the material from the

beginning to the end of the machine, and increase the line speed gradually while observing the tension feedback value. Adjust the line speed so that appropriate tension feedback value can be obtained.

Adjust the PID gain so that the dancer roll works without problems at acceleration, constant speed, deceleration, and sudden deceleration.

It is important to adjust the tension PI gain as high as possible for the minimum-diameter roll. Normally, adjust the gain with Pr.129 PID proportional band and Pr.130 PID integral time.

POINT Adjust the gain so that overshooting occurs once or so before the tension feedback value returns to the set point.

Refer to the following according to the tension feedback condition.

NOTE Set Pr.134 PID differential time only when it is necessary as it causes hunting. However, set a small value in Pr.134 PID

differential time to cease fluctuation of the tension feedback value by disturbance and such at an early point. (Set 0.01 s at first and gradually increase the value.)

Status Adjustment method

When the response is slow (the tension feedback value is too low)

Decrease Pr.129 PID proportional band by 10%. Decrease Pr.130 PID integral time by 0.1 s. Repeat the adjustment procedure in the range from the minimum diameter to the maximum diameter so that the dancer roll moves properly at acceleration, constant speed, deceleration, and sudden deceleration.

When the response is fast (hunting occurs too frequently)

Increase Pr.129 PID proportional band by 10%. Increase Pr.130 PID integral time by 0.1 s. Repeat the adjustment procedure in the range from the minimum diameter to the maximum diameter so that the dancer roll moves properly at acceleration, constant speed, deceleration, and sudden deceleration.

Slow response (the tension feedback position is too low)

Fast response (hunting occurs too frequently)

Proper condition

Tension sensor feedback speed control details

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4.5 Tension sensor feedback speed control details

This section explains the details unique to the tension sensor feedback speed control. Many of the functions are common between dancer feedback speed control and tension sensor feedback speed control. The functions explained in 3.5.1 to 3.5.5 and 3.5.11 to 3.5.15 can be also used during tension sensor feedback speed control. For tension sensor feedback speed control, set the function by replacing "dancer feedback speed control" with "tension sensor feedback speed control" in the description of the above-mentioned subsections.

Purpose Parameter to set Refer to page

To select forward/reverse action for PID control PID action selection P.R100 Pr.128 65

To select winding or unwinding for a shaft

Winding/unwinding selection P.R002 Pr.1230 67

To input tension feedback to the inverter

Tension feedback setting P.R101 to P.R103 Pr.133, Pr.363,

Pr.1227 124

To calibrate the zero point of tension feedback PID offset displacement P.R104 Pr.424 126

To detect tension feedback malposition

Tension feedback malposition detection

P.R160, P.R163, P.A601, P.A602

Pr.131, Pr.132, Pr.137, Pr.425 127

To allow a signal to be output during normal tension feedback

Tension feedback detection P.R422 Pr.423 126

To select the line speed command input method

Line speed command input selection P.R200 Pr.361 67

To select a unit of the line speed Line speed unit P.R201 Pr.358 67 To input the line speed command using multi-speed setting

Line multi-speed setting P.R230 to P.R244 Pr.1265 to Pr.1279 67

To calibrate the line speed command value

Line speed command bias/gain

P.R210 to P.R213, P.R220 to P.R223 Pr.350 to Pr.357 67

To set the line speed command to start operation

Line speed command for starting P.R204 Pr.622 67

To calibrate the compensation value added to the line speed command value

Line speed command added compensation value bias/gain

P.R214 to P.R217 Pr.635 to Pr.638 76

To set acceleration/deceleration time to increase/decrease the line speed command value

Acceleration/ deceleration time selection for line speed command

P.R253 to P.R256, P.R250 to P.R252

Pr.100 to Pr.103, Pr.393 to Pr.395 79

To enable automatic tuning for complex PI gain calculation Tension PI gain tuning P.R170 to P.R176

Pr.1211, Pr.1215, Pr.1217, Pr.1219, Pr.1222, Pr.1223, Pr.1226

91

To enable manual input of gains for PID control PID control gain setting P.R110 to P.R112 Pr.129, Pr.130,

Pr.134 99

Tension sensor feedback speed control details

124 TENSION SENSOR FEEDBACK SPEED CONTROL

4.5.1 Tension feedback setting Set the target position for tension feedback. Select the input method to the inverter (analog input terminal) for tension feedback input.

PID set point (Pr.133) Set the set point for tension feedback in Pr.133 PID action set point.

Set a value according to the full scale value of the tension detector to be used and the corresponding output voltage. For example, when tension feedback is input through terminal 1 and the tension sensor outputs 10 V for 100 N (full scale value), set 530% in Pr.133 to set 30 N tension.

NOTE Set Pr.52 = "86" to monitor the tension feedback value on a percentage basis.

Taper function for the PID set point FTP can be replaced with the PID set point after taper control, and F* with the PID set point after the cushion time. (For

details on FTP and F*, refer to page 151.) The taper ratio is the reduction ratio against 100% (the PID set point set in Pr.133 is regarded as 100%). When the taper

ratio setting is 20% in the example of linear taper control, the PID set point after taper control is 80% of the original value. When the taper function is used for the set point, set Pr.1284 Taper mode selection "0", Pr.364 Dancer tension setting

input selection / taper function enable/disable selection for tension sensor feedback speed control 1 = "9999", and Pr.430 Dancer tension setting / taper function enable/disable selection for tension sensor feedback speed control 2 = "9999".

When the PID set point after the cushion time is negative, the limit is set at 0%. When the taper function is used for the set point, calibrate the settings so that 0% is equivalent to 0 N.

Pr. Name Initial value Setting range Description 133 R101 (A611)

PID action set point 500% 400 to 600% Set the set point for tension feedback.

363 R102

Dancer / tension sensor feedback input selection 9999

3 The measured value is input through terminal 2. 4 The measured value is input through terminal 4. 5 The measured value is input through terminal 1.

6 The measured value is input through terminal 6 (FR-A8AZ).

9 The measured value is input via CC-Link / CC-Link IE Field Network Basic communication.

9999 No function

1227 R103

Dancer / tension sensor feedback input filter time constant

0 0 Without filter

0.01 to 5 s Set the primary delay filter for the tension feedback input value.

Pr.133 setting Actual set point 600% +100% 500% (initial setting) 0% 400% -100%

3 V 30 N

0 V 10 V 100 N

Tension setting using analog input value

Set point

600%

530%

Tension sensor feedback speed control details

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Tension feedback input selection (Pr.363) Use Pr.363 Dancer / tension sensor feedback input selection to select the input terminal for tension feedback.

The input specification in the initial setting is indicated.

Tension feedback calibration example The following parameters are used for calibrating the terminals which the tension feedback is input via. The tension

feedback analog input values at both 0% and 100% can be calibrated.

The initial input range is 20 to 100%.

In the following example, a tension sensor in capacity from 0 to 10 V output is used for inputting the tension feedback value through terminal 1 (input range: -10 to 10 V). This example defines the minimum tension as 0% and the maximum tension as 100% for calibration. C13(Pr.917) Terminal 1 bias (speed) and Terminal 1 gain (speed) are used as calibration parameters.

NOTE For the details of C3 (Pr.902), C4 (Pr.903), C6 (Pr.904), C7 (Pr.905), C13 (Pr.917), and C15 (Pr.918), refer to the FR-A800

Instruction Manual (Detailed).

Tension feedback input filter (Pr.1227) Use Pr.1227 Dancer / tension sensor feedback input filter time constant to set the primary filter for the tension

feedback input value.

Pr.363 setting Input terminal 3 Terminal 2 (0 to 100%) (0 to 5 VDC) 4 Terminal 4 (20 to 100%) (4 to 20 mADC) 5 (initial value) Terminal 1 (-100 to 100%) (0 to 10 VDC) 6 Terminal 6 (FR-A8AZ) (-100 to 100%) (0 to 10 VDC) 9 CC-Link or CC-Link IE Field Network Basic (-100 to 100%)

Input terminal Calibration parameter Terminal 2 (0 to 100%) C3 (Pr.902), C4 (Pr.903) Terminal 4 (0 to 100%) C6 (Pr.904), C7 (Pr.905) Terminal 1 (-100 to 100%) C13 (Pr.917), C15 (Pr.918) Terminal 6 (FR-A8AZ) (-100 to 100%) C31 (Pr.926), C33 (Pr.927) CC-Link, CC-Link IE Field Network Basic

0 to 10 V

100%

0 V (0%) C13 (Pr.917)

Analog input value

10 V (100%) C15 (Pr.918)

Tension feedback

Tension sensor

Tension sensor feedback speed control details

126 TENSION SENSOR FEEDBACK SPEED CONTROL

4.5.2 Tension feedback detection A signal is output while the tension feedback value maintains the specified normal level.

Tension feedback detection (Pr.423, Y235 signal) The Dancer position / tension feedback detection (Y235) signal is output while the tension feedback value is within the

range set in Pr.423 Dancer / tension sensor feedback detection level around the set point. For the Y235 signal, set "235 (positive logic) or 335 (negative logic)" in one of Pr.190 to Pr.196 (output terminal function

selection) to assign the function to the output terminal.

4.5.3 PID offset displacement Calibrate the reference value of the tension sensor feedback amount (PID measured value).

PID offset displacement (Pr.424, X102 signal) When setting the tension sensor feedback amount as a desired reference value, turn ON the Offset displacement storage

(X102) signal to add an offset to the PID measured value. The tension sensor feedback amount when the X102 signal turns ON can then be set to 0%.

At the ON edge of the X102 signal, the present input value (-100 to 100%) is written in Pr.424 Dancer / tension sensor feedback input offset. A value within the range from 400 to 600% is written in Pr.424, considering the measured value of 0% as 500%.

Measured value (after the offset) = Measured value (before the offset) - Pr.424 (offset value)

NOTE The measured value (after the offset) is limited within the range of 100%.

Pr. Name Initial value Setting range Description

423 R422

Dancer / tension sensor feedback detection level 10% 0 to 100%

Set the scope of normal value for tension feedback. Define the percentage of deviation with respect to the set point.

Pr. Name Initial value Setting range Description

424 R104

Dancer / tension sensor feedback input offset 500% 400 to 600% The offset displacement input value is written.

Tension sensor feedback speed control details

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4.5.4 Tension feedback malposition detection Set the following parameters to prevent the motor speed from increasing due to a line break (tension feedback = 0 N).

Tension feedback malposition detection (break detection) (Pr.131, Pr.132, Pr.425)

Set the upper limit of tension feedback in Pr.131 PID upper limit. Set the lower limit of tension feedback in Pr.132 PID lower limit.

The FUP signal is output when a tension feedback value exceeds the Pr.131 setting. When a value falls below the Pr.132 setting, the FDN signal is output.

When tension feedback remains higher than the Pr.131 setting or lower than the Pr.132 setting for the time set in Pr.425 Break detection waiting time or longer, the condition is determined as tension feedback malposition (break), and compensation by PID control becomes 0. The winding diameter at the time of malposition detection is retained.

When tension feedback malposition (break) is detected, the Break detection (Y231) signal can be output. When the following two conditions are both met, PID calculation is resumed.

- The motor is stopped or output is shutoff. - The start signal is OFF.

Pr. Name Initial value Setting range Description

131 A601 PID upper limit 9999

400 to 600% Set the value for outputting the PID upper limit (FUP) signal .

9999 No function

132 A602 PID lower limit 9999

400 to 600% Set the value for outputting the PID lower limit (FDN) signal .

9999 No function 137 R163

PID upper/lower limit hysteresis width 9999

0 to 100% Prevent chattering of the FUP/FDN signals. 9999 No function

425 R160 Break detection waiting time 9999

0 to 100 s Set the time until tension feedback malposition is determined.

9999 No break detection

553 A603 PID deviation limit 9999

0 to 100% The Y48 signal is output when the absolute value of the deviation exceeds the deviation limit value.

9999 No function

554 A604

PID signal operation selection 0 0 to 3

The action when the upper or lower limit for a measured value input is detected or when a limit for the deviation is detected can be selected.

Tension sensor feedback speed control details

128 TENSION SENSOR FEEDBACK SPEED CONTROL

When using each signal, assign the function to Pr.190 and Pr.196 (output terminal function selection) referring to the following table.

PID upper/lower limit hysteresis width (Pr.137) When the tension feedback value fluctuates, the FUP/FDN signal may chatter (turn ON and OFF repeatedly), depending on the position. To prevent the signal chattering, configure Pr.137 PID upper/lower limit hysteresis width to set a hysteresis for the FUP and FDN signals.

NOTE Pr.137 setting does not affect the operation of the Y231 signal. (Refer to page 127 for the details of the Y231 signal.) When a value other than "9999" is set in Pr.137, depending on the fluctuation of the tension feedback value, the FUP/FDN

signal may not turn ON even if the tension feedback value exceeds the Pr.131 setting or falls below the Pr.132 setting.

Output signal Pr.190 to Pr.196 setting

Positive logic Negative logic FDN 14 114 FUP 15 115 Y231 231 331

Winding diameter compensation amount

Break detection

Start command ON OFF

OFF OFFONY231

Pr.425 (Break detection waiting time)

PID compensation amount = 0

Normal operation Tension feedback is ON.

Tension command

Turns OFF when the motor stops running and the start command turns OFF.

Line speed command

Motor speed

Lower limit (Pr.132)

Tension feedback

Pr.137 Pr.131

ON ON

ONFUP

Example of the PID upper limit (FUP) signal

Tension sensor feedback speed control details

TENSION SENSOR FEEDBACK SPEED CONTROL 129

4

Operation selection when a limit is detected (Pr.554, FUP signal, FDN signal, Y48 signal)

Using Pr.554 PID signal operation selection, set the action when the measured value input exceeds the upper limit (Pr.131 PID upper limit) or lower limit (Pr.132 PID lower limit), or when the deviation input exceeds the permissible value (Pr.553 PID deviation limit).

Choose whether to output the signals (FUP, FDN, Y48) only or to activate the protective function to output the inverter shutoff.

NOTE When each of Pr.131, Pr.132 and Pr.553 settings corresponding to each of the FUP, FDN and Y48 signals is "9999" (no

function), signal output and protective function are not available.

Pr.554 setting Inverter operation

FUP, FDN Y48 0 (initial value) Signal output only

Signal output only 1 Signal output + output shutoff (E.PID) 2 Signal output only

Signal output + output shutoff (E.PID) 3 Signal output + output shutoff (E.PID)

Dedicated function list

130 TENSION SENSORLESS TORQUE CONTROL

5 TENSION SENSORLESS TORQUE CONTROL

5.1 Dedicated function list

NOTE For the details of the winding diameter compensation function, refer to page 194.

5.2 System configuration example

Item Description

Tension sensorless torque control

Taper function Set a taper ratio.

Inertia compensation function Set the compensation for acceleration and deceleration individually using external signals.

Mechanical loss compensation function Straight movement (with five break points) against the speed can be performed.

Common Dedicated input signal

Dancer/tension control selection, Inertia compensation acceleration, Inertia compensation deceleration, Inertia compensation second acceleration/ deceleration time selection, Winding diameter measurement, Stall mode trigger, Two-way operation.

Dedicated output signal Winding diameter calculation completion at start Dedicated monitor Tension command, mechanical loss compensation, inertia compensation

M

FR-A800-R2R

STF/STR

X112 (Pr.185 = 112)

X111 (Pr.184 = 111)

M

FR-A800-R2R

2 Y237

Y238 STF/STR

Intermediate shafts / speed control

Line speed detection

Actual line speed

2 (Pr.362 = 3)

Tension control selection

Inertia compensation acceleration signal

X114 (Pr.180 = 114)

Line speed command

Start command

X114 Tension control

selection

Tension command FR-A8AZ

For winding roller (Pr.1230 = 0)

Start command

6 (Pr.804 = 0)

Inertia compensation deceleration signal

Stall mode trigger signal

Stored winding diameter clear X109 (Pr.181 = 109)

Winding length clear X117 (Pr.182 = 117)

Encoder

Encoder

FR-A8AP FR-A8AP

Programmable controller

Vector control

Minimum diameter

Maximum diameter

Reduction gear

X123 (Pr.183 = 123)

TH1 TH2

Thermistor input

Control block diagram

TENSION SENSORLESS TORQUE CONTROL 131

5

5.3 Control block diagram

5.3.1 Block diagram of tension sensorless torque control function

Mechanical loss compensation

Pr.1419 to Pr.1429

Inertia compensation Pr.393, Pr.1410 to Pr.1418

+ +

+ +Tension control

(torque calculation) Pr.1235, Pr.1236

Taper function Pr.1284 to Pr.1297

Pr.1236

Winding diameter calculation

Pr.1235, Pr.1236 Pr.1243, Pr.1244

Torque control M

Encoder

X114-ON

X114-OFF

Tension command

Actual line speed

Winding diameter

Motor speed (Torque command)

Tension command cushioning

Pr.1282, Pr.1283

Tension reverse selection Pr.1072

Parameter setting procedure for tension sensorless torque control

132 TENSION SENSORLESS TORQUE CONTROL

5.4 Parameter setting procedure for tension sensorless torque control

The following procedure shows the parameter setting example for the tension sensorless torque control.

5.4.1 Parameter setting procedure 1 Wiring

Perform secure wiring.

NOTE Do not feed the workpiece through the machine.

2 Control method selection Select the control method according to the application and the motor.

For the control method, vector control is recommended. Setting is required for a motor other than a Mitsubishi Electric motor (the SF-PR, SF-JR, SF-HR, SF-JRCA, SF-HRCA, or SF-V5RU (1500 r/min

series) motor). For the FR-A820-03160(55K) or lower and FR-A840-01800(55K) or lower. For the FR-A820-03800(75K) or higher and FR-A840-02160(75K) or higher.

NOTE Torque control is not available for regenerative driving in a low-speed range (about 10 Hz or lower) or light-load operation in a

low-speed range (about 5 Hz or lower and about 20% or lower of the rated torque) under Real sensorless vector control. Select Vector control for regenerative driving or light-load operation in a low-speed range.

For the parameter details, refer to the FR-A800 Instruction Manual (Detailed).

3 Speed limit setting Set the speed limit as required as follows.

NOTE Use Pr.807 to Pr.809 and Pr.1113 to set the speed limit. As the speed limit value is overwritten frequently, set "0" in Pr.342

Communication EEPROM write selection to enable RAM write. For the parameter details, refer to the FR-A800 Instruction Manual (Detailed).

Pr. Name Setting range Minimum setting

increments Initial value

71 Applied motor 0, 1, 3 to 6, 13 to 16, 20, 23, 24, 30, 33, 34, 40, 43, 44, 50, 53, 54, 70, 73, 74 1 0

9 Electronic thermal O/L relay 0 to 500A 0.01A Inverter rated

current0 to 3600A 0.1A

80 Motor capacity 0.4 to 55kW, 9999 0.01kW

9999 0 to 3600kW, 9999 0.1kW

81 Number of motor poles 2, 4, 6, 8, 10, 12, 9999 1 9999

83 Rated motor voltage 0 to 1000V 0.1V

200 V (200 V class) 400 V (400 V class)

84 Rated motor frequency 10 to 400Hz, 9999 0.01Hz 9999 800 Control method selection 0 to 2, 9 to 12, 20, 100 to 102, 109 to 112 1 20

803 Constant output range torque characteristic selection 0 to 2, 10, 11 1 0

807 Speed limit selection 0 to 2 1 0 810 Torque limit input method selection 0 to 2 1 0 359 Encoder rotation direction 0, 1, 100, 101 1 1 369 Number of encoder pulses 0 to 4096 1 1024 707 Motor inertia (integer) 10 to 999, 9999 1 9999 724 Motor inertia (exponent) 0 to 7, 9999 1 9999 862 Encoder option selection 0, 1 1 0

1.1 to 1.2 Present diameter Gear ratio

Present line speed Speed limit value =

Parameter setting procedure for tension sensorless torque control

TENSION SENSORLESS TORQUE CONTROL 133

5

4 Torque characteristic setting Set "1" in Pr.803 to make the torque characteristic constant for the tension command in the low-speed range and in the constant output range.

5 Offline auto tuning Perform offline auto tuning as required. For offline auto tuning, refer to page 55.

After the offline auto tuning, perform the test run of the motor alone to make sure that no fault is found in the motor's behavior.

6 Mechanical specifications setting Set the following parameters according to the specifications of the machine used. Refer to 11.6 (Application examples) on page 243.

Set the parameter according to the specification of the machine used. The increment applies when Pr.21 = "0 (initial value)". The increment applies when Pr.358 = "0 (initial value)".

Pr. Name Setting range

Minimum setting

increments Initial value

96 Auto tuning setting/status 0, 1, 11, 101 1 0

Pr. Name Setting Remarks 1235 Maximum winding diameter 1 Set the maximum/minimum value in 1 mm increments (1 to

6553 mm) relative to the winding diameter calculation result.1236 Minimum winding diameter 1

178 to 189 Input terminal function selection

114 Set "114" for the X114 signal.

109 Set "109" for using the Stored winding diameter clear (X109) signal.

117 Set "117" for using the Winding length clear (X117) signal.

1230 Winding/unwinding selection 0: Winding shaft 1: Unwinding shaft

645 Winding diameter storage selection

0: Not stored. 1: The present winding diameter is stored.

1247 Winding diameter change increment amount limit

Set the maximum change in 0.001 mm increments (0 to 9.998 mm or 9999) per roll diameter calculation.

1243 Gear ratio numerator Set a gear ratio in 1 increments (1 to 65534) when a reduction gear is installed between the driving shaft and motor shaft.1244 Gear ratio denominator

7 Acceleration time 0 s 0 to 3600 seconds, in 0.1 second increments

8 Deceleration time 0 s

394 First acceleration time for line speed command Setting is required in 0.1 second increments (0 to 3600

seconds) when the cushion time is not considered for the line speed command.395 First deceleration time for line

speed command

101 Second deceleration time for line speed command

Set the time in 0.1 second increments (0 to 3600 seconds) as required (for example, for rapid deceleration). Turn ON the X105 signal to enable the setting.

393 Line speed command acceleration/deceleration reference

Set the reference line speed (travel amount per minute) in 0.1 m/min increments (1 to 6553.4 m/min) for the acceleration/ deceleration time for the line speed command.

1231 Material thickness d1 Setting is required in 0.001 mm increments (0 to 20 mm or 9999) when thickness is used for winding diameter calculation.

1072 Tension reverse selection

0: The tension direction is not reversed. 1: The tension direction is reversed. Set the torque generation direction

in accordance with the machine used.

1114 Torque command reverse selection

0: The torque direction is not reversed. 1: The torque direction is reversed.

Parameter setting procedure for tension sensorless torque control

134 TENSION SENSORLESS TORQUE CONTROL

7 Tension command input selection Set the following parameter according the tension input method.

The following table shows a setting example.

Pr. Name Setting Input terminal

804 Tension / Torque command source selection

0 (initial value)

Tension command by terminal 1 analog input (-10 to 10 VDC) Tension command by terminal 6 analog input (-10 to 10 VDC) (FR-A8AZ)

1 Tension command by the parameter setting (Pr.365 or Pr.366) 2 Tension command by the pulse train command (FR-A8AL)

3 Tension command via CC-Link communication (FR-A8NC/FR-A8NCE) Tension command via PROFIBUS-DP communication (FR-A8NP)

4 Tension command by 12/16-bit digital input (FR-A8AX) 5 Tension command via CC-Link communication

(FR-A8NC/FR-A8NCE) Tension command via PROFIBUS-DP communication (FR-A8NP)6

Item Setting example

Tension command input method

Setting by analog voltage (0 to 10 V) input through terminal 1 (Pr.804 = "0")

Parameter setting

Pr.868 Terminal 1 function assignment = "3 or 4" Pr.1402 Tension command input voltage bias = 0% Pr.1403 Tension command bias = Minimum tension Pr.1404 Tension command input voltage gain = 100% Pr.1405 Tension command gain = Maximum tension Pr.1401 Tension command increment = "0" (0.01 N increment)

Pr.1405 (Maximum tension)

Pr.1403 (Minimum tension)

0 V Pr.1402 (0%)

Analog input value10 V Pr.1404 (100%)

Tension command value

Parameter setting procedure for tension sensorless torque control

TENSION SENSORLESS TORQUE CONTROL 135

5

8 Actual line speed input Use Pr.362 to select the input terminal for actual line speed.

To perform Vector control, install the Vector control compatible option. The input specification in the initial setting is indicated. (Refer to page 47.)

The following table shows setting examples.

Set the pulse division scaling factor in Pr.384 for pulse train input through terminal JOG. Number of pulses calculated internally = Number of input pulses / Pr.384 setting value When inputting 50k pulses/s while Pr.281 = 0 m/min, Pr.279 = 100 m/min, Pr.282 = 0 pulses/s, Pr.283 = 50k pulses/s, and Pr.384 = "2", the actual line speed will be 50 m/min.

Pr. Name Setting Input terminal

362 Actual line speed input selection

0 (initial value) V* (line speed command)

1 Terminal JOG single-phase pulse train input (Refer to page 200)

2 FR-A8AP/FR-A8AL/FR-A8TP encoder pulse train input (complementary 12 V / differential 5 V (A-, B-phases)) (Refer to page 200)

3 Terminal 2 (analog value: 0 to 100%) (0 to 5 VDC) (Refer to page 202)

4 Terminal 4 (analog value: 20 to 100%) (4 to 20 mADC) (Refer to page 202)

5 Terminal 1 (analog value: -100 to 100%) (0 to 10 VDC) (Refer to page 202)

6 Terminal 6 (FR-A8AZ) (analog value: -100 to 100%) (0 to 10 VDC) (Refer to page 202)

7 FR-A8AL single-phase pulse train input (PP, NP) (Refer to page 200)

9 CC-Link or CC-Link IE Field Network Basic (0 to 65534) 9999 No function

Item Setting example 1 Setting example 2

Actual line speed input method

Setting by analog current (4 to 20 mA) input through terminal 4 (Pr.362 = "4")

Setting by pulse train input through terminal JOG (Pr.362 = "1")

Parameter setting

Pr.280 Actual line speed voltage/current bias = 20% Pr.281 Actual line speed bias = 0 m/min Pr.278 Actual line speed voltage/current gain = 100% Pr.279 Actual line speed gain = Maximum line speed

Pr.384 Input pulse division scaling factor = "1" Pr.281 Actual line speed bias = 0 m/min Pr.282 Actual line speed pulse input bias = 0 pulses/s Pr.279 Actual line speed gain = Maximum line speed Pr.283 Actual line speed pulse input gain = Maximum number of pulses

Pr.279 (Maximum line speed)

Pr.281 (0 m/min)

4 mA Pr.280 (20%) Analog input value

20 mA Pr.278 (100%)

Actual line speed

Pr.279 (Maximum line speed)

6553.4

Pr.281 (0 m/min)

Pr.282 (0 pulses/s)

Number of input pulses

Pr.283 (Maximum number of pulses)

Actual line speed

Parameter setting procedure for tension sensorless torque control

136 TENSION SENSORLESS TORQUE CONTROL

9 Taper ratio setting Set the taper ratio input method for using the taper ratio.

The input specification in the initial setting is indicated. (Refer to page 47.)

The following table shows a setting example.

For using the taper ratio, set the following parameters according to the taper mode.

NOTE For the details of the taper function, refer to page 151.

Pr. Name 1285 Taper setting analog input selection 1287 Taper ratio setting

Pr.1287 setting Pr.1285 setting Taper ratio setting 0 to 100% As set in Pr.1287

9999

3 Terminal 2 (analog value: 0 to 100%) (0 to 5 VDC) 4 Terminal 4 (analog value: 20 to 100%) (4 to 20 mADC) 5 Terminal 1 (analog value: -100 to 100%) (0 to 10 VDC)

6 Terminal 6 (FR-A8AZ) (analog value: -100 to 100%) (0 to 10 VDC)

9999 No function

Item Setting example

Taper ratio setting method

Setting by analog voltage (0 to 5 V) input through terminal 2 (Pr.1287 = "9999", Pr.1285 = "3")

Parameter setting C3 (Pr.902) Terminal 2 frequency setting bias = 0% C4 (Pr.903) Terminal 2 frequency setting gain = Taper ratio (%)

Pr. Name Setting range Minimum setting

increments

Initial value

1284 Taper mode selection 0 to 4 1 0 1286 Winding diameter at taper start 0 to 6553 mm, 9999 1 mm 9999

C4 (Pr.903) (Taper ratio)

C3 (Pr.902) (0%)

0 V Analog input value

5 V

Taper ratio

Parameter setting procedure for tension sensorless torque control

TENSION SENSORLESS TORQUE CONTROL 137

5

10 Inertia compensation function setting Set the following parameters for using the inertia compensation function.

Set the parameters according to the specification of the machine used.

NOTE For the details of the inertia compensation function, refer to page 157.

11 Mechanical loss compensation function setting Set the following parameters for using the mechanical loss compensation function.

Set the parameters according to the specification of the machine used.

NOTE For the details of the mechanical loss compensation function, refer to page 163.

Pr. Name Setting Remarks

393 Line speed command acceleration/deceleration reference

Set the line speed at minimum diameter (the maximum line speed during tension control) in 0.1 m/min increments (1 to 6553.4 m/ min).

178 to 189 Input terminal function selection

111 Assign the Inertia compensation acceleration (X111) signal. Input the Line speed acceleration (Y237) signal from the inverter connected to the intermediate shaft.

112 Assign the Inertia compensation deceleration (X112) signal. Input the Line speed deceleration (Y238) signal from the inverter connected to the intermediate shaft.

122 Assign the Winding diameter measurement (X122) signal.

1410 Motor inertia

Set the motor inertia in 0.01 kgm2 increments (0 to 500 kgm2 or 9999). To further improve the accuracy for the inertia compensation function, set a motor inertia value using Pr.707 and Pr.724.

1411 Empty reel inertia

Set the empty reel inertia in 0.01 kgm2 increments (0 to 500 kgm2 or 9999). To further improve the accuracy for the inertia compensation function, set an empty reel inertia value using Pr.753 and Pr.754.

1412 Roll width Set the roll width in 1 mm increments (0 to 5000 mm).

1413 Material specific gravity Set the specific gravity of the material in 0.001 g/cm3 increments (0 to 20 g/cm3).

1141 Line speed command acceleration/deceleration pattern

Set S-curve acceleration/deceleration to reduce shock during inertia compensation operation. (Refer to page 160.)

1142 Line speed command acceleration start S-curve time

1143 Line speed command acceleration completion S-curve time

1144 Line speed command deceleration start S-curve time

1145 Line speed command deceleration completion S-curve time

Pr. Name Setting Remarks

1419 Mechanical loss setting frequency bias 1000 The setting "1000" represents 0%. An offset can be set in 0.1% increment from the setting "1000".

1420 Mechanical loss setting frequency 1 Drive the machine with an empty reel at the frequency of Pr.1420, Pr.1422, Pr.1424, Pr.1426, and Pr.1428 (0 to 400 Hz, 0.01 Hz increments), and set the monitored torque values in Pr.1421, Pr.1423, Pr.1425, Pr.1427, and Pr.1429 respectively. (The setting "1000" in Pr.1421, Pr.1423, Pr.1425, Pr.1427, and Pr.1429 represents 0%. An offset can be set in 0.1% increments (900 to 1100%) from setting "1000".)

1421 Mechanical loss 1

1422 Mechanical loss setting frequency 2

1423 Mechanical loss 2

1424 Mechanical loss setting frequency 3

1425 Mechanical loss 3

1426 Mechanical loss setting frequency 4

1427 Mechanical loss 4

1428 Mechanical loss setting frequency 5

1429 Mechanical loss 5

Parameter setting procedure for tension sensorless torque control

138 TENSION SENSORLESS TORQUE CONTROL

12 Stall mode function selection Set the following parameters for using the stall mode function.

Set the parameters according to the specification of the machine used.

NOTE For the details of the stall mode function, refer to page 165.

13 Test run Operate the system starting from the maximum-diameter roll to the minimum-diameter roll and vice versa and check that no fault is found in the system behavior.

Pr. Name Setting Remarks 178 to 189 Input terminal function selection 123 Assign the Stall mode trigger (X123) signal.

270 Acceleration/deceleration time during stall condition 0 to 3600 seconds, in 0.1 second increments

1406 Commanded tension reduction scaling factor during stall condition 0 to 200%, in 0.1% increments

1407 Speed limit during stall condition 0 to 60 Hz, in 0.01 Hz increments

Tension sensorless torque control details

TENSION SENSORLESS TORQUE CONTROL 139

5

5.5 Tension sensorless torque control details The tension sensorless torque control is performed to control the output torque of a motor according to the winding diameter of a roll so that the tension applied to a material is constant. Winding and unwinding of the material is enabled without using dancer rolls or tension controllers.

POINT Select torque control under vector control or Real sensorless vector control to perform tension sensorless torque control. Turn the X114 signal ON to perform tension sensorless torque control. When the X114 signal is OFF, the tension sensorless

torque control is not available.

5.5.1 Tension sensorless torque control setting method

Control method selection Select torque control under vector control or Real sensorless vector control to perform tension sensorless torque control. Use Pr.800 Control method selection to select torque control under vector control or Real sensorless vector control.

: Valid, : Invalid The setting values of 100 and above are used when the fast-response operation is selected. (For the SND rating, the fast-response operation is

not available.) Advanced magnetic flux vector control is applied if a vector control compatible option is not installed. The control method can be changed using the MC signal while the inverter is stopped.

Tension control selection signal (X114 signal) Turn ON the Tension control selection (X114) signal to enable the tension sensorless torque control. Ensure the motor has stopped before switching between operation with tension sensorless torque control and normal

operation. To input the X114 signal, set "114" in any of Pr.178 to Pr.189 (input terminal function selection) to assign the function.

Purpose Parameter to set Refer to page

To perform setting for tension sensorless torque control

Control method selection

P.C100 (P.C200), P.C101 (P.C201), P.C102 (P.C202), P.G200, P.G300

Pr.80 (Pr.453), Pr.81 (Pr.454), Pr.71 (Pr.450), Pr.800, Pr.451

139

To select the tension command input method

Tension command source selection P.R300 Pr.804 140

To select the tension command setting increment

Tension command increment P.R301 Pr.1401 140

To select the torque generation direction

Torque generation direction setting P.R304, P.R305 Pr.1072, Pr.1114 143

To prevent the roll from getting too tight when the winding diameter increases

Taper function

P.R320, P.R321, P.R500 to P.R504, P.R510 to P.R519, P.R600, P.R601

Pr.829, Pr.1243, Pr.1244, Pr.1282 to Pr.1297

151

To keep the tension applied to the material constant also during acceleration/deceleration

Inertia compensation function P.R530 to P.R540

Pr.271, Pr.272, Pr.753, Pr.754, Pr.1410 to Pr.1415, Pr.1418

157

To prevent tension change due to factors such as mechanical friction

Mechanical loss compensation function

P.R003, P.R550 to P.R560

Pr.1230, Pr.1419 to Pr.1429 163

To prevent sagging of the material before starting winding Stall mode function P.R340 to P.R343 Pr.270, Pr.1406,

Pr.1407, Pr.1409 165

Pr.80 (Pr.453), Pr.81 (Pr.454)

Pr.800 setting

Pr.451 setting Control method Control mode

Tension sensorless torque control

MC-ON MC-OFF

Motor capacity, number of motor poles

1, 101 Vector control

Torque control

2, 102 Speed control/torque control switchover 11, 111 Real sensorless

vector control Torque control

12, 112 Speed control/torque control switchover

Tension sensorless torque control details

140 TENSION SENSORLESS TORQUE CONTROL

5.5.2 Input method of tension command The selectable tension command input methods include the following: parameter setting, analog input, multi-speed setting input, pulse input, and input via communication.

The setting varies with the Pr.1401 setting.

Block diagram

Pr. Name Initial value Setting range Description

365 R302

Tension command value (RAM) 0 N 0 to 500 N Writes the tension command value in RAM.

366 R303

Tension command value (RAM, EEPROM) 0 N 0 to 500 N

Writes the tension command value in RAM and EEPROM

804 R300 (D400)

Tension / Torque command source selection 0

0 Tension command by terminal 1 analog input Tension command by terminal 6 analog input (FR- A8AZ)

1

Tension command by setting the parameter (Pr.365 or Pr.366) Tension command via CC-Link communication (FR- A8NC/FR-A8NCE) Tension command via PROFIBUS-DP communication (FR-A8NP)

2 Tension command by the pulse train command (FR- A8AL)

3, 5, 6

Tension command via CC-Link communication (FR- A8NC/FR-A8NCE) Tension command via PROFIBUS-DP communication (FR-A8NP)

4 Tension command by 12/16-bit digital input (FR-A8AX)

1401 R301 Tension command increment 0

0 Initial value: 100 N, setting increment: 0.01 N, setting range: 0 to 500 N

1 Initial value: 1000 N, setting increment: 0.1 N, setting range: 0 to 5000 N

2 Initial value: 10000 N, setting increment: 1 N, setting range: 0 to 50000 N

1402 R310

Tension command input voltage bias 0% 0 to 100% Set the converted % of the bias voltage for analog

input.

1403 R311 Tension command bias 0 N 0 to 500 N Set the bias tension command for analog input.

1404 R312

Tension command input voltage gain 100% 0 to 100% Set the converted % of the gain voltage for analog

input.

1405 R313 Tension command gain 100 N 0 to 500 N Set the gain tension command for analog input.

Terminal 1 Terminal 6

0

2

4

1, 3, 5, 6

Pulse train input (FR-A8AL)

Digital input (FR-A8AX)

FR-A8NC FR-A8NCE FR-A8NP

Pr.365, Pr.366

Primary filter

Clamping

0 to 10000 Pr.1401

Pr.804 Tension command

Analog calibration Pr.1402 to Pr.1405

Pulse train calibration Pr.1403, Pr.1405

Digital input calibration

Pr.1403, Pr.1405

Pr.1403 = 0 or Pr.1405 = 0

Pr.1403 = 0 and Pr.1405 = 0

Pr.74, Pr.826, Pr.836

Unit switchover

Pr.1401

Tension sensorless torque control details

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5

Tension command source selection (Pr.804) Selects the tension command input method in Pr.804 Tension / Torque command source selection. The priorities of the input signals are defined as follows. If the input method for a signal is the same as that for the input

signal with higher priority, the tension command value is regarded as "0". Dancer signal input (Pr.363) > Actual line speed input (Pr.362) > Tension command input (Pr.804) > Line speed command input (Pr.361 "0") > Taper setting input (Pr.1285) > Dancer tension setting input (Pr.364) > Line speed command compensation input > Line speed command input (Pr.361 = "0")

Tension command by analog input (Pr.804 = "0") Input the tension command value using analog input to the terminal 1 or the terminal 6 of the FR-A8AZ. To use terminal 1,

set Pr.868 Terminal 1 function assignment = "3 or 4". To use terminal 6, set Pr.406 High resolution analog input selection = "3 or 4".

The tension command using analog input is calibrated with Pr.1402 to Pr.1405. When "0" is set in both Pr.1403 and Pr.1405, the setting is invalid (line speed command value: 0).

NOTE When the tension command is input using analog input, the input value can be filtered using Pr.74 Input filter time constant,

Pr.826 Torque setting filter 1, and Pr.836 Torque setting filter 2. The maximum value of the tension command can be changed by the Pr.1401 Tension command increment setting.

Tension command by parameters (Pr.804 = "1") Set Pr.365 Tension command value (RAM) or Pr.366 Tension command value (RAM, EEPROM) to set the tension

command value. To change the tension command value frequently, write it in Pr.365. If the value is written to Pr.366 frequently, the life of the

EEPROM will be shortened.

Tension command by pulse train input (FR-A8AL) (Pr.804 = "2") Input the tension command value using pulse train input of the FR-A8AL. The tension command using pulse train input (FR-A8AL) is calibrated with Pr.1403 and Pr.1405. When "0" is set in both

Pr.1403 and Pr.1405, the setting is invalid (line speed command value: 0).

NOTE The maximum value of the tension command can be changed by the Pr.1401 Tension command increment setting.

Pr.1402 Pr.1404

Pr.1403

Pr.1405

Analog input value

Tension command value

Maximum tension command value

400k pulses/s

Pr.1403

Pr.1405

Pulse train input value

Tension command value

Maximum tension command value

Tension sensorless torque control details

142 TENSION SENSORLESS TORQUE CONTROL

Tension command through the CC-Link / CC-Link IE Field Network / PROFIBUS-DP (Pr.804 = "1, 3, 5, 6")

Set the tension command via the CC-Link communication (FR-A8NC), CC-Link IE Field Network communication (FR- A8NCE), or PROFIBUS-DP communication (FR-A8NP).

Set the tension command the same way as the torque command. (Refer to the Instruction Manual of each option for details.)

Can also be set from operation panel or parameter unit. The tension command can also be performed by setting a value in Pr.365 or Pr.366. The setting varies with the Pr.1401 setting. When Pr.1401 = "0", enter the setting value multiplied by 100. When Pr.1401 = "1", enter the setting value multiplied by 10. For example, enter

10000 to set 100.00N when "0" is set in Pr.1401.

NOTE For the details of FR-A8NC, FR-A8NCE, FR-A8NP setting, refer to the Instruction Manual for the respective communication

options. For the details of the setting using the PLC function, refer to the PLC Function Programming Manual.

Tension command by 16-bit digital input (Pr.804 = "4") Execute tension command by 12-bit or 16-bit digital input using FR-A8AX (plug-in option). When a value other than "0" is set in Pr.1403 or Pr.1405, use Pr.1403 or Pr.1405 to calibrate the tension command value

input to the FR-A8AX.

When "0" is set in both Pr.1403 and Pr.1405, the digital value input to the FR-A8AX is used as it is as the tension command value.

Use Pr.1401 to set the maximum tension command value.

NOTE For the details of the FR-A8AX setting, refer to the Instruction Manual of the FR-A8AX.

Pr.804 setting

Tension command input Setting range Setting

incrementsCC-Link CC-Link IE PROFIBUS-DP

1, 6 Tension command by Pr.365, Pr.366 Tension command by

remote register (RWw2)

Tension command by Pr.365, Pr.366

0 to 500 N 0.01 N

3, 5 Tension command by remote register (RWw1 or RWw2)

Tension command by the buffer memory of PROFIBUS-DP (REF1 to 7)

Tension command value

Digital input signal

Pr.1405

Pr.14030 H7FFF (H7FF)

H7FFF (H7FF)

Most significant bit = 0Most significant bit = 1

Initial value

Tension command value

Digital input signal

10000

2047

0

Most significant bit = 0Most significant bit = 1

H7FFF (16 bits)

H7FFF (16 bits)

H7FF (12 bits)

H2710H7FF (12 bits)

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The setting range and setting increment of the tension command (Pr.1401)

The setting increment of the tension command can be changed by the Pr.1401 Tension command increment setting. The setting range is also changed according to the increment.

NOTE Changing the Pr.1401 setting changes the tension command setting (Pr.365, Pr.366, Pr.1283, Pr.1403, and Pr.1405). Before

changing the Pr.1401 setting, confirm that changing the tension command setting will not cause any problem.

Tension command - torque command switchover (X125 signal) When the X125 signal is turned ON during torque control, the commanded tension can be written via communication (CC-

Link/CC-Link IE/PROFIBUS-DP) regardless of whether the tension sensorless torque control is valid or invalid. Turn ON the X125 signal to input the tension command value before activating the tension sensorless torque control, or to

disable the tension sensorless torque control without accidentally changing the torque command value.

: Available through communication, : Not available through communication Set Pr.362 "0" for the actual line speed input selection while tension sensorless torque control is valid. By setting Pr.362 = "0" (the line speed

command value is set as the actual line speed), the line speed command value is used as the actual line speed. However, the line speed command setting is not used as it is. The actual line speed command output value in consideration of acceleration/deceleration is applied.

Set Pr.807 "0 (the frequency command value is set as the speed limit)" for setting the speed limit while tension sensorless torque control or tension sensor feedback torque control is valid. While tension sensorless torque control or tension sensor feedback torque control is valid, the tension command value and the frequency command value cannot be set simultaneously.

5.5.3 Torque generation direction setting Set parameters according to the requirement because the torque direction for winding/unwinding differs for each device. Set the torque generation direction in accordance with the machine used.

The direction of torque generation during tension sensorless torque control is determined by a combination of the settings of the start command, Pr.1072 Tension reverse selection, and Pr.1114 Torque command reverse selection.

Pr.1401 setting Initial value Setting increments Setting range 0 (initial value) 100 N 0.01 N 0 to 500 N 1 1000 N 0.1 N 0 to 5000 N 2 10000 N 1 N 0 to 50000 N

Tension sensorless

torque control X125 signal

Command value setting availability through communication Tension command

value Torque command

value Line speed

command value Frequency

command value

Valid ON OFF

Not assigned

Invalid ON OFF

Not assigned

Pr. Name Initial value Setting range Description

1072 R304 Tension reverse selection 0

0 The tension direction is not reversed. 1 The tension direction is reversed.

1114 R305 (D403)

Torque command reverse selection 0

0 The torque direction is not reversed.

1 The torque direction is reversed.

Pr.1114 Pr.1072 Torque generation direction

STF signal ON STR signal ON 0 (The torque direction is not reversed at STR-ON.)

0 (Not reversed) Forward rotation direction Forward rotation direction 1 (Reversed) Reverse rotation direction Reverse rotation direction

1 (The torque direction is reversed at STR-ON.)

0 (Not reversed) Forward rotation direction Reverse rotation direction 1 (Reversed) Reverse rotation direction Forward rotation direction

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144 TENSION SENSORLESS TORQUE CONTROL

Set parameters according to the requirement because the torque direction for winding/unwinding differs for each device. The setting examples are shown in the following table. When switching between the upper winding and lower winding, set Pr.1114 = "1" to switch between the STF and STR signals. (Even when Pr.1114 = "0", switching between the upper winding and lower winding is enabled by changing the Pr.1072 setting.)

System setting Parameter setting

Motor Installation orientation Material position

Winding/unwinding movement when the start command is input Pr.1114 Pr.1072

STF signal ON STR signal ON

Right side

Upper winding/unwinding 0

0

Lower winding/unwinding

1

Upper winding/unwinding Lower winding/unwinding 1

0

Lower winding/unwinding Upper winding/unwinding

1

Left side

Upper winding/unwinding 0

1

Lower winding/unwinding

0

Upper winding/unwinding Lower winding/unwinding 1

1

Lower winding/unwinding Upper winding/unwinding

0

Motor

Shaft rotation direction during forward motor rotation

Shaft

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: Required torque direction

The above figures show the shaft as viewed from the opposite side of the motor installation side.

Right side

Upper winding/unwinding 0

1

Lower winding/unwinding

0

Upper winding/unwinding Lower winding/unwinding 1

1

Lower winding/unwinding Upper winding/unwinding

0

Left side

Upper winding/unwinding 0

0

Lower winding/unwinding

1

Upper winding/unwinding Lower winding/unwinding 1

0

Lower winding/unwinding Upper winding/unwinding

1

System setting Parameter setting

Motor Installation orientation Material position

Winding/unwinding movement when the start command is input Pr.1114 Pr.1072

STF signal ON STR signal ON

Motor

Shaft rotation direction during forward motor rotation

Shaft

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146 TENSION SENSORLESS TORQUE CONTROL

5.5.4 Speed limit When operating under torque control, motor overspeeding may occur if the load torque drops to a value less than the torque command value, etc. Set the speed limit value to prevent overspeeding. If the actual speed reaches or exceeds the speed limit value, the control method switches from torque control to speed control, preventing overspeeding.

Speed limit method selection (Pr.1113)

Pr. Name Initial value Setting

range Description FM CA

807 H410 Speed limit selection 0

0 Uses the speed command during speed control as the speed limit.

1 Sets speed limits for forward and reverse directions individually by using Pr.808 and Pr.809.

2

Forward/reverse rotation speed limit Applies speed limit by analog voltage input to the terminal 1. Speed limit for forward/reverse side is switched by its polarity.

808 H411

Forward rotation speed limit/ speed limit 60 Hz 50 Hz 0 to 400 Hz Sets the forward side speed limit.

809 H412

Reverse rotation speed limit/ reverse-side speed limit 9999

0 to 400 Hz Sets the reverse side speed limit. 9999 Pr.808 setting value is effective.

1113 H414 Speed limit method selection 0

0 Speed limit mode 2 1 Speed limit mode 3 2 Speed limit mode 4

10 X93 signal OFF: Speed limit mode 3, X93 signal ON: Speed limit mode 4

Pr.1113 setting

Speed limit method Speed limit value

0 (initial value) Speed limit mode 2 Speed limit Pr.807 = "0": Speed command during speed control Pr.807 = "1": Pr.808 Pr.807 = "2": Analog input via terminal 1 Reverse-side speed limit Pr.809, or Pr.808 when Pr.809 = "9999"

1 Speed limit mode 3

2 Speed limit mode 4

10 Switching by external terminals

X93 signal OFF: Speed limit mode 3, X93 signal ON: Speed limit mode 4

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Speed limit mode 2 (Pr.1113 = "0" initial value) Following the polarity change in the torque command, the polarity of the speed limit value changes. This prevents the

speed from increasing in the torque polarity direction. (When the torque command value is 0, the polarity of the speed limit value is positive.)

When Pr.807 Speed limit selection = "0", the setting during speed control is applied for the speed limit. When Pr.807 Speed limit selection = "1", Pr.808 Forward rotation speed limit/speed limit is applied for the speed limit.

When Pr.807 = "2", the speed limit command is given by analog input via terminal 1. Set "5" in Pr.868 Terminal 1 function assignment.

When the load has reversed the rotation opposite to the torque polarity, the setting of Pr.809 Reverse rotation speed limit/ reverse-side speed limit is applied for the speed limit. (The speed limit value and reverse-side speed limit value are limited at Pr.1 Maximum frequency (maximum 400 Hz under Vector control).)

Pr.7

ONOFFStart signal

Rotation speed

Time

Torque command

value Speed limit value

-Speed limit value

Reverse-side speed limit value

Reverse-side speed limit value

Rotation speed

-Pr.809

Pr.809

Range where torque control is available

Range where torque control is available

Speed limit value Pr.8

Pr.809 Reverse-side

speed limit value Pr.7

ONOFFStart signal

Rotation speed

Time

Speed limit value Pr.8

-Pr.809 Reverse-side

speed limit value

Range where torque control is available

When the torque command value is negativeWhen the torque command value is positive

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148 TENSION SENSORLESS TORQUE CONTROL

Speed limit mode 3 (Pr.1113 = "1") Select this mode when the torque command is positive. The forward rotation command is for power driving (such as

winding) and the reverse rotation command is for regenerative driving (such as unwinding). (Refer to each following figures.)

When Pr.807 Speed limit selection = "0", the setting during speed control is applied for the speed limit. When Pr.807 Speed limit selection = "1", Pr.808 Forward rotation speed limit/speed limit is applied for the speed limit.

When Pr.807 = "2", the speed limit command is given by an analog signal input via terminal 1. Set "5" in Pr.868 Terminal 1 function assignment.

When the torque command becomes negative, the setting of Pr.809 Reverse rotation speed limit/reverse-side speed limit is applied to prevent the speed from increasing in the reverse rotation direction. (The speed limit value and reverse- side speed limit value are limited at Pr.1 Maximum frequency (maximum 400 Hz under Vector control).)

Unwinding (regenerative driving)

Winding (power driving)

Winding (power driving)

Unwinding (regenerative driving)

Forward rotation

Forward rotation

Reverse rotation

Reverse rotation

Pr.7

ONOFFStart signal

Rotation speed

Time

Torque command

value Speed limit value

Reverse-side speed limit value

Rotation speed

-Pr.809

Range where torque control is available

Range where torque control is available

Speed limit value

Pr.8

-Pr.809 Reverse-side

speed limit value

Pr.7

ONOFFStart signal

Rotation speed

Time

Speed limit value Pr.8

-Pr.809 Reverse-side

speed limit value

Range where torque control is available

For regenerative driving by reverse rotation command (unwinding)

For power driving by forward rotation command (winding)

For forward rotation command

Torque command value

Speed limit value

Reverse-side speed limit value

Rotation speed

-Pr.809

Range where torque control is available

For reverse rotation command

Forward rotation power driving

Reverse rotation regenerative driving

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Speed limit mode 4 (Pr.1113 = "2") Select this mode when the torque command is negative. The forward rotation command is for regenerative driving (such as

unwinding) and the reverse rotation command is for power driving (such as winding). (Refer to each following figures.) When Pr.807 Speed limit selection = "0", the setting during speed control is applied for the speed limit. When Pr.807

Speed limit selection = "1", Pr.808 Forward rotation speed limit/speed limit is applied for the speed limit. When Pr.807 = "2", the speed limit command is given by an analog signal input via terminal 1. Set "5" in Pr.868 Terminal 1

function assignment. When the torque command becomes negative, the setting of Pr.809 Reverse rotation speed limit/reverse-side speed

limit is applied to prevent the speed from increasing in the reverse rotation direction. (The speed limit value and reverse- side speed limit value are limited at Pr.1 Maximum frequency (maximum 400 Hz under Vector control).)

Unwinding (regenerative driving)

Winding (power driving)

Winding (power driving)

Unwinding (regenerative driving)

Forward rotation

Forward rotation

Reverse rotation

Reverse rotation

Pr.7

ONOFFStart signal

Rotation speed

Time

Torque command

valueSpeed limit value

Reverse-side speed limit value

Rotation speed

Pr.809

Range where torque control is available

Range where torque control is available

Speed limit value

Pr.8

Pr.809 Reverse-side

speed limit value

Pr.7

ONOFFStart signal

Rotation speed

Time Speed limit value

Pr.8

Pr.809 Reverse-side

speed limit value

Range where torque control is available

For regenerative driving by forward rotation command (unwinding)

For power driving by reverse rotation command (winding)

For reverse rotation command

Torque command

value Speed limit value

Reverse-side speed limit value

Rotation speed

Pr.809

Range where torque control is available

For forward rotation command

Reverse rotation power driving

Forward rotation regenerative driving

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150 TENSION SENSORLESS TORQUE CONTROL

Speed limit mode switching via external terminals (Pr.1113 = "10") The speed limit mode can be switched between 3 and 4 using the Torque control selection (X93) signal. To assign the X93 signal, set "93" in any of Pr.178 to Pr.189 (Input terminal function selection).

NOTE

During the speed limit operation, " " (SL) is displayed on the operation panel and the OL signal is output.

OL signal is assigned to terminal OL in the initial status. Set "3" in one of Pr.190 to Pr.196 (Output terminal function selection) to assign the RT signal to another terminal. Changing the terminal assignment using Pr.190 to Pr.196 may affect the other functions. Set parameters after confirming the function of each terminal.

Changing the terminal assignment using Pr.178 to Pr.189 (Input terminal function selection) may affect the other functions. Set parameters after confirming the function of each terminal.

X93 signal Speed limit mode OFF Mode 3 (positive torque command, same status as setting Pr.1113 = "1") ON Mode 4 (negative torque command, same status as setting Pr.1113 = "2")

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5.5.5 Taper function The taper function reduces the tension when the winding diameter increases in order to prevent the roll from getting too tight. From a tension value commanded for taper control and the roll diameter determined by the winding diameter calculation, a torque command value required for the tension control is calculated.

The setting varies with the Pr.1401 setting. (Refer to page 140.)

Pr. Name Initial value Setting range Description

829 R504

Taper ratio setting input filter time constant 0.02 s 0 to 5 s Set the time constant of primary delay filter for analog

input at taper ratio setting input using the analog input.

1243 R600 Gear ratio numerator 1 1 to 65534

Set gear ratio when the motor shaft has a reduction gear.1244

R601 Gear ratio denominator 1 1 to 65534

1282 R320

Tension command cushion time 0 s 0 to 360 s Set the time until the tension command value reaches

the reference tension command.

1283 R321

Cushion time reference tension 100 N 0.01 to 500 N

Set the reference tension command value of the tension command cushion time.

1284 R500 Taper mode selection 0

0 No taper 1 Linear taper profile 2 Hyperbolic taper profile 1 3 Hyperbolic taper profile 2 4 Data table profile

1285 R501

Taper setting analog input selection 9999

3 The taper ratio is input through terminal 2. 4 The taper ratio is input through terminal 4. 5 The taper ratio is input through terminal 1. 6 The taper ratio is input through terminal 6 (FR-A8AZ). 9999 No function

1286 R503

Winding diameter at taper start 9999

0 to 6553 mm Set the winding diameter to start taper control.

9999 Taper control is started at the minimum winding diameter.

1287 R502 Taper ratio setting 0%

0 to 100% Set the taper ratio. 9999 The taper ratio is set through the analog input terminal.

1288 R510 Data table winding diameter 1 9999 0 to 6553 mm,

9999

Set the data table profile for the taper mode selection. 9999: The corresponding taper ratio is invalid.

1289 R511 Data table taper ratio 1 0% 0 to 100%

1290 R512 Data table winding diameter 2 9999 0 to 6553 mm,

9999

1291 R513 Data table taper ratio 2 0% 0 to 100%

1292 R514 Data table winding diameter 3 9999 0 to 6553 mm,

9999

1293 R515 Data table taper ratio 3 0% 0 to 100%

1294 R516 Data table winding diameter 4 9999 0 to 6553 mm,

9999

1295 R517 Data table taper ratio 4 0% 0 to 100%

1296 R518 Data table winding diameter 5 9999 0 to 6553 mm,

9999

1297 R519 Data table taper ratio 5 0% 0 to 100%

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152 TENSION SENSORLESS TORQUE CONTROL

Block diagram

Tension command cushion time (Pr.1282, Pr.1283) Set the cushion time for the tension command. Set Pr.1282 Tension command cushion time for the time to reach Pr.1283 Cushion time reference tension.

Taper ratio setting (Pr.1285, Pr.1287) The tension command after the tension command cushion is 100%. Set how much to loosen the tension as a taper ratio in

percent. The input method for setting the taper ratio can be set by parameters.

When Pr.1287 = "9999", the taper ratio is 0%.

NOTE The priorities of the input signals are defined as follows. If the input method for a signal is the same as that for the input signal

with higher priority, the signal with lower priority does not work. Dancer signal input (Pr.363) > Actual line speed input (Pr.362) > Tension command input (Pr.804) > Line speed command input (Pr.361 "0") > Taper setting input (Pr.1285) > Dancer tension setting input (Pr.364) > Line speed command compensation input > Line speed command input (Pr.361 = "0")

Pr.1287 setting Pr.1285 setting Taper ratio setting 0 to 100% As set in Pr.1287

9999

3 Terminal 2 input value 4 Terminal 4 input value 5 Terminal 1 input value 6 Terminal 6 (FR-A8AZ) input value 9999 No function

Analog calibration C2 to C4

Taper mode selection Pr.1284

Terminal 2

X123-ON

X123-OFF

Cushioning

Torque command

Winding diameter

Tension command

Analog calibration C5 to C7Terminal 4

Analog calibration C12 to C15Terminal 1

Analog calibration C30 to C33Terminal 6

3

4

5

6

9999

Pr.1285

Pr.1287

Pr.1287 = 9999

Pr.1282

Pr.1409

Gear ratio Rated motor torque

0 Pr.1287 = 9999

Tension command value

Tension

Time

Pr.1282 Pr.1282

Pr.1283

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Taper ratio setting input adjustment (Pr.829, Pr.902 to Pr.905, Pr.917, Pr.918, Pr.926, Pr.927)

When the taper ratio setting is input using analog input, use the following parameters to calibrate the input value of each terminal. The taper ratios are calibrated for the 0% and 100% analog inputs. (The values for the 0% and 100% analog inputs are fixed.)

The initial input range is 20 to 100%.

When the taper ratio setting is input using analog input, the input value can be filtered using Pr.829 Taper ratio setting input filter time constant.

Taper mode selection (Pr.1284) Use Pr.1284 Taper mode selection to select the tension reduction method (taper mode) for the taper function.

Input terminal Calibration parameter Terminal 2 (0 to 100%) C3 (Pr.902), C4 (Pr.903) Terminal 4 (0 to 100%) C6 (Pr.904), C7 (Pr.905) Terminal 1 (-100 to 100%) C13 (Pr.917), C15 (Pr.918) Terminal 6 (FR-A8AZ) (-100 to 100%) C31 (Pr.926), C33 (Pr.927)

Pr.1284 setting Taper mode

0 No taper

Constant tension command control FTP = F* FTP: Taper control tension command, F*: Tension command

Taper ratio setting (%)

100

0 10 VAnalog input value

Gain C4(Pr.903) C7(Pr.905) C15(Pr.918) C33(Pr.927)-10 V

Bias C3(Pr.902) C6(Pr.904) C13(Pr.917) C31(Pr.926)

Tension command value

Winding diameter Minimum

winding diameter Maximum

winding diameter

Taper control tension command

Tension command

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154 TENSION SENSORLESS TORQUE CONTROL

1 Linear taper profile

Winding diameter Pr.1286 FTP = F*

Pr.1286 < Winding diameter Maximum winding diameter

FTP: Taper control tension command, F*: Tension command, D: winding diameter

When the Pr.1286 setting is smaller than the minimum winding diameter and Pr.1286 = "9999", the winding diameter at taper start is the minimum winding diameter. When the minimum winding diameter is equal to or larger than the maximum winding diameter, the taper function is invalid.

2 Hyperbolic taper profile 1

Winding diameter Pr.1286 FTP = F*

Pr.1286 < Winding diameter Maximum winding diameter

FTP: Taper control tension command, F*: Tension command, D: winding diameter

When the Pr.1286 setting is smaller than the minimum winding diameter and Pr.1286 = "9999", the winding diameter at taper start is the minimum winding diameter. When the minimum winding diameter is equal to or larger than the maximum winding diameter, the taper function is invalid.

Pr.1284 setting Taper mode

100 Maximum winding diameter Pr.1286 D Pr.1286F Taper ratio setting

FTP = F

Tension command value

Winding diameter Pr.1286Minimum

winding diameter Maximum

winding diameter

Taper control tension command

Tension command

Taper ratio setting

Taper ratio setting

Taper ratio = 100%

100 Maximum winding diameter Pr.1286 Maximum winding diameter

D D Pr.1286F Taper ratio setting

FTP = F

Tension command value

Winding diameter Pr.1286Minimum

winding diameter Maximum

winding diameter

Taper control tension command

Tension command

Taper ratio setting

Taper ratio setting

Taper ratio = 100%

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3 Hyperbolic taper profile 2

Winding diameter Pr.1286 FTP = F*

Pr.1286 < Winding diameter

FTP: Taper control tension command, F*: Tension command, D: winding diameter

When the Pr.1286 setting is smaller than the minimum winding diameter and Pr.1286 = "9999", the winding diameter at taper start is the minimum winding diameter. When the minimum winding diameter is equal to or larger than the maximum winding diameter, the taper function is invalid.

4 Data table profile

Tension commanded for taper control = Data table profile setting X1: Data table winding diameter 1, Y1: Data table taper ratio 1 X2: Data table winding diameter 2, Y2: Data table taper ratio 2 X3: Data table winding diameter 3, Y3: Data table taper ratio 3 X4: Data table winding diameter 4, Y4: Data table taper ratio 4 X5: Data table winding diameter 5, Y5: Data table taper ratio 5

Pr.1284 setting Taper mode

1 100 D Pr.1286F Taper ratio setting

FTP = F

Tension command value

Winding diameter Pr.1286Minimum

winding diameter Maximum

winding diameter

Taper control tension command

Tension command

Taper ratio setting

Taper ratio setting

Taper ratio = 100%

Tension command value

Winding diameter Minimum winding diameter

Maximum winding diameter

Taper control tension command

Tension command

Y1, Y2

X1 X2

Y3

X3

Taper ratio = 100%

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156 TENSION SENSORLESS TORQUE CONTROL

Data table profile setting example (Pr.1288 to Pr.1297) When the data table winding diameter is 0 mm, the taper ratio when the winding diameter is 0 mm is calculated as the

corresponding data table taper ratio. When the winding diameter exceeds the maximum data table diameter, the taper ratio is fixed. The setting example is as follows.

The pairs of parameters (Pr.1288/Pr.1289), (Pr.1290/Pr.1291), (Pr.1292/Pr.1293), (Pr.1294/Pr.1295), and (Pr.1296/ Pr.1297) are arranged internally in the inverter from the pair with the smallest winding diameter to the one with the largest to form a data table profile.

NOTE If the same winding diameter is set in two or more of the Pr.1288, Pr.1290, Pr.1292, Pr.1294, and Pr.1296 settings, the data

table set in the parameter with the smallest parameter number is valid. When "9999" is set in the data table winding diameter setting, the corresponding taper ratio setting is invalid.

Tension sensorless torque control (torque command calculation) Calculate the torque command T from the current winding diameter value, motor constant torque, gear ratio for the tension

command FTP of the taper control. The torque command value (T) is limited within the range of 400%.

Pr.1288 = 0 (mm) Pr.1289 = 20% Pr.1290 = 150 (mm) Pr.1291 = 0% Pr.1292 = 250 (mm) Pr.1293 = 0% Pr.1294 = 350 (mm) Pr.1295 = 10% Pr.1296 = 420 (mm) Pr.1297 = 30% Minimum winding diameter = 50 (mm) Maximum winding diameter = 500 (mm)

Tension command value

Winding diameter Minimum winding diameter

Maximum winding diameter

Taper control tension command

Tension command

Pr.1289

P.12900

Pr.1295

P.1292 Pr.1296P.1294

Pr.1297

Pr.1288 = 550 (mm) Pr.1289 = 50% Pr.1290 = 200 (mm) Pr.1291 = 60% Pr.1292 = 300 (mm) Pr.1293 = 40% Pr.1294 = 100 (mm) Pr.1295 = 10% Pr.1296 = 400 (mm) Pr.1297 = 40% Minimum winding diameter = 50 (mm) Maximum winding diameter = 500 (mm)

Tension command value

Winding diameter

Minimum winding diameter

Maximum winding diameter

Taper control tension command

Tension command

Pr.1296Pr.1292Pr.1290

Pr.1295

Pr.1294 Pr.1288

Pr.1291 Pr.1289

Pr.1293/Pr.1297

100 FTP (N) Present winding diameter (m) Gear ratio

T [%] = 2 Rated motor torque (Nm) Pr.1244

Pr.1243 Gear ratio =

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5.5.6 Inertia compensation function The acceleration/deceleration torque is given to the motor by increasing/decreasing the torque command value to keep the material tension constant even during acceleration/deceleration.

The unit varies depending on the Pr.358 setting. (Refer to page 67.)

Pr. Name Initial value Setting range Description

271 R537

Second acceleration time for inertia compensation 15 s 0 to 3600 s Set the acceleration time for inertia compensation when

the X113 signal is turned ON.

272 R538

Second deceleration time for inertia compensation 15 s 0 to 3600 s Set the deceleration time for inertia compensation when

the X113 signal is turned ON.

393 R250

Line speed command acceleration/deceleration reference

1000 m/ min

1 to 6553.4 m/ min

Set the reference line speed for the acceleration/ deceleration time for the line speed.

753 R539 Empty reel inertia (integer) 9999

10 to 999 Set the significand of the floating-point arithmetic to determine the empty reel inertia.

9999 No function

754 R540 Empty reel inertia (exponent) 9999

0 to 7, 101 to 104 Set the exponent of the floating-point arithmetic to determine the empty reel inertia.

9999 No function

1141 R290

Line speed command acceleration/deceleration pattern

0 0 Linear acceleration/deceleration

1 S-curve acceleration/deceleration

1142 R291

Line speed command acceleration start S-curve time

0.1 s 0.1 to 2.5 s

Set times for S-curve acceleration/deceleration. The settings are also used for the inertia compensation cushion time. The settings are valid for S-curve acceleration/ deceleration (Pr.1141 = "1"). For details on S-curve acceleration/deceleration, refer to page 82.

1143 R292

Line speed command acceleration start S-curve time

0.1 s 0.1 to 2.5 s

1144 R293

Line speed command deceleration start S-curve time

0.1 s 0.1 to 2.5 s

1145 R294

Line speed command deceleration completion S- curve time

0.1 s 0.1 to 2.5 s

1410 R530 Motor inertia 0 kgm2

0 to 500 kgm2 Set the motor inertia.

9999

The Pr.707 and Pr.724 settings are used to determine a motor inertia for the first motor and the Pr.744 and Pr.745 settings for the second motor (refer to page 56). When "9999" is set in either Pr.707 or Pr.724, or either Pr.744 or Pr.745, an internal value is used for the first or second motor inertia.

1411 R531 Empty reel inertia 0 kgm2

0 to 500 kgm2 Set the empty reel inertia value.

9999

The Pr.753 and Pr.754 settings are used to determine the empty reel inertia. When "9999" is set in Pr.753 or Pr.754, the inertia is set to 0.

1412 R532 Roll width 0 mm 0 to 5000 mm Set the roll width.

1413 R533 Material specific gravity 0 g/cm3 0 to 20 g/cm3 Set the specific gravity of the material.

1414 R535

First acceleration time for inertia compensation 15 s 0 to 3600 s Set the acceleration time during inertia compensation

operation.

1415 R536

First deceleration time for inertia compensation 15 s 0 to 3600 s Set the deceleration time during inertia compensation

operation.

1418 R534

Inertia compensation cushion time 0 s 0 to 360 s Set the time for increasing/decreasing the torque for

inertia compensation.

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158 TENSION SENSORLESS TORQUE CONTROL

Block diagram

Formula for calculating the torque for inertia compensation

Symbol Description Remarks

JM Motor inertia value J (kgm2)

Refer to page 159.

JL Material inertia value J (kgm2)

JB Empty reel inertia value J (kgm2)

Refer to page 159.

Z Gear ratio Pr.1243/Pr.1244

Pr.393 Line speed command acceleration/deceleration reference

Pr.393 The parameter setting unit is as set in Pr.358.

t Acceleration time for inertia compensation or deceleration time for inertia compensation (s) Pr.1414, Pr.1415, Pr.271, Pr.272

D2 Minimum winding diameter (m) Pr.1236, Pr.1238, Pr.1240, Pr.1242 The parameter setting unit is mm.

Material specific gravity (Kg/m3) Pr.1413 The parameter setting unit is g/cm3.

L Roll width (m) Pr.1412 The parameter setting unit is mm.

D1 Present winding diameter (m)

Inertia Pr.1410, Pr.707, Pr.724, Pr.744, Pr.745, Pr.1411, Pr.753, Pr.754

Pr.22

Pr.1414

Pr.271

Pr.1415

Pr.272

X113-ON

X113-OFF

X113-ON

X113-OFF

X111-OFF

X111-ON X112-OFF

X112-ON

Torque limit {Pr.393 / ( present winding diameter) / gear ratio} /

(9.55 acceleration time)

{Pr.393 / ( present winding diameter) / gear ratio} / (9.55 deceleration time)

Pr.1141 = 1

Pr.1141 = 0

Inertia compensation torque

Pr.1142 to Pr.1145

Line speed command cushion time for S-curve

Pr.1418

Cushion time

Ta 100 (%)

Rated motor torque TM

Inertia compensation torque T (%)

Roll width (L)

Minimum winding diameter (D2)

Present winding diameter (D1)

Motor inertia (JM)

Material inertia (JL)

Empty reel inertia (JB)

Ta = [{JM + (JL + JB) Z2} {Pr.393 / ( D1) / Z}] / (9.55 t)

32

1 JL= L (D14 - D24)

=

Inverter-driven motor

Reduction gear (gear ratio: Z)

Pr.1243 (Gear ratio numerator)

Pr.1244 (Gear ratio denominator)

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TENSION SENSORLESS TORQUE CONTROL 159

5

Motor inertia setting and empty reel inertia setting Motor inertia setting are determined as follows.

Empty reel inertia setting are determined as follows.

Pr.1410 setting

RT signal Description Setting range

Other than 9999

Pr.1410 setting. 0 to 500 kgm2

9999 OFF Pr.707 10^(-Pr.724)

(When "9999" is set in Pr.707 or Pr.724, an internal value is used.) 10 10-7 to 999 kgm2

ON Pr.744 10^(-Pr.745) (When "9999" is set in Pr.744 or Pr.745, an internal value is used.)

Pr.1411 setting

Pr.754 setting Description Setting range

Other than 9999

Pr.1411 setting. 0 to 500 kgm2

9999 0 to 7 Pr.753 10^(-Pr.754)

(When "9999" is set in Pr.753 or Pr.754, inertia is set to 0.) 10 10-7 to 999 104 kgm2

101 to 104

Pr.753 10^(Pr.754-100) (When "9999" is set in Pr.753 or Pr.754, inertia is set to 0.)

Tension sensorless torque control details

160 TENSION SENSORLESS TORQUE CONTROL

Inertia compensation function operation selection (X111 to X113 signals)

The diagram shows the operation example when Pr.1141 = "0" (initial setting).

Pr.1141 setting Operation according to the X111 signal status Operation according to the X112 signal status

0 (Linear acceleration/ deceleration)

When the X111 signal is turned ON, an inertia compensation for the acceleration torque is started. For winding (power driving), the torque command value is increased. For unwinding (regenerative driving), the torque command value is decreased. The variation ratio is determined according to Pr.1418 Inertia compensation cushion time. When the X111 signal is turned OFF, the acceleration torque for inertia compensation is decreased according to the Pr.1418 setting. The Line speed acceleration (Y237) signal of the inverter connected to the intermediate shaft is input to the terminal to which the X111 signal is assigned.

When the X112 signal is turned ON, an inertia compensation for the deceleration torque is started. For winding (power driving), the torque command value is decreased. For unwinding (regenerative driving), the torque command value is increased. The variation ratio is determined according to Pr.1418 Inertia compensation cushion time, When the X112 signal is turned OFF, the deceleration torque for inertia compensation is decreased according to the Pr.1418 setting. The Line speed deceleration (Y238) signal of the inverter connected to the intermediate shaft is input to the terminal to which the X112 signal is assigned.

1 (S-curve acceleration/ deceleration)

When the X111 signal is turned ON, an inertia compensation for the acceleration torque is started. For winding (power driving), the torque command value is increased. For unwinding (regenerative driving), the torque command value is decreased. The variation ratio is determined according to Pr.1142 Line speed command acceleration start S-curve time. When the X111 signal is turned OFF, the acceleration torque for inertia compensation is decreased according to the Pr.1143 Line speed command acceleration completion S-curve time. The Line speed acceleration (Y237) signal of the inverter connected to the intermediate shaft is input to the terminal to which the X111 signal is assigned.

When the X112 signal is turned ON, an inertia compensation for the deceleration torque is started. For winding (power driving), the torque command value is decreased. For unwinding (regenerative driving), the torque command value is increased. The variation ratio is determined according to Pr.1144 Line speed command deceleration start S-curve time. When the X112 signal is turned OFF, the deceleration torque for inertia compensation is decreased according to the Pr.1145 Line speed command deceleration completion S-curve time. The Line speed deceleration (Y238) signal of the inverter connected to the intermediate shaft is input to the terminal to which the X112 signal is assigned.

Rotation speed

Torque

X111

X112

Torque command

Inertia compensation (acceleration)

Time

Inertia compensation (deceleration)

ON

ON

Time

Example of winding (power driving)

X111

X112

Example of unwinding (regenerative driving)

ON

ON

Time

Time

Inertia compensation (deceleration)Torque command

Rotation speed

Torque

Inertia compensation (acceleration)

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TENSION SENSORLESS TORQUE CONTROL 161

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The diagram shows the operation example when Pr.1141 = "1".

Use the X113 signal to switch the acceleration/deceleration time for inertia compensation.

To use the X111 to X113 signals, set Pr.178 to Pr.189 (input terminal function selection) to assign the function of each signal to an input terminal.

NOTE The function is not activated when the winding diameter is 9 mm or less. The inertia compensation function is invalid while the X122 signal is ON. If both X111 and X112 signals are ON, the inertia compensation function is not activated. When the master's Y237/Y238 signal is used as the slave's X111/X112 signal, do not change the acceleration/deceleration

time for the line speed command in the master during S-curve acceleration/deceleration operation, or do not set parameters to reach the line speed command maximum value during S-curve acceleration/deceleration operation. Doing so will cause inconsistency between the required inertia compensation torque and the inertia compensation torque calculated from the parameter setting values.

For details on changing the line speed command acceleration/deceleration pattern by the Pr.1141 setting value, refer to page 82 .

X113 signal Acceleration time for inertia compensation Deceleration time for inertia compensation

OFF Pr.1414 First acceleration time for inertia compensation

Pr.1415 First deceleration time for inertia compensation

ON Pr.271 Second acceleration time for inertia compensation

Pr.272 Second deceleration time for inertia compensation

Pr.178 to Pr.189 setting Signal name Function 111 X111 Inertia compensation acceleration 112 X112 Inertia compensation deceleration 113 X113 Inertia compensation second acceleration/deceleration time

Rotation speed

Torque

X111

X112

Torque command

100%

-100%

Inertia compensation (acceleration)

Example of winding (power driving)

Time

Inertia compensation (deceleration)

ON

ON

Time

Example of unwinding (regenerative driving)

Pr.1144 Pr.1145

Pr.1143

-100%

100%

Rotation speed

Torque

X111

X112

Torque command

Inertia compensation (acceleration)

Time

Inertia compensation (deceleration)

ON

ON

Time Pr.1142 Pr.1143

Pr.1144 Pr.1145

Pr.1142

Tension sensorless torque control details

162 TENSION SENSORLESS TORQUE CONTROL

Inertia compensation cushion time (Pr.1418, Pr.1142 to Pr.1145) Set the cushion time for the inertia compensation command. When Pr.1141 = "0 (initial value)", the time to reach the 100% torque command is set in Pr.1418 Inertia compensation

cushion time.

When Pr.1141 = "1", times set in Pr.1142 to Pr.1145 are used for the inertia compensation cushion time settings.

Rotation speed

Torque

X111

X112

Torque command

100%

-100%

Inertia compensation (acceleration)

Pr.1418

Example of winding (power driving)

Time

Inertia compensation (deceleration)

ON

ON

Time

Example of unwinding (regenerative driving)

Pr.1418 Pr.1418

Pr.1418

-100%

100%

Rotation speed

Torque

X111

X112

Torque command

Inertia compensation (acceleration)

Time

Inertia compensation (deceleration)

ON

ON

Time Pr.1418 Pr.1418

Pr.1418 Pr.1418

Inertia compensation command value

Inertia compensation command value

Torque

Time

Pr.1142 Pr.1143

Torque command 100%

Torque command -100%

Pr.1144 Pr.1145

Tension sensorless torque control details

TENSION SENSORLESS TORQUE CONTROL 163

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5.5.7 Mechanical loss compensation function By increasing the torque command value to compensate loss caused by factors such as mechanical friction (mechanical loss), tension change due to mechanical loss can be prevented.

Block diagram

Pr. Name Initial value Setting range Description

1230 R003 Winding/unwinding selection 0

0 Winding 1 Unwinding

1419 R550

Mechanical loss setting frequency bias 1000% 900 to 1100% Set the bias compensation value for the mechanical

loss compensation function.

1420 R551

Mechanical loss setting frequency 1 9999 0 to 400 Hz,

9999 Set the frequency for the mechanical loss 1.

1421 R552 Mechanical loss 1 1000% 900 to 1100% Set the compensation value for the mechanical loss 1.

1422 R553

Mechanical loss setting frequency 2 9999 0 to 400 Hz,

9999 Set the frequency for the mechanical loss 2.

1423 R554 Mechanical loss 2 1000% 900 to 1100% Set the compensation value for the mechanical loss 2.

1424 R555

Mechanical loss setting frequency 3 9999 0 to 400 Hz,

9999 Set the frequency for the mechanical loss 3.

1425 R556 Mechanical loss 3 1000% 900 to 1100% Set the compensation value for the mechanical loss 3.

1426 R557

Mechanical loss setting frequency 4 9999 0 to 400 Hz,

9999 Set the frequency for the mechanical loss 4.

1427 R558 Mechanical loss 4 1000% 900 to 1100% Set the compensation value for the mechanical loss 4.

1428 R559

Mechanical loss setting frequency 5 9999 0 to 400 Hz,

9999 Set the frequency for the mechanical loss 5.

1429 R560 Mechanical loss 5 1000% 900 to 1100% Set the compensation value for the mechanical loss 5.

1

-1

Pr.1230 = 0 (winding)

Pr.1230 = 1 (unwinding)

Torque after mechanical loss

compensation

Motor speed

N1 Pr.1420

N2 Pr.1422

N3 Pr.1424

N4 Pr.1426

N5 Pr.1428

Pr.1421 L1

Pr.1423 L2

Pr.1425 L3

Pr.1427 L4

Pr.1429 L5

Mechanical loss compensation value

Motor speed

Mechanical loss setting frequency

M ec

ha ni

ca l l

os s

Pr.1419 LB

Tension sensorless torque control details

164 TENSION SENSORLESS TORQUE CONTROL

Mechanical loss compensation function selection (Pr.1230, Pr.1419 to Pr.1429)

The maximum of five approximate break points can be set as mechanical loss points. Set mechanical loss parameters (mechanical loss setting frequency, mechanical loss) and linearly interpolate the values between the set points.

The mechanical loss compensation value is calculated from the mechanical loss setting and the motor rotation speed (output frequency) and added to the torque command value. The mechanical loss compensation amount is added as follows according to the winding/unwinding setting.

For setting the mechanical loss (Pr.1419, Pr.1421, Pr.1423, Pr.1425, Pr.1427, Pr.1429), regard 1000 as 0% and set an offset from 1000.

Operate the line with a load (with a reel inside), and set the motor speed frequency and the monitored torque value in Pr.1420 to Pr.1429.

NOTE When "9999" is set in the mechanical loss setting frequency, the corresponding mechanical loss setting is invalid. If the same frequency is set in two or more of the Pr.1420, Pr.1422, Pr.1424, Pr.1426, and Pr.1428 settings, the mechanical

loss set in the parameter with the smallest parameter number is valid. When the mechanical loss setting frequency (1 to 5) setting is 0 Hz, the Pr.1419 setting is invalid.

Mechanical loss compensation function setting example The mechanical loss compensation value after linear interpolation is limited within the range of 100%.

The pairs of parameters (Pr.1420/Pr.1421), (Pr.1422/Pr.1423), (Pr.1424/Pr.1425), (Pr.1426/Pr.1427), and (Pr.1428/ Pr.1429) are arranged internally in the inverter from the pair with the smallest mechanical loss setting frequency to the one with the largest.

Winding/unwinding Commanded torque after mechanical loss compensation Winding shaft (Pr.1230 = "0") Torque command value minus mechanical loss compensation value Unwinding shaft (Pr.1230 = "1") Torque command value plus mechanical loss compensation value

Parameter setting Actual mechanical loss setting 900.0 to 999.9% -100.0 to -0.1% 1000.0% 0.0% 1000.1 to 1100.0% 0.1 to 100.0%

N1 Pr.1420

N2 Pr.1422

Pr.1421 L1

Pr.1423 L2

100%

Mechanical loss compensation value

Motor speed

Mechanical loss setting frequency

M ec

ha ni

ca l l

os s

Pr.1419 LB

Pr.1420 = 10 Hz Pr.1419 = 1000% Pr.1422 = 20 Hz Pr.1421 = 1030% Pr.1424 = 9999 Pr.1423 = 1080% Pr.1426 = 9999 Pr.1425 = 1000% Pr.1428 = 9999 Pr.1427 = 1000%

Pr.1429 = 1000%

Mechanical loss compensation value

Motor Rotation speed

Mechanical loss setting frequency

M ec

ha ni

ca l l

os s

Pr.1420 = 50 Hz Pr.1419 = 1000% Pr.1422 = 20 Hz Pr.1421 = 1010% Pr.1424 = 30 Hz Pr.1423 = 1030% Pr.1426 = 10 Hz Pr.1425 = 1040% Pr.1428 = 40 Hz Pr.1427 = 1070%

Pr.1429 = 1080%

N1 Pr.1420

N2 Pr.1422

N3 Pr.1424

N4 Pr.1426

N5 Pr.1428

Pr.1421 L1

Pr.1423 L2 Pr.1425 L3

Pr.1427 L4 Pr.1429 L5

Pr.1419 LB

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5.5.8 Stall mode function By turning ON the Stall mode trigger (X123) signal before starting winding, tension is applied to the material and the stall mode is activated. This function is useful for sagging prevention of the material before it is winded.

Stall mode While the Stall mode trigger (X123) signal is ON, the tension command value is reduced according to the Pr.1406

Commanded tension reduction scaling factor during stall condition setting. The speed limit value is switched to the Pr.1407 Speed limit during stall condition setting.

NOTE The commanded tension after the reduction according to the Pr.1406 setting is limited by the maximum tension command

value. While the inertia compensation function is activated (the X111/X112 signal is ON), the stall mode is cancelled. (The tension

command and speed limit values are switched back to the normal settings.)

Pr. Name Initial value

Setting range Description

270 R342

Acceleration/deceleration time during stall condition 15 s 0 to 3600 s Set the acceleration/deceleration time during stall

mode.

1406 R340

Commanded tension reduction scaling factor during stall condition 20% 0 to 200%

Set the value to reduce the commanded tension during stall mode. Commanded tension during stall mode = Tension command value Pr.1406

1407 R341 Speed limit during stall condition 1 Hz 0 to 60 Hz Set the speed limit to be used during stall mode.

1409 R343

Tension command cushion time during stall condition 9999 0 to 360 s Set the cushion time during stall mode.

Symbol in the diagram Description

a Speed limit during stall condition

b When the X111 or X112 signal turns ON while the X123 signal is ON, the tension command value is switched back to the normal setting.

c When Pr.1409 0 (or Pr.1409 = "9999" and Pr.1282 0), the cushion time is applied.

d When the X111 or X112 signal turns ON while the X123 signal is ON, the speed limit value is switched back to the normal setting.

e When the X123 signal is turned ON during operation, the commanded tension is switched to the tension command value multiplied by the Pr.1406 setting.

f When the X123 signal is turned ON during operation, the speed limit value is switched to the value set in Pr.1407 in the time set in Pr.270.

X123

STF

X111

Tension command

Speed limit

Tension command Pr.1406

Pr.1407 Pr.1407

Pr.1407/Pr.20 Pr.270

Stall mode Normal operation Stall mode

a

b

c

d

e

f

Tension sensorless torque control details

166 TENSION SENSORLESS TORQUE CONTROL

Cushion time during stall mode (Pr.1409) Use Pr.1409 Tension command cushion time during stall condition to set the cushion time during stall mode.

Pr.1282 setting Pr.1409 setting

X123 ON (stall mode) OFF (normal operation)

0 (initial value) 0 No cushioning No cushioning 9999 (initial value) No cushioning No cushioning 0.01 to 360 As set in Pr.1409. As set in Pr.1282.

0.01 to 360 0 No cushioning As set in Pr.1282. 9999 (initial value) As set in Pr.1282. As set in Pr.1282. 0.01 to 360 As set in Pr.1409. As set in Pr.1282.

Dedicated function list

TENSION SENSOR FEEDBACK TORQUE CONTROL 167

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6 TENSION SENSOR FEEDBACK TORQUE CONTROL

6.1 Dedicated function list

NOTE For the details of the winding diameter compensation function, refer to page 194.

6.2 System configuration example

Item Description

Tension sensor feedback torque control

Control method PID control, PI control, P control, and PD control can be selected. Gain switchover by tension feedback is available. Gain switchover by external terminal input is available.

Tension command Parameter setting / analog terminal input / pulse train input / communication Tension detection signal Use an analog terminal for the signal input. (Terminal 1, 2, 4, or 6 is selectable.) Additional function Material break detection function Taper function Set a taper ratio.

Inertia compensation function Set the compensation for acceleration and deceleration individually using external signals.

Mechanical loss compensation function Straight movement (with five break points) against the speed can be performed.

Common Dedicated input signal

Dancer/tension control selection, Inertia compensation acceleration, Inertia compensation deceleration, Inertia compensation second acceleration/ deceleration time selection, Winding diameter measurement, Stall mode trigger, Two-way operation.

Dedicated output signal Winding diameter calculation completion at start Dedicated monitor Tension command, mechanical loss compensation, inertia compensation

M

FR-A800-R2R

STF/STR

X112 (Pr.185 = 112)

X111 (Pr.184 = 111)

M

FR-A800-R2R

2 Y237

Y238 STF/STR

Intermediate shafts / speed control

Line speed detection

Actual line speed

2 (Pr.362 = 3)

1 (Pr.363 = 5)

Tension control selection

Inertia compensation acceleration signal

X114 (Pr.180 = 114)

Line speed command

Start command

X114 Tension control

selection

Tension command FR-A8AZ

Winding shaft (Pr.1230 = 0)

Start command

Tension feedback

6 (Pr.804 = 0)

Inertia compensation deceleration signal

Stall mode trigger signal

Stored winding diameter clear X109 (Pr.181 = 109)

Winding length clear X117 (Pr.182 = 117)

Encoder

Encoder

FR-A8AP FR-A8AP

Programmable controller

Vector control

Minimum diameter

Maximum diameter

Reduction gear

X123 (Pr.183 = 123)

TH1 TH2

Thermistor input

Control block diagram

168 TENSION SENSOR FEEDBACK TORQUE CONTROL

6.3 Control block diagram

6.3.1 Block diagram of tension sensor feedback torque control function

Mechanical loss compensation

Pr.1419 to Pr.1429

Inertia compensation Pr.393, Pr.1410 to Pr.1418

+ +

+ +Tension control

(torque calculation) Pr.1235, Pr.1236

Taper function Pr.1284 to Pr.1297

Pr.1236

Winding diameter calculation

Pr.1235, Pr.1236 Pr.1243, Pr.1244

Torque control M

Encoder

X114-ON

X114-OFF

Tension command

Actual line speed

Winding diameter

Motor speed (Torque command)

Tension command cushioning

Pr.1282, Pr.1283

Tension reverse selection Pr.1072

+-Primary delay filter Pr.1227

Tension PID calculationTension feedback

X116 PID action selection

Parameter setting procedure for tension sensorless torque control

TENSION SENSOR FEEDBACK TORQUE CONTROL 169

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6.4 Parameter setting procedure for tension sensorless torque control

The following procedure shows the parameter setting example for the tension sensor feedback torque control.

6.4.1 Parameter setting procedure 1 Wiring

Perform secure wiring.

NOTE Do not feed the workpiece through the machine.

2 Control method selection Select the control method according to the application and the motor.

For the control method, vector control is recommended. Setting is required for a motor other than a Mitsubishi Electric motor (the SF-PR, SF-JR, SF-HR, SF-JRCA, SF-HRCA, or SF-V5RU (1500 r/min

series) motor). For the FR-A820-03160(55K) or lower and FR-A840-01800(55K) or lower. For the FR-A820-03800(75K) or higher and FR-A840-02160(75K) or higher.

NOTE Torque control is not available in a low-speed (about 10 Hz or lower) regenerative range, or with a low speed and light load

(about 5 Hz or lower and rated torque about 20% or lower). Vector control must be selected. For the parameter details, refer to the FR-A800 Instruction Manual (Detailed).

3 Speed limit setting Set the speed limit as required as follows.

NOTE Use Pr.807 to Pr.809 and Pr.1113 to set the speed limit. As the speed limit value is overwritten frequently, set "0" in Pr.342

Communication EEPROM write selection to enable RAM write. For the parameter details, refer to the FR-A800 Instruction Manual (Detailed).

Pr. Name Setting range Minimum setting

increments Initial value

71 Applied motor 0, 1, 3 to 6, 13 to 16, 20, 23, 24, 30, 33, 34, 40, 43, 44, 50, 53, 54, 70, 73, 74 1 0

9 Electronic thermal O/L relay 0 to 500 A 0.01 A Inverter rated

current0 to 3600 A 0.1 A

80 Motor capacity 0.4 to 55 kW, 9999 0.01 kW

9999 0 to 3600 kW, 9999 0.1 kW

81 Number of motor poles 2, 4, 6, 8, 10, 12, 9999 1 9999

83 Rated motor voltage 0 to 1000 V 0.1 V

200 V (200 V class) 400 V (400 V class)

84 Rated motor frequency 10 to 400 Hz, 9999 0.01 Hz 9999 800 Control method selection 0 to 2, 9 to 12, 20, 100 to 102, 109 to 112 1 20

803 Constant output range torque characteristic selection 0 to 2, 10, 11 1 0

807 Speed limit selection 0 to 2 1 0 810 Torque limit input method selection 0 to 2 1 0 359 Encoder rotation direction 0, 1, 100, 101 1 1 369 Number of encoder pulses 0 to 4096 1 1024 707 Motor inertia (integer) 10 to 999, 9999 1 9999 724 Motor inertia (exponent) 0 to 7, 9999 1 9999 862 Encoder option selection 0, 1 1 0

1.1 to 1.2 Present diameter Gear ratio

Present line speed Speed limit value =

Parameter setting procedure for tension sensorless torque control

170 TENSION SENSOR FEEDBACK TORQUE CONTROL

4 Torque characteristic setting Set "1" in Pr.803 to make the torque characteristic constant for the tension command in the low-speed range and in the constant output range.

5 Offline auto tuning Perform offline auto tuning as required. For offline auto tuning, refer to page 55.

After the offline auto tuning, perform the test run of the motor alone to make sure that no fault is found in the motor's behavior.

6 Mechanical specifications setting Set the following parameters according to the specifications of the machine used. Refer to 11.6 (Application examples) on page 243.

Set the parameter according to the specification of the machine used. The increment applies when Pr.21 = "0 (initial value)". The increment applies when Pr.358 = "0 (initial value)".

Pr. Name Setting range

Minimum setting

increments

Initial value

96 Auto tuning setting/status 0, 1, 11, 101 1 0

Pr. Name Setting Remarks 1235 Maximum winding diameter 1 Set the maximum/minimum value in 1 mm increments (1 to

6553 mm) relative to the winding diameter calculation result.1236 Minimum winding diameter 1

178 to 189 Input terminal function selection

114 Set "114" for the X114 signal.

109 Set "109" for using the Stored winding diameter clear (X109) signal.

117 Set "117" for using the Winding length clear (X117) signal.

1230 Winding/unwinding selection 0: Winding shaft 1: Unwinding shaft

645 Winding diameter storage selection

0: Not stored. 1: The present winding diameter is stored.

1247 Winding diameter change increment amount limit

Set the maximum change in 0.001 mm increments (0 to 9.998 mm or 9999) per roll diameter calculation.

1243 Gear ratio numerator Set a gear ratio in 1 increments (1 to 65534) when a reduction gear is installed between the driving shaft and motor shaft.1244 Gear ratio denominator

7 Acceleration time 0 s 0 to 3600 seconds, in 0.1 second increments

8 Deceleration time 0 s

394 First acceleration time for line speed command Setting is required in 0.1 second increments (0 to 3600

seconds) when the cushion time is not considered for the line speed command.395 First deceleration time for line

speed command

101 Second deceleration time for line speed command

Set the time in 0.1 second increments (0 to 3600 seconds) as required (for example, for rapid deceleration). Turn ON the X105 signal to enable the setting.

393 Line speed command acceleration/deceleration reference

Set the reference line speed (travel amount per minute) in 0.1 m/min increments (1 to 6553.4 m/min) for the acceleration/ deceleration time for the line speed command.

1231 Material thickness d1 Setting is required in 0.001 mm increments (0 to 20 mm or 9999) when thickness is used for winding diameter calculation.

1072 Tension reverse selection

0: The tension direction is not reversed. 1: The tension direction is reversed. Set the torque generation

direction in accordance with the machine used.

1114 Torque command reverse selection

0: The torque direction is not reversed. 1: The torque direction is reversed.

Parameter setting procedure for tension sensorless torque control

TENSION SENSOR FEEDBACK TORQUE CONTROL 171

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7 Tension feedback setting Set the following parameters according to the tension feedback input method when the tension sensor is used.

The input specification in the initial setting is indicated. (Refer to page 47.)

The following table shows a setting example.

8 Tension command input selection Set the following parameter according the tension input method.

The following table shows a setting example.

Pr. Name Setting Input method

363 Dancer / tension sensor feedback input selection

3 Terminal 2 (analog value: 0 to 100%) (0 to 5 VDC) 4 Terminal 4 (analog value: 20 to 100%) (4 to 20 mADC) 5 Terminal 1 (analog value: -100 to 100%) (0 to 10 VDC)

6 Terminal 6 (FR-A8AZ) (analog value: -100 to 100%) (0 to 10 VDC)

9 CC-Link or CC-Link IE Field Network Basic (-100 to 100%) 9999 (initial value) No function

Item Setting example

Tension feedback input method

Setting by analog voltage (0 to 10 V) input through terminal 1 (Pr.363 = "5")

Parameter setting

Pr.1136 Tension sensor feedback voltage/current bias = 0% Pr.1137 Tension sensor feedback bias = 0 N Pr.1138 Tension sensor feedback voltage/current gain = 100% Pr.1139 Tension sensor feedback gain = 100 N

Pr. Name Setting Input terminal

804 Tension / Torque command source selection

0 (initial value)

Tension command by terminal 1 analog input (-10 to 10 VDC) Tension command by terminal 6 analog input (-10 to 10 VDC) (FR-A8AZ)

1 Tension command by the parameter setting (Pr.365 or Pr.366) 2 Tension command by the pulse train command (FR-A8AL)

3 Tension command via CC-Link communication (FR-A8NC/FR-A8NCE) Tension command via PROFIBUS-DP communication (FR-A8NP)

4 Tension command by 12/16-bit digital input (FR-A8AX) 5 Tension command via CC-Link communication

(FR-A8NC/FR-A8NCE) Tension command via PROFIBUS-DP communication (FR-A8NP)6

Item Setting example

Tension command input method

Setting by analog voltage (0 to 10 V) input through terminal 1 (Pr.804 = "0")

Parameter setting

Pr.868 Terminal 1 function assignment = "3 or 4" Pr.1402 Tension command input voltage bias = 0% Pr.1403 Tension command bias = Minimum tension Pr.1404 Tension command input voltage gain = 100% Pr.1405 Tension command gain = Maximum tension Pr.1401 Tension command increment = "0" (0.01 N increment)

0 V Pr.1136 (0%)

100 N Pr.1139

0 N Pr.1137 Analog input value10 V

Pr.1138 (100%)

Tension feedback

Pr.1405 (Maximum tension)

Pr.1403 (Minimum tension)

0 V Pr.1402 (0%)

Analog input value10 V Pr.1404 (100%)

Tension command value

Parameter setting procedure for tension sensorless torque control

172 TENSION SENSOR FEEDBACK TORQUE CONTROL

9 Actual line speed input Use Pr.362 to select the input terminal for actual line speed.

To perform Vector control, install the Vector control compatible option. The input specification in the initial setting is indicated. (Refer to page 47.)

The following table shows setting examples.

Set the pulse division scaling factor in Pr.384 for pulse train input through terminal JOG. Number of pulses calculated internally = Number of input pulses / Pr.384 setting value When inputting 50k pulses/s while Pr.281 = 0 m/min, Pr.279 = 100 m/min, Pr.282 = 0 pulses/s, Pr.283 = 50k pulses/s, and Pr.384 = "2", the actual line speed will be 50 m/min.

Pr. Name Setting Input terminal

362 Actual line speed input selection

0 (initial value) V* (line speed command)

1 Terminal JOG single-phase pulse train input (Refer to page 200)

2 FR-A8AP/FR-A8AL/FR-A8TP encoder pulse train input (complementary 12 V / differential 5 V (A-, B-phases)) (Refer to page 200)

3 Terminal 2 (analog value: 0 to 100%) (0 to 5 VDC) (Refer to page 202)

4 Terminal 4 (analog value: 20 to 100%) (4 to 20 mADC) (Refer to page 202)

5 Terminal 1 (analog value: -100 to 100%) (0 to 10 VDC) (Refer to page 202)

6 Terminal 6 (FR-A8AZ) (analog value: -100 to 100%) (0 to 10 VDC) (Refer to page 202)

7 FR-A8AL single-phase pulse train input (PP, NP) (Refer to page 200)

9 CC-Link or CC-Link IE Field Network Basic (0 to 65534) 9999 No function

Item Setting example 1 Setting example 2

Actual line speed input method

Setting by analog current (4 to 20 mA) input through terminal 4 (Pr.362 = "4")

Setting by pulse train input through terminal JOG (Pr.362 = "1")

Parameter setting

Pr.280 Actual line speed voltage/current bias = 20% Pr.281 Actual line speed bias = 0 m/min Pr.278 Actual line speed voltage/current gain = 100% Pr.279 Actual line speed gain = Maximum line speed

Pr.384 Input pulse division scaling factor = "1" Pr.281 Actual line speed bias = 0 m/min Pr.282 Actual line speed pulse input bias = 0 pulses/s Pr.279 Actual line speed gain = Maximum line speed Pr.283 Actual line speed pulse input gain = Maximum number of pulses

Pr.279 (Maximum line speed)

Pr.281 (0 m/min)

4 mA Pr.280 (20%) Analog input value

20 mA Pr.278 (100%)

Actual line speed

Pr.279 (Maximum line speed)

6553.4

Pr.281 (0 m/min)

Pr.282 (0 pulses/s)

Number of input pulses

Pr.283 (Maximum number of pulses)

Actual line speed

Parameter setting procedure for tension sensorless torque control

TENSION SENSOR FEEDBACK TORQUE CONTROL 173

6

10 Taper ratio setting Set the taper ratio input method for using the taper ratio.

The input specification in the initial setting is indicated. (Refer to page 47.)

The following table shows a setting example.

For using the taper ratio, set the following parameters according to the taper mode.

NOTE For the details of the taper function, refer to page 151.

Pr. Name 1285 Taper setting analog input selection 1287 Taper ratio setting

Pr.1287 setting Pr.1285 setting Taper ratio setting 0 to 100% As set in Pr.1287

9999

3 Terminal 2 (analog value: 0 to 100%) (0 to 5 VDC) 4 Terminal 4 (analog value: 20 to 100%) (4 to 20 mADC) 5 Terminal 1 (analog value: -100 to 100%) (0 to 10 VDC)

6 Terminal 6 (FR-A8AZ) (analog value: -100 to 100%) (0 to 10 VDC)

9999 No function

Item Setting example

Taper ratio setting method

Setting by analog voltage (0 to 5 V) input through terminal 2 (Pr.1287 = "9999", Pr.1285 = "3")

Parameter setting C3 (Pr.902) Terminal 2 frequency setting bias = 0% C4 (Pr.903) Terminal 2 frequency setting gain = Taper ratio (%)

Pr. Name Setting range Minimum setting

increments

Initial value

1284 Taper mode selection 0 to 4 1 0 1286 Winding diameter at taper start 0 to 6553 mm, 9999 1 mm 9999

C4 (Pr.903) (Taper ratio)

C3 (Pr.902) (0%)

0 V Analog input value

5 V

Taper ratio

Parameter setting procedure for tension sensorless torque control

174 TENSION SENSOR FEEDBACK TORQUE CONTROL

11 Inertia compensation function setting Set the following parameters for using the inertia compensation function.

Set the parameters according to the specification of the machine used.

NOTE For the details of the inertia compensation function, refer to page 157.

12Mechanical loss compensation function setting Set the following parameters for using the mechanical loss compensation function.

Set the parameters according to the specification of the machine used.

NOTE For the details of the mechanical loss compensation function, refer to page 163.

Pr. Name Setting Remarks

393 Line speed command acceleration/deceleration reference

Set the line speed at minimum diameter (the maximum line speed during tension control) in 0.1 m/min increments (1 to 6553.4 m/ min).

1141 Line speed command acceleration/deceleration pattern

Set S-curve acceleration/deceleration to reduce shock during inertia compensation operation. (Refer to page 160.)

1142 Line speed command acceleration start S-curve time

1143 Line speed command acceleration completion S-curve time

1144 Line speed command deceleration start S-curve time

1145 Line speed command deceleration completion S-curve time

178 to 189 Input terminal function selection

111 Assign the Inertia compensation acceleration (X111) signal. Input the Line speed acceleration (Y237) signal from the inverter connected to the intermediate shaft.

112 Assign the Inertia compensation deceleration (X112) signal. Input the Line speed deceleration (Y238) signal from the inverter connected to the intermediate shaft.

122 Assign the Winding diameter measurement (X122) signal.

1410 Motor inertia

Set the motor inertia in 0.01 kgm2 increments (0 to 500 kgm2 or 9999). To further improve the accuracy for the inertia compensation function, set a motor inertia value using Pr.707 and Pr.724.

1411 Empty reel inertia

Set the empty reel inertia in 0.01 kgm2 increments (0 to 500 kgm2 or 9999). To further improve the accuracy for the inertia compensation function, set an empty reel inertia value using Pr.753 and Pr.754.

1412 Roll width Set the roll width in 1 mm increments (0 to 5000 mm).

1413 Material specific gravity Set the specific gravity of the material in 0.001 g/cm3 increments (0 to 20 g/cm3).

Pr. Name Setting Remarks

1419 Mechanical loss setting frequency bias 1000 The setting "1000" represents 0%. An offset can be set in 0.1% increment from the setting "1000".

1420 Mechanical loss setting frequency 1 Drive the machine with an empty reel at the frequency of Pr.1420, Pr.1422, Pr.1424, Pr.1426, and Pr.1428 (0 to 400 Hz, 0.01 Hz increments), and set the monitored torque values in Pr.1421, Pr.1423, Pr.1425, Pr.1427, and Pr.1429 respectively. (The setting "1000" in Pr.1421, Pr.1423, Pr.1425, Pr.1427, and Pr.1429 represents 0%. An offset can be set in 0.1% increments (900 to 1100%) from setting "1000".)

1421 Mechanical loss 1

1422 Mechanical loss setting frequency 2

1423 Mechanical loss 2

1424 Mechanical loss setting frequency 3

1425 Mechanical loss 3

1426 Mechanical loss setting frequency 4

1427 Mechanical loss 4

1428 Mechanical loss setting frequency 5

1429 Mechanical loss 5

Parameter setting procedure for tension sensorless torque control

TENSION SENSOR FEEDBACK TORQUE CONTROL 175

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13 Stall mode function selection Set the following parameters for using the stall mode function.

Set the parameters according to the specification of the machine used.

NOTE For the details of the stall mode function, refer to page 165.

14 PID control action setting Set the following parameters for PID control.

Set the parameter according to the specification of the machine used.

The following table shows a setting example.

NOTE The setting unit for manipulated amount of PID control is initially set to Hz (frequency). To change the unit to N (tension), set

the amount using Pr.1383 and Pr.1384. (Refer to page 183.)

15 PID control action check (example) Apply tension force corresponding to the tension command to the tension sensor. Give a tension command of 0% (0 N). Input the X114 signal and start command. Start the motor without feeding the workpiece. Change the tension during motor operation, and check that the following motor speed conditions. If any inconsistency is found, check the Pr.128 setting.

16 PID control gain adjustment Feed the workpiece through the system and adjust the tension PI gain. Refer to page 122 for the tension PI gain adjustment.

17 Test run Operate the system starting from the maximum-diameter roll to the minimum-diameter roll and vice versa and check that no fault is found in the system behavior.

Pr. Name Setting Remarks 178 to 189 Input terminal function selection 123 Assign the Stall mode trigger (X123) signal.

270 Acceleration/deceleration time during stall condition 0 to 3600 seconds, in 0.1 second increments

1406 Commanded tension reduction scaling factor during stall condition 0 to 200%, in 0.1% increments

1407 Speed limit during stall condition 0 to 60 Hz, in 0.01 Hz increments

Pr. Name Setting Remarks

128 PID action selection 40 or 41 40: Tension sensor feedback speed control (reverse action) 41: Tension sensor feedback speed control (forward action)

131 PID upper limit Set the value in 0.1% increments (400 to 600% or 9999) for outputting the PID upper limit (FUP) signal.

132 PID lower limit Set the value in 0.1% increments (400 to 600% or 9999) for outputting the PID lower limit (FDN) signal.

133 PID action set point Set the tension command value in 0.01% increments (400 to 600%). 1382 PID set point cushion time Set the cushion time for the PID set point. (Refer to page 85.) 1284 Taper mode selection Set the taper function for the PID set point. (Refer to page 124.)

Item Setting example Tension command setting method Setting the tension command directly

Parameter setting

Perform calculation to convert the output voltage sent from the tension sensor when an intended tension command is applied. Convert the output voltage of the tension sensor to a percentage. Here 5 V corresponds to 100%. Set the output voltage value (in %) plus 500% in Pr.133.

Winding/unwinding Tension feedback Motor speed

Winding Tension feedback Tension command Deceleration Tension feedback < Tension command Acceleration

Unwinding Tension feedback Tension command Acceleration Tension feedback < Tension command Deceleration

Tension sensor feedback torque control details

176 TENSION SENSOR FEEDBACK TORQUE CONTROL

6.5 Tension sensor feedback torque control details

The tension sensorless torque control is performed to control the output torque of a motor according to the roll diameter so that the tension applied to a material is constant. Using the feedback from tension sensors allows for high-precision winding/ unwinding operations. This section explains the details unique to the tension sensor feedback torque control. Common information among torque control is stated in 5.5 (Tension sensorless torque control details).

POINT Select torque control under Vector control or Real sensorless vector control to perform tension sensor feedback torque

control. Turn the X114 signal ON to perform tension sensor feedback torque control. When the X114 signal is OFF, the tension sensor

feedback torque control is not available.

Purpose Parameter to set Refer to page

To select forward/reverse action for PID control PID action selection P.R100 Pr.128 177

To select winding or unwinding for a shaft

Winding/unwinding shaft selection P.R002 Pr.1230 178

To input tension feedback to the inverter

Tension feedback setting

P.R101 to P.R103, P.R330 to P.R333

Pr.363, Pr.1136 to Pr.1139, Pr.1227 178

To detect tension feedback malposition

Tension feedback malposition detection

P.R160, P.R163, P.A601, P.A602, P.F040

Pr.131, Pr.132, Pr.137, Pr.425, Pr.1103

180

To allow a signal to be output during normal tension feedback

Tension feedback detection P.R422 Pr.423 126

To enable manual input of gains for PID control PID control gain setting P.R110 to P.R112 Pr.129, Pr.130,

Pr.134 99

To perform setting for tension sensorless torque control

Control method selection

P.C100 (P.C200), P.C101 (P.C201), P.C102 (P.C202), P.G200, P.G300

Pr.80 (Pr.453), Pr.81 (Pr.454), Pr.71 (Pr.450), Pr.800, Pr.451

139

To select the tension command input method

Tension command source selection P.R300 Pr.804 140

To select the tension command setting increment

Tension command increment P.R301 Pr.1401 140

To select the torque generation direction

Torque generation direction setting P.R304, P.R305 Pr.1072, Pr.1114 143

To prevent the roll from getting too tight when the winding diameter increases

Taper function

P.R320, P.R321, P.R500 to P.R504, P.R510 to P.R519, P.R600, P.R601

Pr.829, Pr.1243, Pr.1244, Pr.1282 to Pr.1297

151

To keep the tension applied to the material constant also during acceleration/deceleration

Inertia compensation function P.R530 to P.R540

Pr.271, Pr.272, Pr.753, Pr.754, Pr.1410 to Pr.1415, Pr.1418

157

To prevent tension change due to factors such as mechanical friction

Mechanical loss compensation function

P.R003, P.R550 to P.R560

Pr.1230, Pr.1419 to Pr.1429 163

To prevent sagging of the material before starting winding Stall mode function P.R340 to P.R343 Pr.270, Pr.1406,

Pr.1407, Pr.1409 165

Tension sensor feedback torque control details

TENSION SENSOR FEEDBACK TORQUE CONTROL 177

6

6.5.1 Tension sensor feedback torque control function selection

Select forward/reverse action for tension sensor feedback torque control.

PID action selection (Pr.128) Set forward or reverse action according to the control target. The following table shows the input method for the set point, tension feedback signal, and tension command for the tension

sensor feedback torque control function (Pr.128 = 40 or 41).

NOTE The automatic restart after instantaneous power failure function is not activated while tension sensor feedback torque control

is enabled (Pr.128 = "40 or 41"). To perform tension sensor feedback torque control, set Pr.127 PID control automatic switchover frequency = "9999 (initial

value)". (If the Pr.127 setting is other than "9999", a sudden speed change may occur.)

Tension control selection signal (X114 signal) To enable the tension sensor feedback torque control, turn ON the Tension control selection (X114) signal and set "40 or

41" in Pr.128 PID action selection. Ensure the motor has stopped before switching between operation with tension sensor feedback torque control and normal

operation. To input the X114 signal, set "114" in any of Pr.178 to Pr.189 (Input terminal function selection) to assign the function. After turning ON the X114 signal, wait 20 ms or longer to input a start (STF/STR) command.

PID compensation disabled signal (X116 signal) PID compensation can be disabled by turning ON the X116 signal. To input the X116 signal, set "116" in any of Pr.178 to

Pr.189 (Input terminal function selection) to assign the function.

Pr. Name Initial value Setting range Description

128 R100 (A610)

PID action selection 0 0 Tension sensor feedback torque control disabled. 40 Tension sensor feedback torque

control enabled. Reverse action

41 Forward action

Pr.128 setting value

Forward /reverse action setting

Operation status Set point input Tension

feedback signal input

Tension command input

0 (initial value) Tension sensor feedback torque control

disabled.

40 Reverse action

When deviation X (set point subtracted by measured value) is a plus value, the manipulated amount is increased, and when the deviation is a minus value, the manipulated amount is decreased. Tension command

after taper compensation

Set in Pr.363. Set in Pr.804.

41 Forward action

When deviation X (set point subtracted by measured value) is a minus value, the manipulated amount is increased, and when the deviation is a plus value, the manipulated amount is decreased.

STF

X114

20 ms or more

ON

ON

Tension sensor feedback torque control details

178 TENSION SENSOR FEEDBACK TORQUE CONTROL

6.5.2 Winding/unwinding shaft selection Select whether the target roll is a winding shaft or unwinding shaft.

Winding/unwinding selection (Pr.1230) Use Pr.1230 Winding/unwinding selection to select whether the target roll is a winding shaft or unwinding shaft. The initial diameter of the winding shaft is selected according to whether the operation is winding or unwinding.

6.5.3 Tension feedback setting Set parameters for tension feedback. Select the input interface (analog input terminal) used for inputting tension feedback to the inverter.

The setting range varies depending on the Pr.1401 setting. (Refer to page 140.)

PID set point Use a commanded tension value after taper compensation to set the set point for tension feedback. Select the tension

command input method in Pr.804 Tension / Torque command source selection.

NOTE Refer to page 140 for Pr.804 and page 151 for the taper function.

Pr. Name Initial value Setting range Description

1230 R002 Winding/unwinding selection 0

0 Winding 1 Unwinding

Pr.1230 setting Winding/unwinding selection Initial roll diameter

0 Winding Minimum roll diameter 1 Unwinding Maximum roll diameter

Pr. Name Initial value Setting range Description

363 R102

Dancer / tension sensor feedback input selection 9999

3 The measured value is input through terminal 2. 4 The measured value is input through terminal 4. 5 The measured value is input through terminal 1.

6 The measured value is input through terminal 6 on the FR-A8AZ.

9 The measured value is input via CC-Link / CC-Link IE Field Network Basic communication.

9999 No function 1136 R330

Tension sensor feedback voltage/current bias 0% 0 to 100% Set the bias voltage (current) in % for analog input.

1137 R331

Tension sensor feedback bias 0 N 0 to 500 N Set the tension feedback bias value for analog input.

1138 R332

Tension sensor feedback voltage/current gain 100% 0 to 100% Set the gain voltage (current) in % for analog input.

1139 R333

Tension sensor feedback gain 100 N 0 to 500 N Set the tension feedback gain value for analog input.

1227 R103

Dancer / tension sensor feedback input filter time constant

0 0 Without filter

0.01 to 5 s Set the primary delay filter for the tension feedback input value.

Tension sensor feedback torque control details

TENSION SENSOR FEEDBACK TORQUE CONTROL 179

6

Tension feedback input selection (Pr.363) Use Pr.363 Dancer / tension sensor feedback input selection to select the input terminal for tension feedback.

The input specification in the initial setting is indicated.

Tension feedback calibration (Pr.1136 to Pr.1139) Set Pr.1136 to Pr.1139 to calibrate the tension feedback input value.

When Pr.363 = "9", dancer / tension sensor feedback can be input via CC-Link or CC-Link IE Field Network Basic communication.

The 16-bit feedback signal input via communication is recognized as a signed signal. The input data range is from -10000 (-100.00%) to +10000 (+100.00%).

Tension feedback input filter (Pr.1227) Use Pr.1227 Dancer / tension sensor feedback input filter time constant to set the primary filter for the tension

feedback input value. When Pr.1227 = "0", the filter setting is disabled.

Pr.363 setting Input terminal 3 Terminal 2 (0 to 100%) (0 to 5 VDC) 4 Terminal 4 (20 to 100%) (4 to 20 mA) 5 (initial value) Terminal 1 (-100 to 100%) (0 to 10 VDC) 6 Terminal 6 on the FR-A8AZ (-100 to 100%) (0 to 10 VDC) 9 CC-Link or CC-Link IE Field Network Basic (-100 to 100%)

Pr.1136 Pr.1138

Pr.1137

Pr.1139

Analog input value (%)

Tension feedback (N)

Tension sensor feedback torque control details

180 TENSION SENSOR FEEDBACK TORQUE CONTROL

6.5.4 Tension feedback malposition detection Set the following parameters to prevent the motor speed from increasing due to a line break (tension feedback = 0 N).

Tension feedback malposition detection (break detection) (Pr.131, Pr.132, Pr.425)

Set the upper limit of tension feedback in Pr.131 PID upper limit. Set the lower limit of tension feedback in Pr.132 PID lower limit.

The FUP signal is output when a tension feedback value exceeds the Pr.131 setting. When a value falls below the Pr.132 setting, the FDN signal is output.

When tension feedback remains higher than the Pr.131 setting or lower than the Pr.132 setting for the time set in Pr.425 Break detection waiting time or longer, the condition is determined as tension feedback malposition (break), and compensation by PID control becomes 0. The winding diameter at the time of malposition detection is retained.

When a tension feedback malposition occurs, the torque command value becomes 0. To decelerate the motor to a stop, turn OFF the start signal. The deceleration stop is performed according to the setting in Pr.1103 Deceleration time at emergency stop.

Pr. Name Initial value Setting range Description

131 A601 PID upper limit 9999

400 to 600% Set the value for outputting the PID upper limit (FUP) signal .

9999 No function

132 A602 PID lower limit 9999

400 to 600% Set the value for outputting the PID lower limit (FDN) signal .

9999 No function 137 R163

PID upper/lower limit hysteresis width 9999

0 to 100% Prevent chattering of the FUP/FDN signals. 9999 No function

425 R160 Break detection waiting time 9999

0 to 100 s Set the time until tension feedback malposition is determined.

9999 No break detection

553 A603 PID deviation limit 9999

0 to 100% The Y48 signal is output when the absolute value of the deviation exceeds the deviation limit value.

9999 No function

554 A604

PID signal operation selection 0 0 to 3

The action when the upper or lower limit for a measured value input is detected or when a limit for the deviation is detected can be selected.

1103 F040

Deceleration time at emergency stop 5 s 0 to 3600 s

Set the motor deceleration time at a deceleration by turning ON the X92 signal. Set a deceleration time for the deceleration stop at the occurrence of tension feedback malposition.

Tension sensor feedback torque control details

TENSION SENSOR FEEDBACK TORQUE CONTROL 181

6

When tension feedback malposition (break) is detected, the Break detection (Y231) signal can be output. When the following two conditions are both met, PID calculation is resumed.

- The motor is stopped or output is shutoff. - The start signal is OFF.

When using each signal, assign the function to Pr.190 and Pr.196 (output terminal function selection) referring to the following table.

PID upper/lower limit hysteresis width (Pr.137) When the tension feedback value fluctuates, the FUP/FDN signal may chatter (turn ON and OFF repeatedly), depending on the position. To prevent the signal chattering, configure Pr.137 PID upper/lower limit hysteresis width to set a hysteresis for the FUP and FDN signals.

NOTE Pr.137 setting does not affect the operation of the Y231 signal. (Refer to page 180 for the details of the Y231 signal.) When a value other than "9999" is set in Pr.137, depending on the fluctuation of the tension feedback value, the FUP/FDN

signal may not turn ON even if the tension feedback value exceeds the Pr.131 setting or falls below the Pr.132 setting.

Operation selection when a limit is detected (Pr.554, FUP signal, FDN signal, Y48 signal)

Using Pr.554 PID signal operation selection, set the action when the measured value input exceeds the upper limit (Pr.131 PID upper limit) or lower limit (Pr.132 PID lower limit), or when the deviation input exceeds the permissible value (Pr.553 PID deviation limit).

Choose whether to output the signals (FUP, FDN, Y48) only or to activate the protective function to output the inverter shutoff.

NOTE When each of Pr.131, Pr.132 and Pr.553 settings corresponding to each of the FUP, FDN and Y48 signals is "9999" (no

function), signal output and protective function are not available.

6.5.5 Tension feedback detection A signal is output while the tension feedback value maintains the specified normal level.

NOTE For the details, refer to page 126.

Output signal Pr.190 to Pr.196 setting

Positive logic Negative logic FDN 14 114 FUP 15 115 Y231 231 331

Pr.554 setting Inverter operation

FUP, FDN Y48 0 (initial value) Signal output only

Signal output only 1 Signal output + output shutoff (E.PID) 2 Signal output only

Signal output + output shutoff (E.PID) 3 Signal output + output shutoff (E.PID)

Tension feedback

Pr.137 Pr.131

ON ON

ONFUP

Example of the PID upper limit (FUP) signal

Tension sensor feedback torque control details

182 TENSION SENSOR FEEDBACK TORQUE CONTROL

6.5.6 PID offset displacement Calibrate the reference value of the tension sensor feedback amount (PID measured value).

NOTE For the details, refer to page 126.

6.5.7 PID control gain setting Set the proportional band, integral time, and differential time for PID control.

NOTE For the details, refer to page 99.

6.5.8 Integral control action setting The manipulated amount for PID integral action can be limited by setting parameters. The integral control action can be enabled or disabled (the integral term is held) according to the PID control deviation. Integral control can be disabled by the signal input. (The integral term value is cleared.)

NOTE For the details, refer to page 100.

6.5.9 Differential control action setting Differential control can be disabled by the signal input. (The differential term value is cleared.)

NOTE For the details, refer to page 101.

6.5.10 PID control gain selection The proportional band, integral time, and differential time required for PID gain setting can be set individually depending on whether deviation is positive or negative. PID gain settings 1 to 4 (proportional band, integral band, differential time) can be selected by changing the status of two input signals.

NOTE For the details, refer to page 101.

Tension sensor feedback torque control details

TENSION SENSOR FEEDBACK TORQUE CONTROL 183

6

6.5.11 Signed winding diameter compensation torque command selection

Set the availability of negative values for the torque command during tension sensor feedback torque control or after PID compensation.

Signed winding diameter compensation torque command selection (Pr.1140)

When "0 (initial value)" is set in Pr.1140 Signed winding diameter compensation torque command selection, and when the calculation result of command torque after PID compensation is a negative value, the value is used as the torque command value.

When "9999" is set in Pr.1140, and when the calculation result of command torque after PID compensation is a negative value, the torque command will be "0".

6.5.12 Converting the PID manipulated amount to values in different units

The PID manipulated amount (%) can be converted to a value in a different unit (N) for tension sensor feedback torque control.

The increment varies depending on the Pr.1401 setting. (Refer to page 140.) When Pr.1384 = "9999 (initial value)", the amount is converted as shown in the following diagram.

When Pr.1384 "9999", the amount is converted as shown in the following diagram.

Pr. Name Initial value Setting range Description

1140 R334

Signed winding diameter compensation torque command selection

0 0 Signed

9999 Unsigned

Pr. Name Initial value Setting range Description 1383 R335

PID torque control manipulated tension bias [N] 0 N 0 to 500 N Convert the PID manipulated amount to a tension

value (N). 9999: No function1384

R336 PID torque control manipulated tension gain [N] 9999 0 to 500 N, 9999

PID torque control manipulated tension (N)

Pr.1139

Maximum tension command value

0

Pr.1137

PID manipulated amount (%)Pr.1138Pr.1136

PID torque control manipulated tension (N)

Pr.1384

Maximum tension command value

0

Pr.1383

PID manipulated amount (%)100

System configuration example

184 SPEED CONTROL OF INTERMEDIATE SHAFTS

7 SPEED CONTROL OF INTERMEDIATE SHAFTS To control intermediate driving shafts (rollers between an unwinding roll and a winding roll), perform speed control by inputting line speed commands.

7.1 System configuration example Dancer feedback speed control

Tension sensor feedback torque control

FR-A800-R2R

Encoder

Line speed command

Potentiometer

Dancer roll

Dancer signal

Minimum diameter

Maximum diameter

AM

2 (Pr.361=3)

2 1 STF/STRStart signal

Dancer/tension control selection X114

FR-A8AP

Encoder

Line speed command

Line speed command

FR-A800-R2R

FR-A8AP

M

M

STF/STR Start signal

Dancer/tension control selection X114 (Pr.180=114)

M

FR-A800-R2R

STF/STR X112

X111

M

FR-A800-R2R

2 (Pr.361 = 3)

Y237 (Pr.190 = 237)

Y238 (Pr.191 = 238)

STF/STR

Intermediate shafts / speed control

Line speed detection

Actual line speed

2 1

Tension control selection

Inertia compensation acceleration signal

X114

Line speed command

Start command

114 (Pr.180 = 114) Tension control

selection

Tension command FR-A8AZ

Start command

6

Inertia compensation deceleration signal

Stall mode trigger signal

Encoder

Encoder

FR-A8AP

FR-A8AP

Programmable controller

Vector control

Minimum diameter

Maximum diameter

Reduction gear

X123

TH1 TH2

Thermistor input

Tension feedback

Parameter setting procedure for speed control of intermediate shafts

SPEED CONTROL OF INTERMEDIATE SHAFTS 185

7

7.2 Parameter setting procedure for speed control of intermediate shafts

The following procedure shows the parameter setting example for the speed control of intermediate shafts.

7.2.1 Parameter setting procedure 1 Wiring

Perform secure wiring.

NOTE Do not feed the workpiece through the machine.

2 Control method selection

Select the control method according to the application and the motor.

For the control method, Vector control is recommended. Setting is required for a motor other than a Mitsubishi Electric motor (the SF-PR, SF-JR, SF-HR, SF-JRCA, SF-HRCA, or SF-V5RU (1500 r/min

series) motor). For the FR-A820-03160(55K) or lower and FR-A840-01800(55K) or lower. For the FR-A820-03800(75K) or higher and FR-A840-02160(75K) or higher.

NOTE Select Vector control for regenerative driving in a low-speed range (about 10 Hz or lower), . For the parameter details, refer to the FR-A800 Instruction Manual (Detailed).

3 Offline auto tuning Perform offline auto tuning as required. For offline auto tuning, refer to page 55.

After the offline auto tuning, perform the test run of the motor alone to make sure that no fault is found in the motor's behavior.

Pr. Name Setting range Minimum setting

increments Initial value

71 Applied motor 0, 1, 3 to 6, 13 to 16, 20, 23, 24, 30, 33, 34, 40, 43, 44, 50, 53, 54, 70, 73, 74 1 0

9 Electronic thermal O/L relay 0 to 500 A 0.01 A Inverter rated

current0 to 3600 A 0.1 A

80 Motor capacity 0.4 to 55 kW, 9999 0.01 kW

9999 0 to 3600 kW, 9999 0.1 kW

81 Number of motor poles 2, 4, 6, 8, 10, 12, 9999 1 9999

83 Rated motor voltage 0 to 1000 V 0.1 V

200 V (200 V class) 400 V (400 V class)

84 Rated motor frequency 10 to 400 Hz, 9999 0.01 Hz 9999 800 Control method selection 0 to 2, 9 to 12, 20, 100 to 102, 109 to 112 1 20 810 Torque limit input method selection 0 to 2 1 0 359 Encoder rotation direction 0, 1, 100, 101 1 1 369 Number of encoder pulses 0 to 4096 1 1024 707 Motor inertia (integer) 10 to 999, 9999 1 9999 724 Motor inertia (exponent) 0 to 7, 9999 1 9999 862 Encoder option selection 0, 1 1 0

Pr. Name Setting range

Minimum setting

increments

Initial value

96 Auto tuning setting/status 0, 1, 11, 101 1 0

Parameter setting procedure for speed control of intermediate shafts

186 SPEED CONTROL OF INTERMEDIATE SHAFTS

4 Speed control gain adjustment Adjust the speed control gain. Refer to page 59 for the speed control gain adjustment. Since the diameter is fixed for the intermediate shaft, settings in steps 6 to 8 in the "Adjustment by easy gain tuning (recommended)" section on page 59 are not required.

5 Mechanical specifications setting Set the following parameters according to the specifications of the machine used.

Set the parameter according to the specification of the machine used. The increment applies when Pr.21 = "0 (initial value)". The increment applies when Pr.358 = "0 (initial value)".

Pr. Name Description 1235 Maximum winding diameter 1 Set the roll diameter of the intermediate shaft in 1 mm increments (1 to 6553

mm) in both Pr.1235 and Pr.1236.1236 Minimum winding diameter 1

394 First acceleration time for line speed command Set the acceleration time in 0.1 second increments (0 to 3600 seconds).

395 First deceleration time for line speed command Set the deceleration time in 0.1 second increments (0 to 3600 seconds).

1141 Line speed command acceleration/deceleration pattern

Set S-curve acceleration/deceleration to reduce shock during line speed acceleration/deceleration operation. (Refer to page 82.)

1142 Line speed command acceleration start S-curve time

1143 Line speed command acceleration completion S-curve time

1144 Line speed command deceleration start S-curve time

1145 Line speed command deceleration completion S-curve time

362 Actual line speed input selection Set "0" (Line speed command).

393 Line speed command acceleration/deceleration reference

Set the reference line speed (travel amount per minute) in 0.1 m/min increments (1 to 6553.4 m/min) for the acceleration/deceleration time for the line speed command.

398 Draw rate Set a draw rate for the line speed command value or the line speed command acceleration/deceleration reference. (Refer to page 75.)

178 to 189 Input terminal function selection To assign the Tension control selection (X114) signal, set "114" in any of the

parameters. 190 to 196

Output terminal function selection

To assign the Line speed acceleration (Y237) signal and the Line speed deceleration (Y238) signal, set "237" and "238" in any two of the parameters.

7 Acceleration time Set "0". 8 Deceleration time Set "0".

1247 Winding diameter change increment amount limit Set "9999" (Winding diameter calculation disabled).

158 AM terminal function selection Set "26" (Line speed command value).

276 Line speed monitoring reference Set the line speed (travel amount per minute) in 0.1 m/min increments (0 to 6553.4 m/min) for maximum (100%) output via terminal AM.

1243 Gear ratio numerator Set a gear ratio in 1 increments (1 to 65534) when the motor shaft has a reduction gear.1244 Gear ratio denominator

363 Dancer / tension sensor feedback input selection Set "9999" (Function disabled).

128 PID action selection Set "40".

129 PID proportional band Set "9999" (Without proportional control).

130 PID integral time Set "9999" (Without integral control).

134 PID differential time Set "9999" (Without differential control).

358 Line speed unit The initial value is "0" (m/min). (0 to 3, in 1 increments) Choose an appropriate value (increment) according to the specifications of the machine used.

621 Allowable deviation from target line speed

The Y237/Y238 signal output range can be set in 0.1 m/min increments (0 to 6553.4 m/min) for the target line speed command. (Refer to page 79.)

Parameter setting procedure for speed control of intermediate shafts

SPEED CONTROL OF INTERMEDIATE SHAFTS 187

7

6 Line speed command input setting Set Pr.361 to select an interface for the line speed command value input.

To perform Vector control, install the Vector control compatible option. The input specification in the initial setting is indicated. (Refer to page 47.)

The following table shows a setting example.

Set the pulse division scaling factor in Pr.384 for pulse train input through terminal JOG. Number of pulses calculated internally = Number of input pulses / Pr.384 setting value When inputting 50k pulses/s while Pr.351 = 0 m/min, Pr.353 = 100 m/min, Pr.354 = 0 pulses/s, Pr.355 = 50k pulses/s, and Pr.384 = "2", the line speed will be 50 m/min.

NOTE Information on various settings about the line speed is provided in the chapter for the dancer feedback speed control. Refer

to page 64.

Pr. Name Setting Input method

361 Line speed command input selection

0 According to the priority of the speed command sources. (Refer to page 70.)

1 Terminal JOG single-phase pulse train input (Refer to page 71.)

2 FR-A8AP/FR-A8AL/FR-A8TP encoder pulse train input (complementary 12 V / differential 5 V (A-, B-phases)) (Refer to page 71.)

3 Terminal 2 (analog value: 0 to 100%) (0 to 5 VDC) (Refer to page 73.)

4 Terminal 4 (analog value: 20 to 100%) (4 to 20 mADC) (Refer to page 73.)

5 Terminal 1 (analog value: -100 to 100%) (0 to 10 VDC) (Refer to page 73.)

6 Terminal 6 on the FR-A8AZ (analog value: -100 to 100%) (0 to 10 VDC) (Refer to page 73.)

7 FR-A8AL single-phase pulse train input (terminal PP/NP) (Refer to page 71.)

8 Line speed command according to the Pr.360 setting (Refer to page 73.)

10 Inverter-to-inverter link function (Available only for the FR- A800-E-R2R. For details, refer to the Ethernet Function Manual.)

9999 (initial value) Function disabled.

Item Setting example 1 Setting example 2

Line speed command input method

Setting by analog voltage (0 to 5 V) input through terminal 2 (Pr.361 = "3")

Setting by pulse train input through terminal JOG (Pr.361 = "1")

Parameter setting

Pr.350 Line speed command voltage/current bias = 0% Pr.351 Line speed command bias = 0 m/min Pr.352 Line speed command voltage/current gain = 100% Pr.353 Line speed command gain = Maximum line speed

Pr.384 Input pulse division scaling factor = "1" Pr.351 Line speed command bias = 0 m/min Pr.354 Line speed command pulse input bias = "0" Pr.353 Line speed command gain = Maximum line speed Pr.355 Line speed command pulse input gain = Maximum number of pulses

Pr.353 (Maximum line speed)

Pr.351 (0 m/min)

0 V Pr.350 (0%)

Analog input value

5 V Pr.352 (100%)

Line speed command value

Pr.353 (Maximum line speed)

6553.4

Pr.351 (0 m/min)

Pr.354 (0 pulses/s)

Number of input pulses

Pr.355 (Maximum number of pulses)

Line speed command value

Parameter setting procedure for speed control of intermediate shafts

188 SPEED CONTROL OF INTERMEDIATE SHAFTS

7.2.2 Offline auto tuning The offline auto tuning enables the optimal operation of a motor.

NOTE For the details, refer to page 55.

7.2.3 Speed control gain adjustment The load inertia ratio (load moment of inertia) for the motor is calculated from the torque command and rotation speed

during motor driving under Vector control. Because the optimum gain for speed control using dancer feedback / tension sensor feedback is calculated automatically from the load inertia ratio and the response level, the work required for gain adjustment is reduced (easy gain tuning).

By manually entering the load inertia ratio (if known), the control gain is set automatically. Manual gain adjustment is useful for achieving optimum machine performance or improving unfavorable conditions, such

as vibration and acoustic noise during operation with high load inertia.

NOTE For the details, refer to page 59.

Since the diameter is fixed for the intermediate shaft, settings in steps 6 to 8 in the "Adjustment by easy gain tuning (recommended)" section on page 59 are not required.

System configuration example

SPEED CONTROL OF REFERENCE SHAFT 189

8

8 SPEED CONTROL OF REFERENCE SHAFT To control the reference shaft and other intermediate driving shafts, perform speed control using actual line speed detected at the reference shaft.

8.1 System configuration example Dancer feedback speed control

FR-A800-R2R

M Encoder

Actual line speed

Potentiometer

Dancer roll

For actual line speed detection

Dancer signal

M

AM (Pr.158 = 27)

Potentiometer

Dancer roll

2 (Pr.361 = 3)

4

1

Dancer signal 1

STF/STR Start signal

2 Line speed command

Dancer/tension control selection

X114

FR-A8AP

Encoder

Line speed command

Actual line speed

FR-A800-R2R

FR-A8APFR-A8TP

STF/STR Start signal

Dancer/tension control selection

X114 (Pr.180=114)

M

2

Encoder

Line speed command

FR-A800-R2R

FR-A8AP

STF/STR Start signal

4 Actual line speed

Dancer/tension control selection

X114

Encoder

Reference shaftIntermediate shaft Winding shaft

Parameter setting procedure for speed control of reference shaft

190 SPEED CONTROL OF REFERENCE SHAFT

8.2 Parameter setting procedure for speed control of reference shaft

The following procedure shows the parameter setting example for the speed control of the reference shaft.

8.2.1 Parameter setting procedure 1 Wiring

Perform secure wiring.

NOTE Do not feed the workpiece through the machine.

2 Control method selection

Select the control method according to the application and the motor.

For the control method, Vector control is recommended. Setting is required for a motor other than a Mitsubishi Electric motor (the SF-PR, SF-JR, SF-HR, SF-JRCA, SF-HRCA, or SF-V5RU (1500 r/min

series) motor). For the FR-A820-03160(55K) or lower and FR-A840-01800(55K) or lower. For the FR-A820-03800(75K) or higher and FR-A840-02160(75K) or higher.

NOTE Select Vector control for regenerative driving in a low-speed range (about 10 Hz or lower), . For the parameter details, refer to the FR-A800 Instruction Manual (Detailed).

3 Offline auto tuning Perform offline auto tuning as required. For offline auto tuning, refer to page 55.

After the offline auto tuning, perform the test run of the motor alone to make sure that no fault is found in the motor's behavior.

Pr. Name Setting range Minimum

setting increments

Initial value

71 Applied motor 0, 1, 3 to 6, 13 to 16, 20, 23, 24, 30, 33, 34, 40, 43, 44, 50, 53, 54, 70, 73, 74 1 0

9 Electronic thermal O/L relay 0 to 500 A 0.01 A Inverter rated

current0 to 3600 A 0.1 A

80 Motor capacity 0.4 to 55 kW, 9999 0.01 kW

9999 0 to 3600 kW, 9999 0.1 kW

81 Number of motor poles 2, 4, 6, 8, 10, 12, 9999 1 9999

83 Rated motor voltage 0 to 1000 V 0.1 V

200 V (200 V class) 400 V (400 V class)

84 Rated motor frequency 10 to 400 Hz, 9999 0.01 Hz 9999 800 Control method selection 0 to 2, 9 to 12, 20, 100 to 102, 109 to 112 1 20 810 Torque limit input method selection 0 to 2 1 0 359 Encoder rotation direction 0, 1, 100, 101 1 1 369 Number of encoder pulses 0 to 4096 1 1024 707 Motor inertia (integer) 10 to 999, 9999 1 9999 724 Motor inertia (exponent) 0 to 7, 9999 1 9999 862 Encoder option selection 0, 1 1 0

Pr. Name Setting range

Minimum setting

increments

Initial value

96 Auto tuning setting/status 0, 1, 11, 101 1 0

Parameter setting procedure for speed control of reference shaft

SPEED CONTROL OF REFERENCE SHAFT 191

8

4 Speed control gain adjustment Adjust the speed control gain. Refer to page 59 for the speed control gain adjustment.

5 Mechanical specifications setting Set the following parameters according to the specifications of the machine used.

Set the parameter according to the specification of the machine used. The increment applies when Pr.21 = "0 (initial value)". The increment applies when Pr.358 = "0 (initial value)".

Pr. Name Description 1235 Maximum winding diameter 1 Set the roll diameter of the intermediate shaft in 1 mm increments (1 to 6553

mm) in both Pr.1235 and Pr.1236.1236 Minimum winding diameter 1

394 First acceleration time for line speed command Set the acceleration time in 0.1 second increments (0 to 3600 seconds).

395 First deceleration time for line speed command Set the deceleration time in 0.1 second increments (0 to 3600 seconds).

1141 Line speed command acceleration/deceleration pattern

Set S-curve acceleration/deceleration to reduce shock during line speed acceleration/deceleration operation. (Refer to page 82.)

1142 Line speed command acceleration start S-curve time

1143 Line speed command acceleration completion S-curve time

1144 Line speed command deceleration start S-curve time

1145 Line speed command deceleration completion S-curve time

362 Actual line speed input selection Set "2" (FR-A8TP).

393 Line speed command acceleration/deceleration reference

Set the reference line speed (travel amount per minute) in 0.1 m/min increments (1 to 6553.4 m/min) for the acceleration/deceleration time for the line speed command.

398 Draw rate Set a draw rate for the line speed command value or the line speed command acceleration/deceleration reference. (Refer to page 75.)

178 to 189 Input terminal function selection To assign the Tension control selection (X114) signal, set "114" in any of the

parameters. 190 to 196

Output terminal function selection

To assign the Line speed acceleration (Y237) signal and the Line speed deceleration (Y238) signal, set "237" and "238" in any two of the parameters.

7 Acceleration time Set "0". 8 Deceleration time Set "0".

1247 Winding diameter change increment amount limit Set "9999" (Winding diameter calculation disabled).

158 AM terminal function selection Set "27" (Actual line speed).

276 Line speed monitoring reference Set the line speed (travel amount per minute) in 0.1 m/min increments (0 to 6553.4 m/min) for maximum (100%) output via terminal AM.

1243 Gear ratio numerator Set a gear ratio in 1 increments (1 to 65534) when the motor shaft has a reduction gear.1244 Gear ratio denominator

363 Dancer / tension sensor feedback input selection Set "9999" (Function disabled).

128 PID action selection Set "40".

129 PID proportional band Set "9999" (Without proportional control).

130 PID integral time Set "9999" (Without integral control).

134 PID differential time Set "9999" (Without differential control).

358 Line speed unit The initial value is "0" (m/min). (0 to 3, in 1 increments) Choose an appropriate value (increment) according to the specifications of the machine used.

621 Allowable deviation from target line speed

The Y237/Y238 signal output range can be set in 0.1 m/min increments (0 to 6553.4 m/min) for the target line speed command. (Refer to page 79.)

Parameter setting procedure for speed control of reference shaft

192 SPEED CONTROL OF REFERENCE SHAFT

6 Line speed command input setting Set Pr.361 to select an interface for the line speed command value input.

To perform Vector control, install the Vector control compatible option. The input specification in the initial setting is indicated. (Refer to page 47.)

The following table shows a setting example.

Set the pulse division scaling factor in Pr.384 for pulse train input through terminal JOG. Number of pulses calculated internally = Number of input pulses / Pr.384 setting value When inputting 50k pulses/s while Pr.351 = 0 m/min, Pr.353 = 100 m/min, Pr.354 = 0 pulses/s, Pr.355 = 50k pulses/s, and Pr.384 = "2", the line speed will be 50 m/min.

NOTE Information on various settings about the line speed is provided in the chapter for the dancer feedback speed control. Refer

to page 64.

Pr. Name Setting Input method

361 Line speed command input selection

0 According to the priority of the speed command sources. (Refer to page 70.)

1 Terminal JOG single-phase pulse train input (Refer to page 71.)

2 FR-A8AP/FR-A8AL/FR-A8TP encoder pulse train input (complementary 12 V / differential 5 V (A-, B-phases)) (Refer to page 71.)

3 Terminal 2 (analog value: 0 to 100%) (0 to 5 VDC) (Refer to page 73.)

4 Terminal 4 (analog value: 20 to 100%) (4 to 20 mADC) (Refer to page 73.)

5 Terminal 1 (analog value: -100 to 100%) (0 to 10 VDC) (Refer to page 73.)

6 Terminal 6 on the FR-A8AZ (analog value: -100 to 100%) (0 to 10 VDC) (Refer to page 73.)

7 FR-A8AL single-phase pulse train input (terminal PP/NP) (Refer to page 71.)

8 Line speed command according to the Pr.360 setting (Refer to page 73.)

10 Inverter-to-inverter link function (Available only for the FR- A800-E-R2R. For details, refer to the Ethernet Function Manual.)

9999 (initial value) Function disabled.

Item Setting example 1 Setting example 2

Line speed command input method

Setting by analog voltage (0 to 5 V) input through terminal 2 (Pr.361 = "3")

Setting by pulse train input through terminal JOG (Pr.361 = "1")

Parameter setting

Pr.350 Line speed command voltage/current bias = 0% Pr.351 Line speed command bias = 0 m/min Pr.352 Line speed command voltage/current gain = 100% Pr.353 Line speed command gain = Maximum line speed

Pr.384 Input pulse division scaling factor = "1" Pr.351 Line speed command bias = 0 m/min Pr.354 Line speed command pulse input bias = "0" Pr.353 Line speed command gain = Maximum line speed Pr.355 Line speed command pulse input gain = Maximum number of pulses

Pr.353 (Maximum line speed)

Pr.351 (0 m/min)

0 V Pr.350 (0%)

Analog input value

5 V Pr.352 (100%)

Line speed command value

Pr.353 (Maximum line speed)

6553.4

Pr.351 (0 m/min)

Pr.354 (0 pulses/s)

Number of input pulses

Pr.355 (Maximum number of pulses)

Line speed command value

Parameter setting procedure for speed control of reference shaft

SPEED CONTROL OF REFERENCE SHAFT 193

8

8.2.2 Offline auto tuning The offline auto tuning enables the optimal operation of a motor.

NOTE For the details, refer to page 55.

194 WINDING DIAMETER COMPENSATION FUNCTION

9 WINDING DIAMETER COMPENSATION FUNCTION

The winding diameter calculation is used to estimate the present winding diameter from the actual line speed or the actual motor speed for the winding/unwinding shaft. The estimated winding diameter is used to convert the line speed command to the frequency command, or convert the tension command to the torque command. Using the winding diameter compensation function under dancer feedback speed control, tension sensor feedback speed control, tension sensorless torque control, or tension sensor feedback torque control improves control accuracy.

POINT To enable the winding diameter compensation function under dancer feedback speed control, tension sensor feedback speed

control, or tension sensor feedback torque control, turn ON the X114 signal and set "40 or 41" in Pr.128 PID action selection. (When the X114 signal is OFF or "0" is set in Pr.128, the winding diameter compensation function is disabled under dancer feedback speed control, tension sensor feedback speed control, and tension sensor feedback torque control.)

Turn ON the X114 signal to enable the sensorless torque control and the winding diameter compensation function. (When the X114 signal is OFF, the tension sensorless torque control and the winding diameter compensation function are not available.)

To disable dancer feedback speed control and enable only the winding diameter compensation function, turn ON both X114 and X116 signals, or turn ON the X114 signal and set "9999" in Pr.129, Pr.130, and Pr.134.

For the X114 and X116 signals, assign the function by setting "114 (X114)" or "116 (X116)" in any of Pr.178 to Pr.189 (input terminal function selection).

Winding diameter calculation and winding diameter compensation function

WINDING DIAMETER COMPENSATION FUNCTION 195

9

9.1 Winding diameter calculation and winding diameter compensation function

Winding diameter calculation Winding diameter calculation using actual line speed

Calculate the winding diameter "D" from the actual line speed input value "V" and motor speed.

(Example) Calculation when line speed (V) = 409.9 m/min, actual motor speed (fb) = 659.0 r/min, and gear ratio (Z) = 0.396

Winding diameter calculation using a sum total of material thickness Calculate the winding diameter "D" from the wound (unwound) material thickness "d".

NOTE Use the following values as the actual motor speed according to the control method.

To use the motor rotations per minute, setting of Pr.81 Number of motor poles is required also under V/F control. (When Pr.81 = "9999", a 4-pole motor is assumed.)

Winding diameter compensation speed (dancer) Calculate the winding diameter compensation speed from the current diameter "D" obtained from winding diameter

calculation (or stored winding diameter) and the line speed command "V*".

D fb Z = V V : Line speed fb : Actual motor speed

D = V

fb Z Z : Gear ratio

D = V

= 409.9 [m/min] 1000

= 499.97 [mm] fb Z 659.0 [r/min] 0.396

D = D1 2 d N Z D1 : Initial diameter d : Material thickness N : Number of roll rotations Z : Gear ratio

Control method Value used as actual motor speed Vector control Actual motor speed Real sensorless vector control Estimated value of actual motor speed V/F control Advanced magnetic flux vector control

Motor rotations per minute (converted from output frequency)

= V*

D Z

: Winding diameter compensation speed D : Present winding diameter (or stored winding diameter)

V* : Line speed command

Z : Gear ratio

Winding diameter calculation setting

196 WINDING DIAMETER COMPENSATION FUNCTION

9.2 Winding diameter calculation setting

9.2.1 Block diagram

After clearing, the value becomes the minimum winding diameter when Pr.1230 = "0" (winding), and the maximum winding diameter when Pr.1230 = "1" (unwinding).

Purpose Parameter to set Refer to page

To perform setting for winding diameter calculation

Basic setting for winding diameter calculation

P.R000, P.R001, P.R600, P.R601

Pr.1243, Pr.1244, Pr.1247, Pr.1248 197

To calculate the winding diameter from the actual line speed

Winding diameter calculation using actual line speed

P.R041, P.R050 to P.R057, P.R201, P.D101

Pr.278 to Pr.284, Pr.358, Pr.362, Pr.384, Pr.1245

199

To select the actual line speed input method

Actual line speed input selection P.R050 Pr.362 203

To select the line speed command setting unit

Line speed command unit setting P.R201 Pr.358 199

To calculate the winding diameter from the material thickness

Winding diameter calculation using material thickness (thickness method)

P.R010 to P.R013 Pr.1231 to Pr.1234 203

To set the line speed command or actual line speed to start winding diameter calculation

Line speed at winding diameter calculated value activation

P.R040 Pr.1246 204

To set a limit to the minimum/ maximum value of the winding diameter calculation result

Minimum/maximum winding diameter P.R020 to P.R027 Pr.1235 to Pr.1242 206

To output the signal when the predetermined winding diameter is reached

Target winding diameter achieved P.R420 Pr.648 208

To store the present winding diameter/length value

Winding diameter / winding length storage

P.R003 to P.R008, P.R041, P.R420, P.R421, P.R424

Pr.645 to Pr.648, Pr.1262 to Pr.1264, Pr.1298, Pr.1299, Pr.1346

213

Winding/unwinding selection Pr.1230

Setting determined by the initial winding measurement

Sampling Pr.1245

Sampling (about 5 ms)

Actual line speed Actual line speed method

Thickness method

Initial winding diameter

Actual line speed D = Line speed command value Gear ratio

2 Accumulated amount Motor rotations per minute Gear ratio

D = Initial winding diameter2 Material thickness Number of motor shaft rotations

Pr.1231 = 9999

Pr.1249 = 0

Pr.1231 = 9999

Pr.1247 = 9999

Pr.1247 = 9999

Pr.1249 = 0 After the Pr.1248

setting time elapsed

Pr.1249Pr.1247

Out of the deadband

Within the deadband Held

Dancer feedback speed control

Tension sensor feedback speed control / Tension sensorless / tension sensor feedback

torque control

Clamping

X122-ON

X122-OFF

Before the time elapsed

Averaging

Pr.1235 to Pr.1242

Clamping

Winding diameter

Held

X115-OFF

X115-ON

X109-OFF

X109-ON

Held

Winding diameter clear 1

Winding diameter calculation setting

WINDING DIAMETER COMPENSATION FUNCTION 197

9

9.2.2 Basic setting for winding diameter calculation

Block diagram

Pr. Name Initial value Setting range Description

1243 R600 Gear ratio numerator 1 1 to 65534

Set a gear ratio for a reduction-gear-equipped motor. 1244 R601 Gear ratio denominator 1 1 to 65534

1247 R000

Winding diameter change increment amount limit 9999

0 to 9.998 mm Set the maximum amount of change in each winding diameter calculation.

9999 Winding diameter calculation invalid

1248 R001

Winding diameter change limit disable time 0 s 0 to 100 s

Set the waiting time to start limiting the change increment amount after the winding diameter calculation is started.

Pr.362 Terminal 4

Terminal 2

Encoder pulse train input (FR-A8AP/A8AL)

Encoder pulse train input (FR-A8TP)

Terminal JOG single-phase pulse train input

Line speed command selection

Terminal 6

Terminal 1

4

3

0

1

6

5

Pr.291 = 0, 10, 20

Pr.291 = 1, 11, 21, 100

Pr.862 = 1

Pr.284

Pr.362

Pr.862 = 0

Input pulse Pr.384

Pulse train calibration Pr.279,

Pr.281 to Pr.283

Pulse train calibration Pr.279,

Pr.281 to Pr.283

Pulse train calibration Pr.279,

Pr.281 to Pr.283

Primary delay filter

Pr.284

Primary delay filter

Pr.284

Primary delay filter

2

7

9

Analog calibration Pr.278 to Pr.281

Pr.74, Pr.822, Pr.832

Primary delay filter 3 to 6

FR-A8AL pulse train input (PP, NP)

Actual line speedUnit switchover Pr.358

Line speed acceleration/deceleration

0

CC-Link, CC-Link IE Field Network Basic

99990

Winding diameter calculation setting

198 WINDING DIAMETER COMPENSATION FUNCTION

Winding diameter calculation function (Pr.1247, Pr.1248, X115 signal) The winding diameter calculation function is enabled once all the following conditions are met.

- Dancer feedback speed control or tension sensorless torque control is valid. - Pr.1247 Winding diameter change increment amount limit "9999" - The X115 signal is OFF or not assigned.

Set Pr.1247 to limit the amount of change in the winding diameter calculation (per winding diameter calculation cycle) to avoid sudden changes of the winding diameter calculation result from the last time. Use Pr.1247 to set the maximum amount of change in each winding diameter calculation.

Use Pr.1248 Winding diameter change limit disable time to set the waiting time to start limiting the change increment amount after the winding diameter calculation is started.

The present value of winding diameter is retained while the X115 signal is ON. (The winding diameter calculation is stopped, and the winding diameter value is not updated.)

To assign the X115 signal, set "115" in any of Pr.178 to Pr.189 (input terminal function selection).

NOTE The change increment amount limit is invalid in the initial winding measurement mode (while the X122 signal is ON). (The

change amount is not limited.) While Pr.1247 = "9999" or the winding diameter calculation is disabled by the X115 signal, the present winding diameter

value is retained.

Gear ratio setting (Pr.1243, Pr.1244) Set a number to determine the gear ratio in Pr.1243 Gear ratio numerator and Pr.1244 Gear ratio denominator when a

reduction gear is installed between the driving shaft and the motor shaft.

Gear ratio calculation

Setting example Set the gear ratio as follows when a geared motor with a gear ratio of 1/30 (actual reduction ratio 1/28.51) is used. Set a value as close to the actual reduction ratio as possible. Gear ratio Z = 100/2851

NOTE Set the gear ratio accurately.

Gear ratio Z = Pr.1243 Pr.1244

Winding diameter held Winding diameter calculation

Pr.1248

Winding diameter held

Pr.1247

For one-time calculation

Winding diameter

Inverter-driven motor

Reduction gear

System Pr.1243 (Gear ratio numerator)

Pr.1244 (Gear ratio denominator)

Winding diameter calculation setting

WINDING DIAMETER COMPENSATION FUNCTION 199

9

9.2.3 Winding diameter calculation using actual line speed (actual line speed method)

The winding diameter is calculated from the actual line speed and the actual motor speed.

The increment varies depending on the Pr.358 setting. (Refer to page 67.)

Pr. Name Initial value Setting range Description

278 R051

Actual line speed voltage/ current gain 9999

0 to 100% Set the converted % of the gain voltage (current) for analog input.

9999 As set in the line speed command calibration setting. 279 R052 Actual line speed gain 9999

0 to 6553.4 m/min Set the actual gain line speed for analog input. 9999 As set in the line speed command calibration setting.

280 R053

Actual line speed voltage/ current bias 9999

0 to 100% Set the converted % of the bias voltage (current) for analog input.

9999 As set in the line speed command calibration setting. 281 R054 Actual line speed bias 9999

0 to 6553.4 m/min Set the actual bias line speed for analog input. 9999 As set in the line speed command calibration setting.

282 R055

Actual line speed pulse input bias 9999

0 to 500k pulses/s Set the bias side number of input pulses for pulse train input.

9999 As set in the line speed command calibration setting. 283 R056

Actual line speed pulse input gain 9999

0 to 500k pulses/s Set the bias line speed for pulse train input. 9999 As set in the line speed command calibration setting.

284 R057

Actual line speed input filter time constant 0.02 s 0 to 5 s Set the time constant of the primary delay filter relative

to the pulse input value.

358 R201 Line speed unit 0

0 m/min 1 m/s 2 mm/min 3 mm/s

362 R050

Actual line speed input selection 0

0 V* (line speed command) 1 Terminal JOG single-phase pulse train input 2 FR-A8AP/FR-A8AL/FR-A8TP encoder pulse train input 3 Terminal 2 (0 to 100%) 4 Terminal 4 (20 to 100%) 5 Terminal 1 (-100 to 100%) 6 Terminal 6 (FR-A8AZ) (-100 to 100%) 7 FR-A8AL single-phase pulse train input 9 CC-Link or CC-Link IE Field Network Basic (0 to 65534) 9999 No function

384 D101

Input pulse division scaling factor 0 0 to 250 Set the pulse division scaling factor for pulse train input

through terminal JOG.

1245 R042

Sampling time for winding diameter calculation 9999

0.01 to 1 s Set a sampling time for the winding diameter calculation.

9999 Sampling time: About 5 ms

Winding diameter calculation setting

200 WINDING DIAMETER COMPENSATION FUNCTION

Actual line speed input selection (Pr.362) Use Pr.362 Actual line speed input selection to select the input method for actual line speed to perform winding diameter

calculation. When material thickness is set to Pr.1231 Material thickness d1 (Pr.1231 "9999"), calculate winding diameter not from

line speed but from the product of material thickness and number of rotations of a roll. (Refer to page 203.)

When Pr.362 = "9999" (no function), the line speed command is regarded as zero. When Pr.362 = "2", use Pr.862 to select the option used for the actual line speed input. (Refer to page 234.) The input specification in the initial setting is indicated. When the Pr.362 setting is changed from "9" to a value other than "9", the actual line speed will be input via an interface other than the

communication interface immediately after the setting change. When the Pr.362 setting is changed from a value other than "9" to "9" at an inverter reset, the actual line speed will be input via communication after the reset. The actual line speed input is treated as "0" until the inverter reset is completed.

NOTE The priorities of the input signals are defined as follows. If the input method for a signal is the same as that for the input signal

with higher priority, the signal with lower priority does not work. Dancer signal input (Pr.363) > Actual line speed input (Pr.362) > Tension command input (Pr.804) > Line speed command input (Pr.361 "0") > Taper setting input (Pr.1285) > Dancer tension setting input (Pr.364) > Line speed command compensation input > Line speed command input (Pr.361 = "0")

Actual line speed unit (Pr.358) Use Pr.358 Line speed unit to select the unit of the line speed.

Actual line speed input by pulse train input (Pr.362="1, 2, 7", Pr.279, Pr.281 to Pr.284)

The actual line speed can be input using single phase pulse train input through terminal JOG, encoder pulse train input through FR-A8AP/FR-A8AL/FR-A8TP, or single phase pulse train input through FR-A8AL (PP, NP).

The number of pulses is calculated internally as follows.

Use Pr.428 Command pulse selection to set the pulse train type. (Refer to page 67.) To perform Vector control, install the Vector control compatible option.

Pr.362 setting Actual line speed input method Input value calibration

parameter 0 (initial value) V* (line speed command) 1 Terminal JOG single-phase pulse train input Pr.279, Pr.281 to Pr.283

2 FR-A8AP/FR-A8AL/FR-A8TP encoder pulse train input (complementary 12 V / differential 5 V (A-, B-phases)) Pr.279, Pr.281 to Pr.283

3 Terminal 2 (analog value: 0 to 100%) (0 to 5 VDC) Pr.278 to Pr.281 4 Terminal 4 (analog value: 20 to 100%) (4 to 20 mADC) Pr.278 to Pr.281 5 Terminal 1 (analog value: -100 to 100%) (0 to 10 VDC) Pr.278 to Pr.281

6 Terminal 6 (FR-A8AZ) (analog value: -100 to 100%) (0 to 10 VDC) Pr.278 to Pr.281

7 FR-A8AL single-phase pulse train input (PP, NP) Pr.279, Pr.281 to Pr.283 9 CC-Link or CC-Link IE Field Network Basic (0 to 65534) 9999 No function

Pr.358 setting Commanded line speed monitoring

Actual line speed monitoring

Line speed setting in parameters

0 (initial value) m/min m/min m/min 1 m/s m/s m/s 2 mm/min mm/min mm/min 3 mm/s mm/s mm/s

Pr.362 setting Pulse train input Number of pulses calculated internally

1 Terminal JOG single-phase pulse train input

Set the pulse division scaling factor in Pr.384 for pulse train input through terminal JOG. Number of pulses calculated internally = Number of input pulses / Pr.384 setting value

2 FR-A8AP/FR-A8AL/FR-A8TP encoder pulse input Time-averaged number of input pulses using Pr.1245 Sampling time for winding diameter calculation.7 Single-phase pulse train input through FR-A8AL (PP,

NP)

Winding diameter calculation setting

WINDING DIAMETER COMPENSATION FUNCTION 201

9

The actual line speed input by pulse train input is calibrated with Pr.279 Actual line speed gain, Pr.281 Actual line speed bias, Pr.282 Actual line speed pulse input bias, and Pr.283 Actual line speed pulse input gain. The calculation result is applied as the actual line speed input value (lower limit: 0 m/min, upper limit: 6553.4 m/min).

When "9999" is set in any of Pr.279 or Pr.281 to Pr.283, the settings for the corresponding line speed command (Pr.351, or Pr.353 to Pr.355) are applied for calibration. (Refer to page 67.)

To calibrate the actual line speed when Pr.362 = "2" or when Pr.362 = "7" and Pr.428 = "2 or 5", set the number of pulses multiplied by four in Pr.282 and Pr.283. A calculation example is as follows.

For the actual line speed input using pulse train, use Pr.284 Actual line speed input filter time constant to set the time constant of primary delay filter for pulse train input. When Pr.284 = 0 s, the filter is not set.

50 (Pr.279)

5 (Pr.281)

Actual line speed [m/min]

Input pulse [k pulses/s]

13.58 (Pr.283)

1.36 (Pr.282)

6553.4

0

System specifications Roll diameter: 80 mm Encoder resolution: 1024 Pulse/Rev Line speed range: 5 to 50 m/min

Theoretical formula V [m/min] = D [m] n [r/min]

When the line speed is 5 m/min:

When the line speed is 50 m/min:

5 [m/min] 19.89 [r/min]

1.36 [k pulses/s]

13.58 [k pulses/s]

0.08 [m] n [r/min] =

19.89 [r/min] 1024 [Pulse/Rev] 4

60 [s] Input pulse [k pulses/s] =

50 [m/min] 198.9 [r/min]

0.08 [m] n [r/min] =

198.9 [r/min] 1024 [Pulse/Rev] 4

60 [s] Input pulse [k pulses/s] =

Pr.279

Pr.281

Actual line speed (m/min)

Actual line speed (m/min)

Actual line speed (m/min)

Actual line speed (m/min)

Input pulse (k pulses/s)

Input pulse (k pulses/s)

Input pulse (k pulses/s)

Input pulse (k pulses/s)

Pr.283

Pr.283

Pr.283Pr.282

Pr.282 Pr.283 Pr.282

Pr.282

6553.4

Pr.279

Pr.281

6553.4

Pr.279

Pr.281

6553.4

Pr.279

Pr.281

6553.4

0 0

0 0

Pr.281 < Pr.279, and Pr.282 < Pr.283 Pr.281 > Pr.279, and Pr.282 < Pr.283

Pr.281 < Pr.279, and Pr.282 > Pr.283 Pr.281 > Pr.279, and Pr.282 > Pr.283

Winding diameter calculation setting

202 WINDING DIAMETER COMPENSATION FUNCTION

Actual line speed analog input (Pr.362 = "3 to 6", Pr.278 to Pr.281) The actual line speed can be input by analog input. The analog input value of the actual line speed is calibrated with Pr.278 Actual line speed voltage/current gain, Pr.279

Actual line speed gain, Pr.280 Actual line speed voltage/current bias, and Pr.281 Actual line speed bias. The calculation result is applied as the line speed command value (lower limit: 0 m/min, upper limit: 6553.4 m/min).

When "9999" is set in any of Pr.279 to Pr.281, the settings for the corresponding line speed command (Pr.350 to Pr.353) are applied for calibration. (Refer to page 67.)

NOTE The difference between the setting values of Pr.278 and Pr.280 can be set within 5%. (Even if the difference is 5% or less,

Er3 (calibration error) does not occur.) The Pr.280 setting can be larger than the Pr.278 setting. Also, the Pr.281 setting can be larger than the Pr.279 setting.

Actual line speed input via communication (Pr.362 = "9") When Pr.362 = "9", the actual line speed can be input via CC-Link or CC-Link IE Field Network Basic communication. The actual line speed input via communication is recognized as 16-bit unsigned data. The input data range is from 0 to

65534 (6553.4). When out-of-range values are input, the limit is set at 0 or 65534 (6553.4).

Sampling time for winding diameter calculation (Pr.1245) For winding diameter calculation using actual line speed, use Pr.1245 Sampling time for winding diameter calculation

to set how often the winding diameter calculation result is applied. When Pr.1245 = "9999", a sampling time is about 5 ms for winding diameter calculation.

NOTE When the thickness method is selected, the Pr.1245 setting is invalid and a sampling time is about 5 ms.

(Refer to page 203.) The sampling time in Pr.1245 is valid also for pulse train input of the line speed command (when Pr.361 = "2 or 7").

(Refer to page 67.)

Pr.280 Pr.278

Pr.281

6553.4

Pr.279

Analog input value (%)

Actual line speed (m/min)

Winding diameter calculation setting

WINDING DIAMETER COMPENSATION FUNCTION 203

9

9.2.4 Winding diameter calculation using material thickness (thickness method)

The material thickness is added up for winding diameter calculation. First to fourth material thickness can be selected by the signal input.

Selection of the thickness method (Pr.1231) When a value other than "9999" is set in Pr.1231, the winding diameter is calculated not from line speed but from the

addition of material thickness and number of roll rotations. (Thickness method) When selecting the thickness method, use an option, the FR-A8AP, FR-A8AL, or FR-A8TP, to input the encoder pulse (A/B

phase).

NOTE When Pr.1231 = "9999", the winding diameter is calculated from the actual line speed. (Refer to page 199.) In the thickness method, the stored values of the initial winding diameter, material thickness, and number of roll rotations are

used for calculation. Set correct values for the initial winding diameter and the material thickness. If the setting of the initial winding diameter is incorrect, or the actual material thickness and the material thickness setting (parameter setting) are inconsistent, calculation errors are more likely to occur. If calculation errors occur, select the actual line speed method.

Material thickness selection (Pr.1232 to Pr.1234, X107 signal, X108 signal)

Turn ON/OFF the Minimum/maximum winding diameter selection (X107 and X108) signals to select the material thickness set in Pr.1232 to Pr.1234.

For the X107 and X108 signals, assign the function by setting "107 (X107)" or "108 (X108)" in any of Pr.178 to Pr.189 (input terminal function selection).

NOTE By turning ON/OFF the X107 and X108 signals, the maximum and minimum winding diameters are also selected. (For the

details, refer to page 206.) When the maximum/minimum diameter is selected using the X107 and X108 signals, or the setting in Pr.1235 to Pr.1242 is

changed, the present winding diameter may be limited and change depending on the maximum/minimum winding diameter setting. When the maximum/minimum winding diameter setting is newly selected or changed, check that the present winding diameter is correct. If the value changes to an unintended value, correct the present diameter by performing one of the following actions. - Use Pr.646 Stored winding diameter to set the present diameter. - Perform initial winding diameter calculation. - Turn OFF the X114 signal (restore the initial winding diameter).

Pr. Name Initial value Setting range Description

1231 R010 Material thickness d1 9999

0 to 20 mm Set the material thickness for winding diameter calculation.

9999 Actual line speed method 1232 R011 Material thickness d2 1 mm 0 to 20 mm

The material thickness can be selected using the X107 and X108 signals.

1233 R012 Material thickness d3 1 mm 0 to 20 mm

1234 R013 Material thickness d4 1 mm 0 to 20 mm

Input signal Material thickness Maximum winding diameter / minimum winding diameterX107

signal X108 signal

OFF OFF Material thickness d1 (Pr.1231) Maximum winding diameter 1 (Pr.1235) / Minimum winding diameter 1 (Pr.1236) ON OFF Material thickness d2 (Pr.1232) Maximum winding diameter 2 (Pr.1237) / Minimum winding diameter 2 (Pr.1238) OFF ON Material thickness d3 (Pr.1233) Maximum winding diameter 3 (Pr.1239) / Minimum winding diameter 3 (Pr.1240) ON ON Material thickness d4 (Pr.1234) Maximum winding diameter 4 (Pr.1241) / Minimum winding diameter 4 (Pr.1242)

Winding diameter calculation setting

204 WINDING DIAMETER COMPENSATION FUNCTION

9.2.5 Line speed at winding diameter calculated value activation

Set the line speed command value or actual line speed to start winding diameter calculation. When the line speed command value or actual line speed is lower than the speed to start winding diameter calculation, winding diameter calculation is not performed and the last winding diameter value is kept.

The increment varies depending on the Pr.358 setting. (Refer to page 67.)

Line speed at winding diameter calculated value activation during dancer feedback / tension sensor feedback speed control

During dancer feedback speed control or tension sensor feedback speed control, when the line speed command value is equal to or higher than Pr.1246, winding diameter calculation is performed, and the winding diameter calculation result is updated. When the line speed command value is lower than the Pr.1246 setting, winding diameter calculation is not performed and the last winding diameter value is kept.

It is possible to prevent the change in the winding diameter, which may be caused by calculation errors at low-speed operation.

Pr. Name Initial value Setting range Description

1246 R040

Line speed at winding diameter calculated value activation

1 m/min 0 to 6553.4 m/min Set the line speed command value or actual line speed to start winding diameter calculation.

Winding diameter

Line speed command value

Pr.1246

Winding diameter value held

Winding diameter value held

Winding diameter calculation in progress

(winding diameter value being updated)

Line speed command (m/min)

Time

Winding diameter calculation setting

WINDING DIAMETER COMPENSATION FUNCTION 205

9

Line speed at winding diameter calculated value activation during tension sensorless / tension sensor feedback torque control

During tension sensorless / tension sensor feedback torque control, when the actual line speed is equal to or higher than Pr.1246 Line speed at winding diameter calculated value activation, winding diameter calculation is performed, and the winding diameter calculation result is updated. When the actual line speed is lower than the Pr.1246 setting, winding diameter calculation is not performed and the last winding diameter value is kept.

It is possible to prevent the change in the winding diameter, which may be caused by calculation errors at low-speed operation.

NOTE In the thickness method, the actual line speed is not used for calculating the winding diameter. However, both in the actual

line speed method and the thickness method, the actual line speed is used for determining whether winding diameter calculation is performed.

If the actual line speed is not input, setting Pr.362 = "0" (select V* (line speed command) as the actual speed input) enables the use of V* as a reference to determine whether winding diameter calculation is performed.

9.2.6 Averaging process for winding diameter calculation

Set the time constant of the primary delay filter relative to the winding diameter calculation result.

The filter time constant for the Pr.1249 setting is as follows.

NOTE Averaging process for winding diameter calculation is performed after limiting the maximum change for winding diameter

calculation (Pr.1247).

Pr. Name Initial value Setting range Description 1249 R043

Number of averaging for winding diameter calculation 4 0 to 10 Set the time constant of the primary delay filter

relative to the winding diameter calculation result.

Pr.1249 setting Filter time constant 0 Without filter 1 0.02 s 2 0.04 s 3 0.08 s 4 (initial value) 0.16 s 5 0.32 s 6 0.64 s 7 1.28 s 8 2.56 s 9 5.12 s 10 10.24 s

Winding diameter

Pr.1246

Winding diameter value held

Winding diameter value held

Winding diameter calculation in progress (winding diameter value being updated)

Actual line speed (m/min)

Time

Winding diameter after limiting the change amount (Pr.1247)

Averaging

Pr.12490

Pr.1249=0

Winding diameter after averaging

Winding diameter calculation setting

206 WINDING DIAMETER COMPENSATION FUNCTION

9.2.7 Minimum/maximum winding diameter Use the following parameters to store a pair of the maximum and minimum roll diameters. Select from the pair 1 to 4 by changing the status of the two input signals.

Minimum/maximum winding diameter (Pr.1235, Pr.1236) Winding diameter calculation values are limited at the maximum diameter set in Pr.1235 Maximum winding diameter 1, or

the minimum diameter set in Pr.1236 Minimum winding diameter 1. The winding diameter after the averaging process (Pr.1249) is limited at the minimum/maximum diameter.

Minimum/maximum winding diameter selection (Pr.1237 to Pr.1242, X107 signal, X108 signal)

Turn ON/OFF the Minimum/maximum winding diameter selection (X107 and X108) signals to select the maximum and minimum winding diameters set in Pr.1237 to Pr.1242.

For the X107 and X108 signals, assign the function by setting "107 (X107)" or "108 (X108)" in any of Pr.178 to Pr.189 (input terminal function selection).

Pr. Name Initial value Setting range Description

1235 R020 Maximum winding diameter 1 2 mm 1 to 6553 mm Set the maximum value relative to the roll diameter

calculation result.

1236 R021 Minimum winding diameter 1 1 mm 1 to 6553 mm Set the minimum value relative to the roll diameter

calculation result.

1237 R022 Maximum winding diameter 2 2 mm 1 to 6553 mm

Set the maximum value relative to the roll diameter calculation result. To select this setting, turn ON the X107 signal.

1238 R023 Minimum winding diameter 2 1 mm 1 to 6553 mm

Set the minimum value relative to the roll diameter calculation result. To select this setting, turn ON the X107 signal.

1239 R024 Maximum winding diameter 3 2 mm 1 to 6553 mm

Set the maximum value relative to the roll diameter calculation result. To select this setting, turn ON the X108 signal.

1240 R025 Minimum winding diameter 3 1 mm 1 to 6553 mm

Set the minimum value relative to the roll diameter calculation result. To select this setting, turn ON the X108 signal.

1241 R026 Maximum winding diameter 4 2 mm 1 to 6553 mm

Set the maximum value relative to the roll diameter calculation result. To select this setting, turn ON the X107 and X108 signals.

1242 R027 Minimum winding diameter 4 1 mm 1 to 6553 mm

Set the minimum value relative to the roll diameter calculation result. To select this setting, turn ON the X107 and X108 signals.

Input signal Maximum winding diameter / minimum winding diameter Material thicknessX107

signal X108 signal

OFF OFF Maximum winding diameter 1 (Pr.1235) / Minimum winding diameter 1 (Pr.1236) Material thickness d1 (Pr.1231) ON OFF Maximum winding diameter 2 (Pr.1237) / Minimum winding diameter 2 (Pr.1238) Material thickness d2 (Pr.1232) OFF ON Maximum winding diameter 3 (Pr.1239) / Minimum winding diameter 3 (Pr.1240) Material thickness d3 (Pr.1233) ON ON Maximum winding diameter 4 (Pr.1241) / Minimum winding diameter 4 (Pr.1242) Material thickness d4 (Pr.1234)

Maximum diameter

Minimum diameter

Winding diameter

Time

Maximum diameter

Minimum diameter

Winding diameter

Time Operation during winding Operation during unwinding

Winding diameter calculation setting

WINDING DIAMETER COMPENSATION FUNCTION 207

9

NOTE By turning ON/OFF the X107/X108 signal, the material thickness is also selected. (For the details, refer to page 203.) If the minimum winding diameter setting is equal to or larger than the maximum winding diameter setting, the winding

diameter is fixed at the maximum diameter (minimum diameter) and therefore, the winding diameter does not change from the maximum diameter (minimum diameter).

When the maximum/minimum diameter is selected using the X107 and X108 signals, or the setting in Pr.1235 to Pr.1242 is changed, the present winding diameter may be limited and change depending on the maximum/minimum winding diameter setting. When the maximum/minimum winding diameter setting is newly selected or changed, check that the present winding diameter is correct. If the value changes to an unintended value, correct the present diameter by performing one of the following actions. - Use Pr.646 Stored winding diameter to set the present diameter. - Perform initial winding diameter calculation. - Turn OFF the X114 signal (restore the initial winding diameter).

9.2.8 Winding diameter compensation speed filter Set the time constant of the primary delay filter relative to the winding diameter compensation speed.

Use Pr.1251 to set the time constant of the primary delay filter. When Pr.1251 = "0", the filter is not set. Use Pr.1250 to set a waiting time before applying the primary delay filter after the initial winding diameter calculation is

completed. When the initial winding diameter calculation is not performed, set the waiting time after a start.

Pr. Name Initial value Setting range Description

1250 R260

Winding diameter compensation speed filtering waiting time

0 0 to 100 s Set a waiting time before applying the primary delay filter.

1251 R261

Winding diameter compensation speed filter time constant

0 0 to 100 s Set the time constant of the primary delay filter relative to the winding diameter compensation speed.

Winding diameter Winding diameter compensation speed after filtering

Before the Pr.1250 setting time elapsed

After the Pr.1250 setting time elapsed

Pr.1251 Winding diameter

compensation speed calculation

Winding diameter calculation setting

208 WINDING DIAMETER COMPENSATION FUNCTION

9.2.9 Target winding diameter achieved When the winding diameter calculated in the inverter is equal to or more than the parameter setting, the Target winding diameter achieved (Y233) signal is output.

Target winding diameter achieved (Pr.648, Y233 signal) When the result of winding diameter calculation in the inverter is equal to or more than the Pr.648 Target winding

diameter setting, the Target winding diameter achieved (Y233) signal can be output. The Y233 output condition depends on whether the operation is winding or unwinding.

9.2.10 Winding diameter calculation at a start (dancer feedback speed control)

When the dancer roll is moved from the upper/lower limit position to the target position at start, the present winding diameter is calculated.

Pr. Name Initial value Setting range Description

648 R420 Target winding diameter 1 1 to 6553 Set the winding diameter to output the Target winding

diameter achieved (Y233) signal.

Winding/unwinding Y233 output condition Winding Output when the winding diameter reaches or exceeds the Pr.648 setting. Unwinding Output when the winding diameter reaches or falls below the Pr.648 setting.

Pr. Name Initial value Setting range Description

133 R101 (A611)

PID action set point 500% 400 to 600% Set the target position for the dancer roll.

1252 R070 Dancer lower limit position 400% 400 to 600%

The initial winding diameter calculation is performed when the dancer roll position is equal to or lower than the setting of this parameter.

1253 R071

Initial winding diameter calculation deadband 1% 0 to 50% Set the deadband on the lower limit position.

1254 R072

Initial winding diameter calculation deadband 2 9999

0 to 50% Set the deadband on the target position.

9999 The deadband on the target position is as set in Pr.1253.

1255 R073 Accumulated amount 9999

1 to 5000 mm Set the accumulated amount.

8888 The initial winding diameter calculation is invalid. (When the dancer roll position is equal to or lower than the Pr.1252 setting, the dancer roll is lifted.)

9999 Initial winding diameter calculation invalid 1256 R074 Speed control P gain at start 60% 0 to 1000% Set the speed control proportional gain during initial

winding diameter calculation at start.

1257 R075

Speed control integral time at start 2 s 0 to 20 s Set the speed control integral time during initial winding

diameter calculation at start.

1258 R076 Integral term limit at start 2.5% 0 to 100% Set the integral action limit value during initial winding

diameter calculation at start.

1259 R077 PID term limit at start 2.5% 0 to 100% Set the PID manipulated amount limit value during

initial winding diameter calculation at start.

Winding diameter calculation setting

WINDING DIAMETER COMPENSATION FUNCTION 209

9

Initial winding diameter calculation at a start (enabled under Vector control only)

Calculate the initial winding diameter "D" from the dancer travel distance "L" when the dancer roll moves from the lower limit position to the neutral position at a start.

When Pr.1255 Accumulated amount = "8888" and the dancer roll position is equal to or lower than the setting of Pr.1252 Dancer lower limit position, dancer roll is lifted with PI gain at a start, but initial winding diameter calculation is not performed. This operation is useful to wind up sagging material slowly.

When Pr.1255 = "9999", winding diameter calculation is not performed, and the winding diameter, which has been used, is kept. In such a case like this, PI gain of speed control for normal operation is used instead of gain for winding diameter calculation.

NOTE Set a value other than "9999" in Pr.1247 Winding diameter change increment amount limit even when lifting the dancer

roll without performing the initial winding diameter calculation (Pr.1255 = "8888"). Do not use Pr.78 Reverse rotation prevention selection when using initial winding diameter calculator function. To adjust the overshoot amount at an initial winding diameter calculation, use Pr.73 Analog input selection to set the

polarity reversible operation. To minimize fluctuation of the dancer roll when shifting from initial winding diameter calculation to normal operation, set Pr.13

Starting frequency = "0".

Dancer lower limit position and accumulated amount setting (Pr.1252, Pr.1255)

Set Pr.1252 Dancer lower limit position and Pr.1255 Accumulated amount. The winding diameter at a start is calculated from the dancer roll travel distance (accumulated amount) and the corresponding number of pulses (number of rotations).

D = 2 L

L : Dancer travel distance (accumulated amount = 2 L) N Z

N : Number of motor rotations Z : Gear ratio

Pr.1255 setting When the dancer roll position is equal to or lower than the Pr.1252 setting

When the dancer roll position is higher than the Pr.1252 setting

1 to 5000 mm

Initial winding diameter calculation is performed. The winding diameter obtained from the initial winding diameter calculation is used.

The dancer roll is lifted with PI gain (Pr.1256 to Pr.1259) at a start.

Initial winding diameter calculation and dancer lifting operation are not performed.

The winding diameter, which has been used, is kept.

8888

Initial winding diameter calculation is not performed. The winding diameter is kept. The dancer roll is lifted with PI gain (Pr.1256 to Pr.1259) at a start.

Initial winding diameter calculation and dancer lifting operation are not performed.

The winding diameter, which has been used, is kept.

9999 Initial winding diameter calculation and dancer lifting operation are not performed.

The winding diameter, which has been used, is kept.

Initial winding diameter calculation and dancer lifting operation are not performed.

The winding diameter, which has been used, is kept.

L

Target position

Lower limit position

Pr.1255=2L

Winding diameter calculation setting

210 WINDING DIAMETER COMPENSATION FUNCTION

Initial winding diameter calculation deadband setting (Pr.1253, Pr.1254) When performing initial winding diameter calculation, winding diameter calculation deadband can be set for the target

position and the lower limit position of the dancer roll. Setting a deadband suppresses hunting of dancer control at a start, and reduces the influence of overshooting on the target

position. Use Pr.1253 Initial winding diameter calculation deadband or Pr.1254 Initial winding diameter calculation deadband

2 to set the ratio of the deadband, assuming that the distance between the target position and the lower limit position is 100%.

Speed control gain during initial winding diameter calculation at a start (Pr.1256, Pr.1257)

When performing initial winding diameter calculation, inverter's speed control proportional gain and integral time during winding diameter calculation can be set separately. After initial winding diameter calculation is completed, normal speed control gain is applied.

Deadband Calculation formula Description Initial winding diameter deadband | Target position - Lower limit position | Pr.1253/100 Deadband on the lower limit position

Initial winding diameter deadband 2 | Target position - Lower limit position | Pr.1254/100 Deadband on the target position

Target position

Lower limit position

L

Deadband 2

Initial winding diameter calculation is performed.

Deadband 1

Target position

Lower limit position

L

Deadband 1

Initial winding diameter calculation is performed.

Deadband 2

Target position < Lower limit positionTarget position Lower limit position

Dancer roll position Deadband 1

ON

ON

Deadband 2 Dancer roll target position

Start command

Speed control proportional gain

Y232

Pr.820Pr.1256

Pr.1257 Pr.821

Initial winding diameter calculation Normal dancer control

Initial winding diameter calculation

is performed.

Speed control integral time

When the deadband is smaller, fluctuation of the dancer roll becomes less at operation shift from initial winding diameter calculation to dancer control.

Winding diameter calculation setting

WINDING DIAMETER COMPENSATION FUNCTION 211

9

Integral action and PID manipulated amount during initial winding diameter calculation at a start (Pr.1258, Pr.1259)

The limit for manipulated amount of PID control for dancer roll can be set to prevent a motor from over-speeding during initial winding diameter calculation at a start.

Set the limit for manipulated amount of integral control action of PID control in Pr.1258 Integral term limit at start. Set the limit for manipulated amount of PID control in Pr.1259 PID term limit at start.

Winding diameter calculation completion signal (Y232 signal) After initial winding diameter calculation at a start is completed, the Winding diameter calculation completion at start (Y232)

signal is output. For the Y232 signal, set "232 (positive logic) or 332 (negative logic)" in one of Pr.190 to Pr.196 (output terminal function

selection) to assign the function to the output terminal.

PID calculated value = Gain G Kp (1 + 1

+ Td S) Ti S

Gain G Kp

Gain G

Gain G Kp

Kp

Differential term

Integral term

Proportional term

Deviation

Pr.1258

Pr.1259

Manipulated amount

Td S

1/(Ti S)

Winding diameter calculation setting

212 WINDING DIAMETER COMPENSATION FUNCTION

9.2.11 Initial winding diameter calculation at a start (Tension sensor feedback speed control / tension sensorless torque control / tension sensor feedback torque control)

Turn ON the Winding diameter measurement (X122) signal to select the initial winding measurement mode and calculate the present winding diameter.

Initial winding diameter calculation (X122 signal) While tension sensorless / tension sensor feedback torque control is valid, the present winding diameter can be measured

in the initial winding measurement mode. Turn ON the Winding diameter measurement (X122) signal to select the initial winding measurement mode. To assign the X122 signal, set "122" in any of Pr.178 to Pr.189 (input terminal function selection). When the actual line speed reaches the Pr.1246 Line speed at winding diameter calculated value activation in the

initial winding diameter measurement mode, calculation for initial winding diameter measurement starts. When the winding diameter difference from the last measurement remains 5 mm or less for 0.25 seconds during measurement, the Y232 signal turns ON.

Turn OFF the X122 signal to return to the normal winding diameter calculation.

Winding diameter calculation completion signal (Y232 signal) After initial winding diameter calculation at a start is completed, the Winding diameter calculation completion at start (Y232)

signal is output. For the Y232 signal, set "232 (positive logic) or 332 (negative logic)" in one of Pr.190 to Pr.196 (output terminal function

selection) to assign the function to the output terminal.

Actual line speed (m/min)

Pr.1246

Winding diameter status Held Held

Time

Winding diameter calculation Normal winding

diameter calculation Initial winding measurement Normal winding diameter calculation

Y232

Winding diameter 0.25 s

ON

X122

Start command

ON

ON

5-mm diameter change or less in 0.25 s

Calculation

Winding diameter calculation setting

WINDING DIAMETER COMPENSATION FUNCTION 213

9

9.2.12 Winding diameter / winding length storage The winding diameter/length calculated in the inverter can be stored. The stored diameter and length are kept even if the inverter power is turned OFF.

The increment varies depending on the Pr.1262 setting.

Winding length calculation While the winding diameter calculation is valid, the winding length can be calculated from the integration of the actual line

speed value. For the operation in the direction set in winding/unwinding selection (refer to page 67), the winding length is increased by

0.1 mm. (When the value exceeds 9999999999.9 mm, the value is reset to 0.0 mm.) For the operation opposite to the winding/unwinding setting for the two-way operation function (refer to the "two-way

operation function"), the winding length is reduced by 0.1 mm. (When the value falls below 0.0 mm, the value is reset to 9999999999.9 mm.)

Pr. Name Initial value Setting range Description

645 R004

Winding diameter storage selection 0 0, 1 Select whether to store the diameter length.

646 R003 Stored winding diameter 1 mm 1 to 6553 mm The stored diameter can be read/written.

647 R041

Operation time with stored winding diameter 0 s 0 to 100 s Set the time to hold the stored diameter after the start

signal turns ON.

648 R420 Target winding diameter 1 mm 1 to 6553 mm Set the diameter to output the Target winding diameter

achieved (Y233) signal.

1262 R005 Winding length increment 3

0 1 km 1 100 m 2 10 m 3 1 m 4 1 cm 5 1 mm

1263 R006

Stored winding length (lower 4 digits) 0 (m) 0 to 9999 (m) The stored winding length (lower 4 digits) can be read/

written.

1264 R421

Winding length detection (lower 4 digits) 1000 (m) 0 to 9999 (m) Set the winding length (lower 4 digits) which triggers the

Winding/unwinding completion (Y234) signal output.

1298 R007

Stored winding length (upper 4 digits) 0 (m) 0 to 9999 (m) The stored winding length (upper 4 digits) can be read/

written.

1299 R008

Stored winding length increment 0

0 1 m 1 1 cm 2 1 mm

1346 R424

Winding length detection (upper 4 digits) 0 (m) 0 to 9999 (m) Set the winding length (upper 4 digits) which triggers the

Winding/unwinding completion (Y234) signal output.

Winding diameter calculation setting

214 WINDING DIAMETER COMPENSATION FUNCTION

Winding/unwinding length detection (Pr.1264, Pr.1346, Y234 signal) When the material winding (unwinding) length is equal to or more than the length determined by the settings of Pr.1264

Winding length detection (lower 4 digits) and Pr.1346 Winding length detection (upper 4 digits), the Winding/ unwinding completion (Y234) signal turns ON. Use Pr.1262 Winding length increment to set the winding length increment.

For the Y234 signal, set "234 (positive logic) or 334 (negative logic)" in one of Pr.190 to Pr.196 (output terminal function selection) to assign the function to the output terminal.

Winding diameter / winding length storage selection (Pr.645) Use Pr.645 Winding diameter storage selection to select the timing to update the values of winding diameter (Pr.646)

and winding length (Pr.1263 and Pr.1298).

If the power supply is disconnected, the winding diameter may not be stored. To make sure that the winding diameter is stored, turn OFF the X114 signal to store the diameter before turning OFF the power.

When the FR-HC2/FR-XC/FR-CV is used, the winding diameter is stored using the X11 signal. To make sure that the winding diameter is stored, use the X11 signal.

NOTE The winding diameter is kept independently of Pr.645 setting when start commands (STF, STR) are OFF. The winding diameter calculation is used or not used depending on the status of the Tension control selection (X114) signal,

Pr.1247 Winding diameter change increment amount limit setting, and a prioritized operation such as JOG operation.

Stored winding diameter (Pr.646, Pr.647) Read Pr.646 Stored winding diameter to check the winding diameter presently stored. The stored winding diameter can be changed by overwriting the setting value in Pr.646 with a desired value. The present winding diameter is kept for the duration set in Pr.647 Operation time with stored winding diameter after the

start command is given.

Pr.645 setting

Winding diameter storage timing (Pr.646 update timing)

Winding length storage timing (update timing for Pr.1263 or Pr.1298)

0 When a value is set in Pr.646 When the Stored winding diameter clear (X109) signal is turned ON

When a value is set in Pr.1263 or Pr.1298. When the Winding length clear (X117) signal is turned ON

1

In addition to the above-mentioned update timings defined for the setting value of "0", the stored values are also updated at the following timings. When the enabled winding diameter calculation is disabled. When the power is turned OFF while the winding diameter calculation is valid (when the power is supplied through the main circuit terminal (Pr.30 = "0, 1, 20, 21, 100, 101, 120, or 121"))

When the X11 signal is turned ON while the winding diameter calculation is valid (when the power is supplied through terminals P/+ and N/- (Pr.30 = "2, 10, 11, 102, 110, or 111"))

At an inverter reset

Initial winding diameter calculation Operation at start

With initial winding diameter calculation

The present winding diameter is kept for the duration set in Pr.647 after the start command is given and initial winding diameter calculation starts. However, when initial winding diameter calculation is completed before the Pr.647 setting time elapsed, the result of the calculation is used.

Without initial winding diameter calculation

The present winding diameter is kept for the duration set in Pr.647 after the start command is given and the winding diameter calculation starts.

Winding diameter calculation setting

WINDING DIAMETER COMPENSATION FUNCTION 215

9

Stored winding length (Pr.1262, Pr.1263, Pr.1298, Pr.1299) While winding diameter calculation is valid, the winding length can be calculated from the integration of the actual line

speed value. For winding length calculation, the actual line speed is used whichever direction the line goes. When the material is

unwound after winding operation, the winding length is not subtracted but added. (When switching between winding and unwinding is performed using the two-way operation function, the winding length is subtracted. (Refer to page 232.))

The winding length is calculated in the inverter in 0.1 mm increments. When the value exceeds 9999999999.9 mm, the value is reset to 0 mm.

Use Pr.1299 Stored winding length increment to change the increment of the stored winding length.

The stored winding length is not changed immediately after changing the Pr.1299 setting. After changing the Pr.1299 setting, the stored wiring length is changed at the update timing set in Pr.645. (Refer to page 213.)

Read Pr.1263 Stored winding length (lower 4 digits) and Pr.1298 Stored winding length (upper 4 digits) to check the stored winding length. The increment is determined by the setting of Pr.1262 Winding length increment.

The stored winding length can be changed by overwriting the setting value in Pr.1263 and Pr.1298 with a desired value. The increment of values to be set in Pr.1263 and Pr.1298 can be set in Pr.1262.

The setting values and readouts of Pr.1263 and Pr.1298 differ according to the settings of Pr.1299 Stored winding length increment and Pr.1262 Winding length increment. For example, when "0" (1 m increment) is set in Pr.1299 and "0" (1 km increment) is set in Pr.1262, a value between "0" and "9999" can be set in Pr.1263, but a value other than "0" cannot be set in Pr.1298. In this case, when "3" (1 m increment) is set in Pr.1262 after "9999" is set in Pr.1263, the readout of Pr.1263 will be "9000", and the readout of Pr.1298 will be "999". When "5" (1 mm increment) is set in Pr.1262, readout of Pr.1263 will be "0" and readout of Pr.1298 will be "9900".

NOTE Set Pr.1299 Stored winding length increment before setting a value in Pr.1263 or Pr.1298. When a value is set in either Pr.1263 or Pr.1298, "0" is automatically set in the other parameter only for the first time after the

setting of Pr.1299 Stored winding length increment is changed. When Pr.1263 and Pr.1298 are read in FR Configurator2, the same value calculated from the following formula is displayed

for both. The Pr.1299 setting is added to the ninth digit. (Pr.1298 setting 10000 + Pr.1263 (Pr.1262 / Pr.1299) Example 1 When Pr.1299 = "2", Pr.1262 = "3", Pr.1298 = "1", and Pr.1263 = "4567" 14567 (1 m / 1 mm) = 14567000 As the Pr.1299 setting is added to the ninth digit, the Pr.1263/Pr.1298 value displayed in FR Configurator2 is 214567000. Example 2 When Pr.1299 = "1", Pr.1262 = "5", Pr.1298 = "1234", and Pr.1263 = "5670" 12345670 (1 mm / 1 cm) = 1234567 As the Pr.1299 setting is added to the ninth digit, the Pr.1263/Pr.1298 value displayed in FR Configurator2 is 101234567.

Pr.1299 setting Increment Maximum stored winding length 0 (initial value) 1 m 9999999 m (about 9999 km) 1 1 cm 99999999 cm (about 999 km) 2 1 mm 99999999 mm (about 99 km)

Pr.1262 setting Increment 0 1 km 1 100 m 2 10 m 3 (initial value) 1 m 4 1 cm 5 1 mm

Winding diameter calculation setting

216 WINDING DIAMETER COMPENSATION FUNCTION

Stored winding diameter/length clear (X109 signal, X117 signal) Input the Stored winding diameter clear (X109) signal or Winding length clear (X117) signal to clear the stored winding

diameter/length. To use the X109 or X117 signal, set Pr.178 to Pr.189 (input terminal function selection) to assign the function to an input

terminal.

When the winding diameter is cleared by the X109 signal, the value after clear is as follows.

Use Pr.1230 Winding/unwinding selection for the selection. The minimum/maximum winding diameter is as selected by the X107/X108 signal. (Refer to page 206.)

9.2.13 Speed control proportional gain selection according to the winding diameter calculation result

Speed control proportional gain at vector control and Real sensorless vector control can be changed based on the value determined by winding diameter calculation. First to fourth speed control proportional gain can be selected by the signal input.

Block diagram

Pr.178 to Pr.189 setting Signal name Function 109 X109 Stored winding diameter clear 117 X117 Winding length clear

Winding/unwinding selection Winding diameter after clear Winding Minimum winding diameter Unwinding Maximum winding diameter

Pr. Name Initial value Setting range Description

639 R030

Speed control proportional term applied diameter 1 9999

1 to 99% Set the winding diameter (X1) used to select proportional gain.

9999 Operates as 33%.

640 R031

Speed control proportional term applied diameter 2 9999

1 to 99% Set the winding diameter (X2) used to select proportional gain.

9999 Operates as 66%. 641 R032

Speed control proportional gain 1 9999 0 to 1000%,

9999

The proportional gain settings are switched according to the winding diameter. 9999: Function disabled

642 R033

Speed control proportional gain 2 9999 0 to 1000%,

9999

643 R034

Speed control proportional gain 3 9999 0 to 1000%,

9999

644 R035

Speed control proportional gain 4 9999 0 to 1000%,

9999

Pr.820

Pr.830

Frequency command

Winding diameter

Speed control proportional gain

RT-ON

RT-OFF

X124-ON

X124-OFF

Pr.639 to Pr.644

Winding diameter calculation setting

WINDING DIAMETER COMPENSATION FUNCTION 217

9

Speed control proportional gain selection (Pr.639 to Pr.644) Speed control proportional gain at vector control and Real sensorless vector control can be changed based on a winding

diameter calculation result.

This function is activated when two or more settings of Pr.641 to Pr.644 (speed control proportional gain 1 to 4) are set. If two or more setting are not set, Pr.820 Speed control P gain 1 (Pr.830 Speed control P gain 2) is valid regardless of the winding diameter.

A machine operates at 33% when Pr.639 = "9999", at 66% when Pr.640 = "9999". The following graph shows the value of speed control proportional gain when two settings are made.

NOTE When Pr.639 = Pr.640, larger gain between proportional gain 2 and proportional gain 3 becomes valid.

Speed control proportional gain disabled signal (X124 signal) Use the Speed control proportional gain disabled (X124) signal to disable the Pr.641 to Pr.644 settings. To assign the X124 signal, set "124" in any of Pr.178 to Pr.189 (input terminal function selection).

X1 = ((Maximum diameter - Minimum diameter) Pr.639/100) + Minimum diameter

X2 = ((Maximum diameter - Minimum diameter) Pr.640/100) + Minimum diameter

Winding diameter calculation X124 Speed control gain

Disabled OFF Pr.820/Pr.830 ON Pr.820/Pr.830

Enabled OFF Pr.641 to Pr.644 ON Pr.820/Pr.830

Pr.1236 (Pr.1238, Pr.1240, Pr.1242)

Minimum diameter

Pr.1235 (Pr.1237, Pr.1239, Pr.1241)

Maximum diameter Small LargeMedium

Pr.644 (Proportional gain 4)

Speed control proportional (P) gain (%)

Pr.643 (Proportional gain 3)

Pr.642 (Proportional gain 2)

Pr.641 (Proportional gain 1)

Winding diameter (mm) X1 X2

Pr.1236 (Pr.1238/Pr.1240/Pr.1242)

Minimum diameter

Pr.1235 (Pr.1237/Pr.1239/Pr.1241)

Maximum diameter

Small LargeMedium

Pr.644 (Proportional gain 4)

Speed control proportional (P) gain (%)

Pr.643 (Proportional gain 3)

Winding diameter (mm)

X1 X2

Monitoring of dedicated functions

218 ROLL TO ROLL FUNCTION RELATED PARAMETERS

10 ROLL TO ROLL FUNCTION RELATED PARAMETERS

10.1 Monitoring of dedicated functions

10.1.1 Monitoring of roll to roll dedicated functions The monitor item and the frequency setting displayed on the operation panel can be switched among the winding diameter, line speed command, etc.

Monitoring on the operation panel or via communication

Purpose Parameter to set Refer to page

To monitor roll to roll dedicated functions

Monitoring of roll to roll dedicated functions (operation panel)

P.M100 to P.M104 Pr.52, Pr.774 to Pr.776, Pr.992 218

Monitoring of roll to roll dedicated functions (analog output)

P.M300, P.M301 Pr.54, Pr.158 220

To use negative output for monitoring

Negative output selection for monitoring P.M044 Pr.290 223

To select the polarity (positive or negative) of the signal output through terminal DA1.

Terminal DA1 output polarity selection P.R450 Pr.159 223

To set reference conditions (display unit, full-scale value, etc.) for monitoring

Monitor reference

P.R005, P.R201, P.R301, P.R400 to P.R402, P.M040, P.M042

Pr.55, Pr.276, Pr.358, Pr.866, Pr.1262, Pr.1280, Pr.1281, Pr.1401

224

To change the unit of the PID measured tension value

PID measured tension monitor increment P.R430, P.R431 Pr.609, Pr.610 226

Monitor item Unit

Pr.52, Pr.774

to Pr.776, Pr.992

RS-485 communication

dedicated monitor

(hexadecimal)

MODBUS RTU real time

monitor

Negative indication

(-)

Description Refer

to page

Frequency / motor speed setting 0.01 Hz 5 H05 40205 Displays the set frequency

Load meter 0.1% 17 H11 40217

Displays torque current as a percentage, considering Pr.56 setting value as 100% (motor rated torque is considered as 100% during Sensorless vector and vector control).

Analog output signal for dancer tension control

0.1% 19 H13 40219 Dancer tension command value 108

Winding diameter 0.1 mm 22 H16 40222 Winding diameter calculated in the inverter 213

Line speed command 0.1 26 H1A 40226

Line speed command value in consideration of acceleration/ deceleration

67

Actual line speed 0.1 27 H1B 40227 Actual line speed 199

Dancer compensation speed

0.01 Hz 28 H1C 40228

Speed compensation amount (manipulated amount) determined by the PID calculation when dancer feedback speed control is valid

99

Monitoring of dedicated functions

ROLL TO ROLL FUNCTION RELATED PARAMETERS 219

10

Winding length (lower 4 digits) 1 29 H1D 40229 Winding length (lower 4 digits)

calculated in the inverter 213

Analog output signal 2 for dancer tension control

0.1% 30 H1E 40230 Dancer tension command value 108

Line speed pulse monitor

0.01k pulses/s 31 H1F 40231

Pulse train input value (when the actual line speed is input with pulse signal)

199

PID set point 0.1% 52 H34 40252 Dancer roll set point 99 PID measured value 0.1% 53 H35 40253 Dancer roll position 99

PID deviation 0.1% 54 H36 40254 Dancer roll deviation from set point 99

Winding length (upper 4 digits) 1 63 H3F 40263 Winding length (upper 4 digits)

calculated in the inverter 213

PID measured value 2 0.1% 67 H43 40267

Dancer roll position. It is displayed even if the dancer feedback speed control operating conditions are not satisfied while the dancer feedback speed control is enabled (Pr.128 "0").

99

Tension command after taper compensation

0.01 N / 0.1 N / 1 N

81 H51 40281 Commanded tension after taper compensation 151

Winding diameter compensation torque command

0.1% 82 H52 40282 Commanded torque after winding diameter compensation

Inertia compensation 0.1% 83 H53 40283 Inertia compensation torque 157

Mechanical loss compensation 0.1% 84 H54 40284

Mechanical loss compensation value 163

Terminal 1 input voltage 0.1 V 85 H55 40285 Voltage applied to terminal 1 85

Terminal 1 input after calibration (%)

0.1% 86 H56 40286 Analog value input through terminal 1 after calibration with Pr.917 and Pr.918 settings

85

PID manipulated amount 0.1% 91 H5B 40291 PID manipulated amount 99

PID measured tension value

0.01 (N)/ 0.1 (N)/ 1 (N)

92 H5C 40292 PID measured tension value 226

PID torque control manipulated amount

0.01 (N)/ 0.1 (N)/ 1 (N)

93 H5D 40293

PID torque control manipulated amount Monitoring is only available between -300 N and 300 N (inclusive)

Dancer compensation line speed

0.1 95 H5F 40295

Line speed compensation amount (manipulated amount) determined by the PID calculation when dancer feedback speed control is valid.

Actual line speed 2 0.1 96 H60 40296

Actual line speed calculated inversely from the winding diameter using the gear ratio and the actual motor speed

Winding diameter compensation speed

0.01 Hz 97 H61 40297

Frequency (winding diameter compensation speed) calculated from the line speed command, current winding diameter value, and gear ratio when dancer feedback speed control is valid

Monitor item Unit

Pr.52, Pr.774

to Pr.776, Pr.992

RS-485 communication

dedicated monitor

(hexadecimal)

MODBUS RTU real time

monitor

Negative indication

(-)

Description Refer

to page

Monitoring of dedicated functions

220 ROLL TO ROLL FUNCTION RELATED PARAMETERS

To enable display with a minus sign, set Pr.290 Monitor negative output selection. (Refer to page 223.) When the negative indication is invalid, the value is indicated as an offset from 1000%. When the negative indication is invalid, a negative value is indicated as an absolute value offset from 100 V. (-10.0 to -0.1 V are indicated as

110.0 to 100.1 V.) The range varies with the Pr.1401 setting.

Monitoring using analog output (terminals FM/CA and AM)

To enable display with a minus sign, set Pr.290 Monitor negative output selection. (Refer to page 223.) When the negative indication is invalid according to the Pr.290 setting, "0" is indicated as the terminal AM output.

Pr.1401 setting Monitor value 0 (initial value) -300 N to 300 N 1 -3000 N to 3000 N 2 -30000 N to 30000 N

Monitor item Unit Pr.54 (FM/CA) setting

Pr.158 (AM) setting Full-scale value

Negative indication

(-)

Refer to page

Frequency setting value 0.01 Hz 5 5 Pr.55 Load meter 0.1% 17 17 Pr.866 Analog output signal for dancer tension control 0.1% 19 19 100% 108

Winding diameter 0.1 mm 22 22 Pr.1280 213 Line speed command 0.1 m/min 26 26 Pr.276 67 Actual line speed 0.1 m/min 27 27 Pr.276 199 Dancer compensation speed 0.01 Hz 28 28 Pr.55 99 Analog output signal 2 for dancer tension control 0.1% 30 30 100% 108

PID set point 0.1% 52 100% 99 PID measured value 0.1% 53 100% 99 PID deviation 0.1% 54 100% 99 PID measured value 2 0.1% 67 100% 99 Tension command after taper compensation

0.01 N / 0.1 N / 1 N 81 81 Pr.1281 151

Winding diameter compensation torque command

0.1% 82 Pr.866

Inertia compensation 0.1% 83 Pr.866 157 Mechanical loss compensation 0.1% 84 Pr.866 163

PID manipulated amount 0.1% 91 100% 99

PID measured tension value 0.01 (N)/ 0.1 (N)/1 (N) 92 92 Pr.1281 226

PID torque control manipulated amount

0.01 (N)/ 0.1 (N)/1 (N) 93 93 Pr.1281

Dancer compensation line speed 0.1m/min 95 95 Pr.276

Actual line speed 2 0.1m/min 96 96 Pr.276 Winding diameter compensation speed 0.01 Hz 97 97 Pr.55

Monitoring of dedicated functions

ROLL TO ROLL FUNCTION RELATED PARAMETERS 221

10

Monitoring using the PLC function / FR Configurator2

: Monitoring is available. SD1245 (terminal 1 input) can be a substitute. Negative values can be output. To enable display with a minus sign, set Pr.290 Monitor negative output selection. (Refer to page 223.) The terminal CA/FM/AM full-scale value is used as the trigger level reference.

Monitor item PLC function Device number

FR Configurator2 graph function Monitor mode High speed mode / trace Trigger level reference

Frequency setting value SD1152

Load meter SD1164

Analog output signal for dancer tension control SD1166

Winding diameter SD1169

Line speed command SD1173

Actual line speed SD1174

Dancer compensation speed SD1175

Winding length (lower 4 digits) SD1176 9999

Analog output signal 2 for dancer tension control SD1177

Line speed pulse monitor SD1178 500k pulses/s PID set point SD1199

PID measured value SD1200

PID deviation SD1201

PID measured tension value SD1202

PID torque control manipulated amount SD1203

Winding length (upper 4 digits) SD1231 9999

PID measured value 2 SD1213

Tension command after taper compensation SD1228

Winding diameter compensation torque command

SD1208

Inertia compensation SD1209

Mechanical loss compensation SD1210

Terminal 1 input voltage 10 V Terminal 1 input after calibration (%) 100%

PID manipulated amount SD1212

Dancer compensation line speed SD1223

Actual line speed 2 SD1222

Winding diameter compensation speed SD1211

Monitoring of dedicated functions

222 ROLL TO ROLL FUNCTION RELATED PARAMETERS

Schematic diagram of monitoring The following diagram shows a monitoring example in a system for dancer/tension feedback speed control.

The following diagram shows a monitoring example in a system for tension sensorless torque control / tension sensor feedback torque control.

PID action set point

Dancer signal/ Tension feedback

signal

+

- PID operation

Line speed command

Winding diameter

calculation

Frequency conversion

Winding diameter compensation

speed generation

Line speed acceleration/ deceleration

X114-OFF

X114-ON+ +

Acceleration/ deceleration

Speed control

Speed control proportional gain

compensation

(Frequency setting)

(Actual line speed) (Motor speed)

Monitor 52

Monitor 54 Monitor 53 Monitor 67 Monitor 92

Monitor 28 Monitor 95

Monitor 26

Monitor 27

Monitor 96

Monitor 97

Monitor 5

Monitor 91

Output frequency

Monitor 22

Monitor value

calculation

Monitor 81

Monitor 27

Monitor 22 Monitor 96

Monitor 17

Monitor 83

Monitor 84

Mechanical loss

compensation

Inertia compensation

+ ++

+ Tension control +

(torque calculation) Taper function

Winding diameter

calculation

Torque control

X114-OFF

(Actual line speed)

(Torque command)

(Motor speed) X114-ON

Tension command

+ + Torque

command X114-ON

Monitor 53, 67, 92 Monitor 54

Monitor 52

Monitor 91, 93

+-Primary delay filter

Tension PID calculation

Tension feedback

X116 PID action selection

Monitoring under tension sensor feedback torque control

Monitor value

calculation

Monitoring of dedicated functions

ROLL TO ROLL FUNCTION RELATED PARAMETERS 223

10

Negative output selection for monitoring (Pr.290) A negative output can be selected for the monitor display of terminal AM (analog voltage output), the operation panel, and

a communication option. For the monitor items for which negative output is possible, refer to the monitor list.

RS-485 communication does not support negative indication.

Terminal DA1 output polarity selection (Pr.159) When the FR-A8AZ is installed, Pr.159 DA1 output sign selection can be used to select the polarity of the output through

terminal DA1.

Pr.290 setting Negative output through terminal AM

Negative indication on operation panel

Negative indication on communication options

0 (initial value) 1 Enabled 2 Enabled 3 Enabled Enabled 4 Enabled 5 Enabled Enabled 6 Enabled Enabled 7 Enabled Enabled Enabled : Disabled (positive only)

Pr.159 setting Output specification Actual output sign

For positive monitor value For negative monitor value 0 (initial value) Standard output Positive output Negative output 1 Absolute value output Positive output Positive output (absolute value) 2 Reverse output Negative output Positive output

Monitoring of dedicated functions

224 ROLL TO ROLL FUNCTION RELATED PARAMETERS

10.1.2 Monitor reference Set the reference value for each item.

The increment varies depending on the Pr.358 setting. (Refer to page 67.) The setting varies with the Pr.1401 setting. (Refer to page 140.)

Pr. Name Initial value

Setting range Description FM CA

55 M040

Frequency monitoring reference 60 Hz 50 Hz 0 to 590 Hz Set the full-scale value when the output frequency

monitor value is output through terminal FM, CA, or AM.

276 R400

Line speed monitoring reference 1000 m/min 0 to 6553.4 m/min Set the full-scale value when the line speed monitor

value is output through terminal FM, CA, or AM.

358 R201 Line speed unit 0

0 m/min 1 m/s 2 mm/min 3 mm/s

866 M042

Torque monitoring reference 150% 0 to 400% Set the full-scale value when the torque monitor value

is output through terminal FM, CA, or AM.

1262 R005

Winding length increment 3

0 1 km 1 100 m 2 10 m 3 1 m 4 1 cm 5 1 mm

1280 R401

Winding diameter monitoring reference 1000 mm 1 to 6553 mm Set the full-scale value when the diameter monitor

value is output through terminal FM, CA, or AM.

1281 R402

Commanded tension monitoring reference 100 N 0 to 500 N

Set the full-scale value of tension monitoring (tension command, PID torque control measured value, and PID torque control manipulated amount) via terminal FM, CA, or AM.

1401 R301

Tension command increment 0

0 Initial value: 100 N, setting increment: 0.01 N, setting range: 0 to 500 N

1 Initial value: 1000 N, setting increment: 0.1 N, setting range: 0 to 5000 N

2 Initial value: 10000 N, setting increment: 1 N, setting range: 0 to 50000 N

Monitoring of dedicated functions

ROLL TO ROLL FUNCTION RELATED PARAMETERS 225

10

Setting monitoring reference (Pr.55, Pr.276, Pr.866, Pr.1280, Pr.1281) Set the full-scale value for outputting the monitor items of output frequency, frequency setting value, and line speed to terminals FM, CA and AM.

The value in parentheses is the number of pulses for the high-speed pulse train output (Pr.291 Pulse train I/O selection = "10, 11, 20, 21, or 100").

Output frequency (Pr.55) Line speed (Pr.276)

Torque (Pr.866) Winding diameter (Pr.1280) Tension command (Pr.1281)

Output frequency (Pr.55) Line speed (Pr.276)

Torque (Pr.866) Winding diameter (Pr.1280) Tension command (Pr.1281)

Output frequency (Pr.55) Line speed (Pr.276)

Torque (Pr.866) Winding diameter (Pr.1280) Tension command (Pr.1281)

Full-scale value Full-scale value

Full-scale value

590 Hz 6553.4 m/min

400% 6553 mm

500N

0 Hz 0 m/min

0% 1 mm

0N

Monitor reference setting range for terminal FM

590 Hz 6553.4 m/min

400% 6553 mm

500N

0 Hz 0 m/min

0% 1 mm

0N

590 Hz 6553.4 m/min

400% 6553 mm

500N

0 Hz 0 m/min 0% 1 mm 0N

Pulse speed (pulses/s)

2400 (55k)1

1440 (50k)1

Monitor setting range for terminal CA

20 mADC

Output current

Monitor setting range for terminal AM

10 VDC

-10 VDC

Output voltage

Monitoring of dedicated functions

226 ROLL TO ROLL FUNCTION RELATED PARAMETERS

10.1.3 PID measured tension value

The PID measured tension value is the value after using Pr.609 PID measured tension monitor filter , which is displayed with increments set according to Pr.1401 and Pr.610. When Pr.609 = "0", the filter time is not set.

The Pr.610 setting to change the increment is applicable only for monitoring the PID measured tension value. The Pr.1401 setting is applicable for monitoring values other than the PID measured tension value. When Pr.610 = "9999", the Pr.1401 setting is applicable to display the monitor item.

The conditions of the operation example are as follows: Input equivalent to 67.89% when Pr.1136 = 0%, Pr.1137 = "0", Pr.1138 = 50%, and Pr.1139 = maximum value

When the Pr.1401 setting is larger than the Pr.610 setting, the value set in Pr.610 is invalid.

Pr. Name Initial value Setting range Description 609 R430

PID measured tension monitor filter 0 0 to 5s Set the primary delay filter time constant to the PID

measured tension value.

610 R431

PID measured tension monitor increment 9999

0 PID measured tension monitored in 0.01 N increments (0 to 500 N)

1 PID measured tension monitored in 0.1 N increments (0 to 5000 N)

2 PID measured tension monitored in 1 N increments (0 to 50000 N)

9999 As set in Pr.1401.

Pr.1401 Pr.610 Increment Maximum value

Value monitored in the operation example

0

9999 0.01 N 500.00 N 500.00 N 0 0.01 N 500.00 N 500.00 N 1 0.1 N 5000.0 N 678.9 N 2 1 N 50000 N 679 N

1

9999 0.1 N 5000.0 N 5000.0 N 0 0.01 N 5000.0 N 5000.0 N

1 0.1 N 5000.0 N 5000.0 N 2 1 N 50000 N 6789 N

2

9999 1 N 50000 N 50000 N 0 0.01 N 50000 N 50000 N

1 0.1 N 50000 N 50000 N

2 1 N 50000 N 50000 N

Roll to roll dedicated I/O signal

ROLL TO ROLL FUNCTION RELATED PARAMETERS 227

10

10.2 Roll to roll dedicated I/O signal

10.2.1 Input signal To use contact input signals, assign them to Pr.178 to Pr.189 (input terminal function selection).

Input signal list Type Pr.178 to Pr.189

setting Signal name Description Refer to page

A na

lo g/

pu ls

e Dancer roll target position / tension feedback set point Set the target value with a parameter (Pr.131). 85, 124

Dancer roll position detection / tension feedback detection Dancer roll position / tension sensor feedback input signal 85, 124,

178 Line speed command Line speed command input signal 67 Actual line speed detection Actual line speed input signal 199

C on

ta ct

in pu

t

0 Low-speed operation command RL

Line speed command signals (15 speed settings available). The commanded speed is determined according to the combination of the RH, RM, RL and REX signals.

79 1 Middle-speed

operation command RM

2 High-speed operation command RH

8 15-speed selection REX

81 Tension PI gain tuning start / forced end

PGT Tension PI gain tuning can be started or forcibly terminated. 91

100 PID integral term reset input X100

Turn ON the X100 signal to disable the integral control and clear the integral term. The integral term can be reset by inputting the MRS signal even when no terminal is assigned.

100

101 PI control switchover X101 Switches between PID control and PI control. Turn ON the X101 signal to disable the differential control and clear the differential term.

101

102 Offset displacement storage X102 Set the present analog value to Pr.424 as an offset. 88, 126

103 Integral term activation selection X103 Turn ON the X103 signal to keep the integral term and calculate

the manipulated amount using the integral term in storage. 100

104 Reel change X104 Enables the reel change function. 106

105

Acceleration/ deceleration time selection 1 for line speed command

X105

Switches the acceleration/deceleration time for the line speed command. 79

106

Acceleration/ deceleration time selection 2 for line speed command

X106

107 Minimum/maximum winding diameter selection

X107 Select the minimum/maximum diameter and the material thickness. 203, 206

108 X108

109 Stored winding diameter clear X109 Clears the stored diameter. 213

111 Inertia compensation acceleration X111 Performs inertia compensation during acceleration. 157

112 Inertia compensation deceleration X112 Performs inertia compensation during deceleration. 157

113 Inertia compensation second acceleration/ deceleration time

X113 Switches the acceleration/deceleration time for inertia compensation. 157

Roll to roll dedicated I/O signal

228 ROLL TO ROLL FUNCTION RELATED PARAMETERS

C on

ta ct

in pu

t

114 Tension control selection X114

Turn ON the X114 signal to enable the dancer feedback speed control, tension feedback speed control, tension sensorless torque control, tension sensor feedback torque control, and winding diameter compensation functions. If the signal is OFF, normal speed control is applied. Always set the signal for using the dancer feedback speed control, tension feedback speed control, tension sensorless torque control, tension sensor feedback torque control, and winding diameter compensation functions. (When the X114 signal is not assigned to any input terminal, general speed control or torque control is enabled.) Ensure the motor has stopped before switching between normal operation and an operation with a particular control type. After turning ON the X114 signal, wait 20 ms or longer to input a start command (STF/STR).

When the JOG (JOG operation selection) signal is input while the X114 signal is ON, the JOG operation will be enabled as the JOG signal has higher priority. When JOG operation is prioritized, the frequency and acceleration/deceleration times set in Pr.15 Jog frequency and Pr.16 Jog acceleration/ deceleration time are used.

64, 139, 177, 194

115 Winding diameter compensation selection

X115 Turn ON the X115 signal to keep the present winding diameter. (The winding diameter compensation is disabled.) 197

116 PID compensation disabled X116

Turning ON the X116 signal interrupts the PID control under dancer feedback speed control, tension sensor feedback speed control, or tension sensor feedback torque control. (The PID compensation amount, integral term, and differential term are cleared.)

65, 177

117 Winding length clear X117 Clears the measured winding/unwinding length. 213 120 PID gain switchover 1 X120

Switches the PID gain. 101 121 PID gain switchover 2 X121

122 Winding diameter measurement X122 Turning ON the X122 signal enables the initial winding

measurement mode. 212

123 Stall mode trigger X123 Turning ON the X123 signal triggers the stall mode. 165

124 Speed control proportional gain disabled

X124 Disables the settings of Pr.641 to Pr.644 (Speed control proportional gain). 216

125 Line speed / tension command input X125

Enables write and read of the line speed command value through communication during dancer / tension sensor feedback speed control, regardless of whether the dancer / tension sensor feedback speed control is valid or invalid. Enables write and read of the tension command value through communication during tension sensorless torque control, regardless of whether the tension sensorless torque control is valid or invalid.

67, 140

126 Two-way operation X126 Switches between winding and unwinding during operation. The dancer roll position can be held during switching. 232

Type Pr.178 to Pr.189 setting Signal name Description Refer to

page

STF

X114

20 ms or more

ON

ON

Roll to roll dedicated I/O signal

ROLL TO ROLL FUNCTION RELATED PARAMETERS 229

10

List of input signals with validity status by control mode (function)

: Valid, : Invalid

Pr.178 to Pr.189 setting

Signal name

Dancer feedback

speed control

Tension sensor

feedback speed control

Tension sensorless

torque control

Tension sensor

feedback torque control

Winding diameter

calculation

0 Low-speed operation command RL 1 Middle-speed operation command RM 2 High-speed operation command RH 8 15-speed selection REX

81 Tension PI gain tuning start / forced end PGT

100 PID integral term reset input X100 101 PI control switchover X101 102 Offset displacement storage X102 103 Integral term activation selection X103 104 Reel change X104

105 Acceleration/deceleration time selection 1 for line speed command X105

106 Acceleration/deceleration time selection 2 for line speed command X106

107 Minimum/maximum winding diameter selection

X107

108 X108

109 Stored winding diameter clear X109

111 Inertia compensation acceleration X111 112 Inertia compensation deceleration X112

113 Inertia compensation second acceleration/deceleration time X113

114 Tension control selection X114

115 Winding diameter compensation selection X115

116 PID compensation disabled X116 117 Winding length clear X117

120 PID gain switchover 1 X120 121 PID gain switchover 2 X121 122 Winding diameter measurement X122

123 Stall mode trigger X123

124 Speed control proportional gain disabled X124

125 Line speed / tension command input X125 126 Two-way operation X126

Roll to roll dedicated I/O signal

230 ROLL TO ROLL FUNCTION RELATED PARAMETERS

10.2.2 Output signal To use output signals, assign them to Pr.190 to Pr.196 (output terminal function selection).

Output signal list Pr.190 to Pr.196

setting Signal name Description Refer

to pagePositive

logic Negative

logic

14 114 PID lower limit FDN Output when the dancer roll position or the roll tension value falls below the limit determined by the setting of Pr.132 PID lower limit. 89

15 115 PID upper limit FUP Output when the dancer roll position or the roll tension value exceeds the limit determined by the setting of Pr.131 PID upper limit. 89

16 116 PID forward/reverse rotation output RL

Output during forward rotation under dancer feedback speed control, tension sensor feedback speed control, or tension sensor feedback torque control.

47 147 During PID control activated PID Output under dancer feedback speed control, tension sensor feedback

speed control, or tension sensor feedback torque control.

48 148 PID deviation limit Y48 Output when the absolute deviation value exceeds the limit value. 89, 127, 180

231 331 Break detection Y231 Output when the dancer roll position or the roll tension becomes abnormal due to a break. 89

232 332 Winding diameter calculation completion at start

Y232 Output when the diameter calculation is completed at an operation start. 208, 212

233 333 Target winding diameter achieved Y233

Output when the diameter reaches the setting in Pr.648 Target winding diameter or longer for winding. Output when the diameter reaches the setting in Pr.648 Target winding diameter or shorter for unwinding.

208

234 334 Winding/unwinding completion Y234

Output when the winding/unwinding length is equal to or more than the value of determined by the settings of Pr.1264 Winding length detection (lower 4 digits) and Pr.1346 Winding length detection (upper 4 digits).

213

235 335 Dancer position / tension feedback detection

Y235 Output while the dancer roll position or the roll tension is within a range determined by the setting of Pr.423 Dancer / tension sensor feedback detection level. This signal is also output when the inverter is at a stop.

88, 126

236 336 Reel change ready Y236 Output when the commanded line speed reaches the target line speed while the reel change function is valid. 106

237 337 Line speed acceleration Y237

Output while the commanded line speed increases. The signal can be input to the terminal to which the Inertia compensation acceleration (X111) signal of the inverter for the driving shaft is assigned.

79, 157

238 338 Line speed deceleration Y238

Output while the commanded line speed decreases. The signal can be input to the terminal to which the Inertia compensation deceleration (X112) signal of the inverter for the driving shaft is assigned.

79, 157

239 339 Average current load detection Y239

Output when the output current average value reaches or exceeds 50% of the inverter rated current. (This function is only available for the SND rating.)

8

Roll to roll dedicated I/O signal

ROLL TO ROLL FUNCTION RELATED PARAMETERS 231

10

List of output signals with validity status by control mode (function) Pr.190 to Pr.196

setting Signal name

Dancer feedback

speed control

Tension sensor

feedback speed control

Tension sensorless

torque control

Tension sensor

feedback torque control

Winding diameter

calculationPositive logic

Negative logic

14 114 PID lower limit FDN 15 115 PID upper limit FUP

16 116 PID forward/reverse rotation output RL

47 147 During PID control activated PID

48 148 PID deviation limit Y48 231 331 Break detection Y231

232 332 Winding diameter calculation completion at start

Y232

233 333 Target winding diameter achieved Y233

234 334 Winding/unwinding completion Y234

235 335 Dancer position / tension feedback detection Y235

236 336 Reel change ready Y236 237 337 Line speed acceleration Y237 238 338 Line speed deceleration Y238

239 339 Average current load detection Y239

Two-way operation function

232 ROLL TO ROLL FUNCTION RELATED PARAMETERS

10.3 Two-way operation function

Description In order to switch the operation between winding and unwinding during dancer feedback speed control or tension sensor

feedback speed control, it is necessary to change the PID action (forward/reverse), winding/unwinding selection, and start command (STF/STR). When the operation is switched between winding and unwinding and the dancer roll position / tension during operation is held, the dancer roll position / tension fluctuates because the PID manipulated amount suddenly changes along with the changes in the PID action and the start command. Therefore, switch the operation between winding and unwinding while the line is stopped (line speed command: "0").

By using the two-way operation function, the sudden change in the PID manipulated amount can be prevented, and the operation can be switched between winding and unwinding while maintaining the dancer roll position / tension during operation. Also, no change is required for parameter setting or signal input after switching the operation.

The function is also enabled during tension sensorless torque control or tension sensor feedback torque control. Only the winding and unwinding settings are changeable during tension sensorless torque control or tension sensor feedback torque control.

Switching between winding and unwinding The action in winding/unwinding operation can be switched by turning the Two-way operation (X126) signal ON/OFF. To input the X126 signal, set "126" in any of Pr.178 to Pr.189 (input terminal function selection) to assign the function. By switching the operation between winding and unwinding, the following action is automatically changed accordingly.

The STF/STR indication on the operation panel does not change.

NOTE During dancer feedback speed control or tension sensor feedback speed control, switching operation using the X126 signal is

available while the commanded line speed is 0 after line speed acceleration/deceleration. (If an analog or other input signal cannot set the line speed to 0, use Pr.622 Line speed command for starting to set the line speed to 0. (Refer to page 75.))

Control Function Setting method

Operation status Before

switching (X126-OFF)

After switching (X126-ON)

Dancer feedback speed control Tension sensor feedback speed control

PID action Pr.128 Reverse action Forward action Forward action Reverse action

Winding/unwinding selection Pr.1230

Winding Unwinding Unwinding Winding

Start command Start signal (STF/STR signal) or operation panel key operation

Forward rotation Reverse rotation

Reverse rotation Forward rotation

Tension sensorless torque control Tension sensor feedback torque control

Winding/unwinding selection Pr.1230

Winding Unwinding Unwinding Winding

Operation command source and speed command source (Pr.338, Pr.339)

ROLL TO ROLL FUNCTION RELATED PARAMETERS 233

10

10.4 Operation command source and speed command source (Pr.338, Pr.339)

In the Network operation mode, the commands for the roll to roll function are sent through the external terminals or communication as follows. (The signal assigned to the inverter differs depending on the input terminal function selection setting.)

EXT: Commands sent through external terminals are only valid. NET: Commands sent via network are only valid. Combined: Any command given via the external terminals or given through communication is valid. : Any commands sent through external terminals or via network are invalid.

NOTE For other signals, refer to the Instruction Manual (Detailed) of the FR-A800 inverter.

Pr. Name Setting range Increment Initial value Remarks

338 Communication operation command source 0, 1 1 0 0: NET command source

1: External command source

339 Communication speed command source 0 to 2 1 0

0: NET command source 1: External command source 1 2: External command source 2

Command sources selection

Pr.338 Communication operation command source 0: NET 1: external

Pr.339 Communication speed command source 0: NET 1: EXT 2: EXT 0: NET 1: EXT 2: EXT

Fixed function (terminal- equivalent function)

Line speed command sent via communication NET NET NET NET Line speed command sent through an analog terminal (Pr.361 = "0") EXT EXT

Line speed command sent through an analog terminal (Pr.361 = "3 to 6") EXT EXT

Se le

ct ab

le fu

nc tio

n

Pr .1

78 to

P r.1

89 s

et tin

g

0 RL Low-speed operation command NET EXT NET EXT 1 RM Middle-speed operation command NET EXT NET EXT 2 RH High-speed operation command NET EXT NET EXT 5 JOG Jog operation selection NET EXT 8 REX 15-speed selection NET EXT NET EXT 81 PGT Tension PI gain tuning start / forced end NET EXT 100 X100 PID integral term reset input NET EXT 101 X101 PI control switchover NET EXT 102 X102 Offset displacement storage NET EXT 103 X103 Integral term activation selection NET EXT 104 X104 Reel change NET EXT

105 X105 Acceleration/deceleration time selection 1 for line speed command NET EXT

106 X106 Acceleration/deceleration time selection 2 for line speed command NET EXT

107 X107 Minimum/maximum winding diameter selection 1 NET EXT

108 X108 Minimum/maximum winding diameter selection 2 NET EXT

109 X109 Stored winding diameter clear NET EXT 111 X111 Inertia compensation acceleration Combined EXT 112 X112 Inertia compensation deceleration Combined EXT

113 X113 Inertia compensation second acceleration/deceleration time NET EXT

114 X114 Tension control selection Combined EXT 115 X115 Winding diameter compensation selection NET EXT 116 X116 PID compensation disabled NET EXT 117 X117 Winding length clear NET EXT 120 X120 PID gain switchover 1 NET EXT 121 X121 PID gain switchover 2 NET EXT 122 X122 Winding diameter measurement NET EXT 123 X123 Stall mode trigger NET EXT 124 X124 Speed control proportional gain disabled NET EXT 125 X125 Line speed / tension command input NET EXT 126 X126 Two-way operation NET EXT

Encoder input option selection

234 ROLL TO ROLL FUNCTION RELATED PARAMETERS

10.5 Encoder input option selection Select the option (plug-in option / control terminal option) used for the motor (encoder) signal input and the option used for the line speed command / actual line speed input.

Select the option used for the motor (encoder) signal input and the option used for the line speed command / actual line speed input. (Plug-in option / control terminal option)

The options are selected according to the setting in Pr.862 Encoder option selection.

When two or more options among the FR-A8AP, FR-A8APR, FR-A8AL, and FR-A8APS are installed, the option with highest priority is enabled. FR-A8AL > FR-A8APS > FR-A8APR > FR-A8AP

When the option is not installed, the pulse input value "0" is applied to the operation. Line speed command / actual line speed input using the FR-A8APR/FR-A8APS is invalid. The control method is selected under the condition that no Vector control compatible option is used. (For example, Advanced magnetic flux

vector control is selected when Pr.800 = "0".)

NOTE When the same option is used for the signal input from the motor (encoder) and the line speed command input (Pr.361) or

actual line speed input (Pr.362), the signal input from the motor (encoder) is enabled.

Pr. Name Initial value Setting range Description

862 C242 Encoder option selection 0

0 Signals from the motor (encoder) is input through the plug-in option (FR-A8AP/FR-A8AL/FR-A8APR/FR- A8APS).

1 Signals from the motor (encoder) is input through the control terminal option (FR-A8TP).

Plug-in option Control terminal option

Pr.862 = "0" Pr.862 = "1"

Motor (encoder) signal

Line speed command /

actual line speed

Motor (encoder) signal

Line speed command /

actual line speed

Installed Installed Plug-in option Control terminal

option Control terminal option Plug-in option

Not installed Plug-in option Regarded as "0" Plug-in option

Not installed Installed

Control terminal option

Control terminal option Regarded as "0"

Not installed Regarded as "0" Regarded as "0"

Differences in the functions from the standard inverter

APPENDIX 235

11

11 APPENDIX

11.1 Differences in the functions from the standard inverter

The following functions of the FR-A800 standard inverter are deleted in the FR-A800-R2R inverter. Parameters, I/O signals, and monitors relative to the deleted functions are also deleted or used differently in the FR-A800-R2R inverter.

Function Parameter Input signal

Output signal Monitor

PM motor control

Pr.373, Pr.702, Pr.706, Pr.711, Pr.712, Pr.717, Pr.721, Pr.725, Pr.738 to Pr.743, Pr.746, Pr.747, Pr.788, Pr.791, Pr.792, Pr.998, Pr.1002, Pr.1105, Pr.1412, Pr.1413 Pr.71 setting range change ("330, 333, 334, 8090, 8093, 8094, 9090, 9093, and 9094" are deleted.) Pr.450 setting range change ("330, 333, 334, 8090, 8093, 8094, 9090, 9093, and 9094" are deleted.)

IPM (57)

PID control

Second PID Pr.753 to Pr.758, Pr.765 to Pr.769, Pr.1136 to Pr.1149

X73 (73) X78 (78) X79 (79) X80 (80)

Y50 (50) Y52 (52) Y54 (54) FDN2 (200) FUP2 (201) RL2 (202) PID2 (203) SLEEP2 (204) Y205 (205)

Second PID set point (92) Second PID measured value (93) Second PID deviation (94) Second PID measured value 2 (95) Second PID manipulated amount (96)

Set point / deviation / measured value input selection

Pr.609, Pr.610 Pr.128 setting range change ("10, 11, 20, 21, 42, 43, 50, 51, 60, 61, 70, 71, 80, 81, 90, 91, 100, 101, 1000, 1001, 1010, 1011, 2000, 2001, 2010, 2011" are deleted.)

X14 (14)

PID pre-charge function Pr.760 to Pr.764 X77 (77)

Y49 (49) Y51 (51) Y53 (53)

PID display unit Pr.759, C42 (Pr.934), C43 (Pr.934), C44 (Pr.935), C45 (Pr.935)

SLEEP function

Pr.575 to Pr.577 Pr.554 setting range change ("10 to 13" are deleted.) Pr.1015 setting range change ("2, 10 to 12" are deleted.)

SLEEP (70)

Dancer control Dancer main set speed (97)

Position control

Pr.419 to Pr.421, Pr.423 to Pr.427, Pr.429, Pr.446, Pr.464 to Pr.494, Pr.1220 to Pr.1290, Pr.1292 to Pr.1298 Pr.451 setting range change ("3 to 5, 13, 14, 103 to 105, 113, and 114" are deleted.) Pr.800 setting range change ("3 to 5, 13, 14, 103 to 105, 113, and 114" are deleted.)

CLRN (59) NP (68) CLR (69) X76 (76) X84 (84) X87 (87)

Y36 (36) MEND (38) ZA (56) FP (60) PBSY (61) ZP (63) RDY (84)

Position pulse (19) Position command (lower) (26) Position command (upper) (27) Current position (lower) (28) Current position (upper) (29) Droop pulse (lower) (30) Droop pulse (upper) (31) Multi-revolution counter (75)

Orientation function Pr.350 to Pr.358, Pr.360 to Pr.366, Pr.393 to Pr.399, Pr.829 X22 (22) ORA (27)

ORM (28) Orientation status (22)

Pulse monitor selection Pr.430

Adjustable 5 points V/F Pr.100 to Pr.109 Pr.71 setting range change ("2" is deleted.)

Remote function Pr.59 Automatic acceleration/ deceleration Pr.61 to Pr.64, Pr.292, Pr.293

Differences in the functions from the standard inverter

236 APPENDIX

The Pr.178 to Pr.189 (input terminal function selection) setting is shown in the parentheses. The Pr.190 to Pr.196 (output terminal function selection) setting is shown in the parentheses. The monitor selection parameter setting is shown in the parentheses.

The parameters related to cumulative pulse in the FR-A800-R2R are as follows, different from those in the FR-A800 standard inverters. The function of the parameters are the same as those of the FR-A800 standard inverters. (For details, refer to the Instruction Manual (Detailed) of the FR-A800 inverter.)

Brake sequence control Pr.278 to Pr.284, Pr.639 to Pr.648, Pr.650, Pr.651

BRI (15) BRI2 (45)

BOF (20) BOF2 (22)

Electronic bypass sequence Pr.135 to Pr.139, Pr.159 X95 (95) X96 (96)

MC1 (17) MC2 (18) MC3 (19)

Stop frequency function Pr.522 Stop-on-contact control Pr.270, Pr.275, Pr.276 Load torque high-speed frequency control Pr.271 to Pr.274 X19 (19)

Anti-sway control function Pr.1072 to Pr.1079 Traverse function Pr.592 to Pr.597 X37 (37) Strengthened excitation deceleration Pr.660 to Pr.662

Self power management Pr.248, Pr.254 X94 (94)

SSCNET III communication (FR-A8NS) Pr.379, Pr.449, Pr.499

X85 (85) X88 (88) X89 (89)

SSCNET III communication status (39)

FL remote communication (FR-A8NF)

LONWORKS communication (FR-A8NL) Pr.387 to Pr.392

Torque control by variable- current limiter control

Pr.451 setting range change ("6 and 106" are deleted.) Pr.800 setting range change ("6 and 106" are deleted.)

Second motor control method selection

Pr.451 setting range change ("0 to 2 and 100 to 102" are deleted.)

4 mA input check Pr.573 setting range change ("4" is deleted.) Pr.777 is deleted.

Stop mode at communication error

Pr.502 setting range change ("3 and 4" are deleted.) Pr.779 is deleted.

Online auto tuning Pr.574 setting range change ("2" is deleted.)

DC injection brake (zero speed control and servo lock) Pr.1299

JOG signal Pr.338 (Commands can be sent through communication.)

JOGF (57) JOGR (58)

Start count monitor Pr.1410, Pr.1411 Changeover between inverter and high power factor converter Pr.328

Parameter information (when the FR-LU08 is installed)

Parameter name FR-A800 standard inverter FR-A800-R2R series inverter Cumulative pulse clear signal selection Pr.635 Pr.755 Cumulative pulse division scaling factor Pr.636 Pr.756 Control terminal option-Cumulative pulse division scaling factor Pr.637 Pr.757

Cumulative pulse storage Pr.638 Pr.758

Function Parameter Input signal

Output signal Monitor

Parameter write selection

APPENDIX 237

11

The speed command will be given by an analog signal input via terminal 1 when the speed limit mode is set to 2, 3, or 4 and Pr.807 Speed limit selection is set to "2". Speed limit mode 1 is disabled. (Refer to page 146 for details.)

NOTE Functions not mentioned above are the same as those of the FR-A800 standard inverter. (The functions added in and after

December 2017 are not supported.) For the details of general specifications, refer to the catalog or Instruction Manual of the FR-A800 inverter.

11.2 Parameter write selection Whether to enable the writing to various parameters or not can be selected. Use this function to prevent parameter values from being rewritten by misoperation.

Pr.77 can be set at any time regardless of the operation mode or operation status. (Setting through communication is unavailable.)

Parameter write enabled only during stop (Pr.77 = "0 (initial value)") Parameters can be written only during a stop in the PU operation mode. The following parameters can always be written regardless of the operation mode or operation status.

Pr.1113 setting

Speed limit method

Speed limit value FR-A800 standard inverter FR-A800-R2R series inverter

9999 Speed limit mode 1 Enabled Disabled 0 (initial value) Speed limit mode 2 Speed limit

Pr.807 = 0 or 2: Speed command under speed control Pr.807 = 1: Pr.808 setting Reverse-side speed limit Pr.809 setting (Pr.808 setting when Pr.809 = "9999")

Speed limit Pr.807 = 0: Speed command under speed control Pr.807 = 1: Pr.808 setting Pr.807 = 2: Analog input via terminal 1 Reverse-side speed limit Pr.809 setting (Pr.808 setting when Pr.809 = "9999")

1 Speed limit mode 3

2 Speed limit mode 4

Pr. Name Initial value Setting range Description

77 E400 Parameter write selection 0

0 Parameter write is enabled only during stop. 1 Parameter writing is disabled.

2 Parameter writing is enabled in any operation mode regardless of the operation status.

Pr. Name

4 to 6 (Multi-speed setting high-speed, middle-speed, low-speed)

22 Stall prevention operation level 24 to 27 (Multi-speed setting speed 4 to speed 7) 52 Operation panel main monitor selection 54 FM/CA terminal function selection 55 Frequency monitoring reference 56 Current monitoring reference 72 PWM frequency selection

75 Reset selection/disconnected PU detection/PU stop selection

77 Parameter write selection 79 Operation mode selection

100 to 103 (Acceleration/deceleration time for line speed command)

129 PID proportional band 130 PID integral time 133 PID action set point 134 PID differential time 135, 136 (Integral clamp) 158 AM terminal function selection 160 User group read selection 232 to 239 (Multi-speed setting speed 8 to speed 15) 240 Soft-PWM operation selection 241 Analog input display unit switchover

268 Monitor decimal digits selection 270 Acceleration/deceleration time during stall condition 271 Second acceleration time for inertia compensation 272 Second deceleration time for inertia compensation 276 Line speed monitoring reference 290 Monitor negative output selection 295 Frequency change increment amount setting 296, 297 (Password setting) 306 Analog output signal selection 310 Analog meter voltage output selection 340 Communication startup mode selection 345, 346 (DeviceNet communication) 360 Line speed command value 365 Tension command value (RAM) 366 Tension command value (RAM, EEPROM)

394, 395 (Acceleration/deceleration time for line speed command)

416, 417 (PLC) 423 Dancer / tension sensor feedback detection level 424 Dancer / tension sensor feedback input offset 425 Break detection waiting time 426, 427, 430 (Dancer tension setting)

434, 435 (CC-Link communication) 464 to 494 (PID control)

Pr. Name

Parameter write selection

238 APPENDIX

Writing during operation is enabled in PU operation mode, but disabled in External operation mode. Writing during operation is disabled. To change the parameter setting value, stop the operation.

Parameter write disabled (Pr.77 = "1") Parameter write, Parameter clear, and All parameter clear are disabled. (Parameter read is enabled.) The following parameters can be written even if Pr.77 = "1".

Writing during operation is disabled. To change the parameter setting value, stop the operation.

Pr. Name 496, 497 (Remote output) 498 PLC function flash memory clear 550 NET mode operation command source selection 551 PU mode operation command source selection 555 to 557 (Current average value monitoring) 620 Line speed bias for reel change 621 Allowable deviation from target line speed 639 to 644 (Speed control proportional term) 645 to 648 (Winding diameter) 650 Terminal 4 input compensation selection 656 to 659 (Analog remote output) 663 Control circuit temperature signal output level 675 User parameter auto storage function selection 750, 751 (Motor thermistor interface) 759 PID unit selection 774 to 776 (PU/DU monitor selection) 805 Torque command value (RAM) 806 Torque command value (RAM,EEPROM) 838 DA1 terminal function selection 866 Torque monitoring reference 888, 889 (Free parameter) 891 to 899 (Energy saving monitoring) C0 (900) FM/CA terminal calibration C1 (901) AM terminal calibration C8 (930) Current output bias signal C9 (930) Current output bias current C10 (931) Current output gain signal C11 (931) Current output gain current 990 PU buzzer control 991 PU contrast adjustment 992 Operation panel setting dial push monitor selection 997 Fault initiation 999 Automatic parameter setting 1000 Direct setting selection 1006 Clock (year) 1007 Clock (month, day) 1008 Clock (hour, minute) 1018 Monitor with sign selection

1019 Analog meter voltage negative output selection 1020 Trace operation selection 1048 Display-off waiting time 1073 to 1078 (Ethernet communication)

1124, 1125 (Inverter-to-inverter link function) 1150 to 1199 (PLC function user parameters)

1211, 1215, 1217, 1219, 1222, 1223, 1226

(PID gain tuning)

1246 Line speed at winding diameter calculated value activation

1249 Number of averaging for winding diameter calculation

1252 to 1259 (Initial winding diameter calculation)

1262 to 1264 (Winding length)

1265 to 1279 (Line multi-speed setting)

1280 Winding diameter monitoring reference 1281 Commanded tension monitoring reference 1282 Tension command cushion time 1286 to 1297 (Taper function)

1298, 1299 (Stored winding length) 1346 Winding length detection (upper 4 digits) 1406, 1407, 1409 (Stall function)

1410 to 1415, 1418 (Inertia compensation function)

1419 to 1429 (Mechanical loss function)

1431, 1432, 1434 to 1455

(Ethernet communication)

1480 to 1485 (Load characteristics fault)

Pr. Name

Pr. Name 22 Stall prevention operation level

75 Reset selection/disconnected PU detection/PU stop selection

77 Parameter write selection 79 Operation mode selection 160 User group read selection 296 Password lock level 297 Password lock/unlock 345, 346 (DeviceNet communication) 360 Line speed command value

365 Tension command value (RAM) 366 Tension command value (RAM, EEPROM) 496, 497 (Remote output) 620 Line speed bias for reel change 621 Allowable deviation from target line speed 656 to 659 (Analog remote output) 805 Torque command value (RAM) 806 Torque command value (RAM,EEPROM) 997 Fault initiation 1020 Trace operation selection

Pr. Name

Parameter write selection

APPENDIX 239

11

Parameter write enabled during operation (Pr.77 = "2") These parameters can always be written. The following parameters cannot be written during operation even if Pr.77 = "2". To change the parameter setting value,

stop the operation.

Pr. Name

23 Stall prevention operation level compensation factor at double speed

48 Second stall prevention operation level 49 Second stall prevention operation frequency 60 Energy saving control selection

66 Stall prevention operation reduction starting frequency

71 Applied motor 79 Operation mode selection 80 Motor capacity 81 Number of motor poles 82 Motor excitation current 83 Rated motor voltage 84 Rated motor frequency 90 to 94 (Motor constant) 95 Online auto tuning selection 96 Auto tuning setting/status 128 PID action selection 178 to 196 (Input and output terminal function selection) 261 Power failure stop selection 289 Inverter output terminal filter 291 Pulse train I/O selection 298 Frequency search gain 313 to 322 (Extended output terminal function selection) 329 Digital input unit selection 358 Line speed unit 406 High resolution analog input selection 414 PLC function operation selection 415 Inverter operation lock mode setting 418 Extension output terminal filter 450 Second applied motor 451 Second motor control method selection 453 Second motor capacity

454 Number of second motor poles 455 Second motor excitation current 456 Rated second motor voltage 457 Rated second motor frequency 458 to 462 (Second motor constant) 463 Second motor auto tuning setting/status 541 Frequency command sign selection 560 Second frequency search gain 561 PTC thermistor protection level 570 Multiple rating setting 574 Second motor online auto tuning 598 Undervoltage level

606 Power failure stop external signal input selection

673 SF-PR slip amount adjustment operation selection

699 Input terminal filter 707, 724, 744, 745 (Motor inertia)

753, 754 (Empty reel inertia) 800 Control method selection 819 Easy gain tuning selection 858 Terminal 4 function assignment 859 Torque current/Rated PM motor current

860 Second motor torque current/Rated PM motor current

862 Encoder option selection 868 Terminal 1 function assignment 977 Input voltage mode selection 999 Automatic parameter setting 1348 P/PI control switchover frequency 1401 Tension command increment

Pr. Name

Compatible options

240 APPENDIX

11.3 Compatible options

Plug-in option The FR-A800-R2R-compatible plug-in options are as follows.

Manufactured by HMS Industrial Networks AB

Control terminal option The FR-A800-R2R-compatible control terminal options are as follows.

The terminal layout is different from the standard control circuit terminal block. Ensure the option is suitable for the system to be used. (For the terminal layout, refer to the FR-A800 inverter catalog or the FR-A8TP Instruction Manual.)

Name Model Vector control FR-A8AP Vector control / encoder pulse dividing output FR-A8AL Vector control / resolver interface FR-A8APR Vector control / EnDat interface FR-A8APS 16-bit digital input FR-A8AX Digital output / additional analog output FR-A8AY Relay output FR-A8AR Bipolar analog output / high-resolution analog input / motor thermistor interface FR-A8AZ

CC-Link communication FR-A8NC Built-in CC-Link IE Field Network communication FR-A8NCE DeviceNet communication FR-A8ND PROFIBUS-DP communication FR-A8NP EtherCAT communication A8NECT_2P

EtherNet/IP communication A8NEIP_2P

PROFINET communication A8NPRT_2P

PROFIBUS-DP communication (DP-V1) A8NDPV1

Name Model Vector control FR-A8TP

Screw terminal block FR-A8TR

Registers dedicated to CC-Link

APPENDIX 241

11

11.4 Registers dedicated to CC-Link When the octuple setting is set in CC-Link Ver.2 (Pr.544 = "18 or 28"), dancer / tension sensor feedback and the actual line

speed can be input using the remote registers.

CC-Link communication remote registers RWwn+1E is used to input dancer / tension sensor feedback, and RWwn+1F is used to input the actual line speed. (Pr.544

= "18 or 28")

"n" indicates a value determined by the station number setting. Available only when Pr.363 = "9". Available only when Pr.362 = "9".

NOTE For other registers, refer to the FR-A8NC Instruction Manual.

PLC function remote registers RWwn+1E (SD1076) is used to input dancer / tension sensor feedback, and RWwn+1F (SD1077) is used to input the actual line speed. (When Pr.544 = "18 or 28")

"n" indicates a value determined by the station number setting.

NOTE For other registers, refer to the PLC Function Programming Manual.

Address Description

Upper 8 bits Lower 8 bits RWwn+1A

H00 (Free) RWwn+1B RWwn+1C RWwn+1D RWwn+1E Dancer / tension sensor feedback RWwn+1F Actual line speed input

PLC function device number Address

Description Upper 8 bits Lower 8 bits

SD1062 RWwn+10

Registers used to read the data received from the master station

SD1063 RWwn+11 SD1064 RWwn+12 SD1065 RWwn+13 SD1066 RWwn+14 SD1067 RWwn+15 SD1068 RWwn+16 SD1069 RWwn+17 SD1070 RWwn+18 SD1071 RWwn+19 SD1072 RWwn+1A SD1073 RWwn+1B SD1074 RWwn+1C SD1075 RWwn+1D

SD1076 RWwn+1E Dancer / tension sensor feedback (when Pr.363 = "9") Registers used to read the data received from the master station (when Pr.363 "9")

SD1077 RWwn+1F Actual line speed input (when Pr.362 = "9") Registers used to read the data received from the master station (when Pr.362 "9")

Common specifications

242 APPENDIX

11.5 Common specifications

Available only when a vector control compatible option is installed. In the initial setting of the FR-A820-00340(5.5K) or higher and the FR-A840-00170(5.5K) or higher, it is limited to 150% by the torque limit level. Enabled only for standard models. This protective function is not available in the initial status. Temperature applicable for a short time, e.g. in transit. For the installation at an altitude above 1000 m, consider a 3% reduction in the rated current per 500 m increase in altitude. 2.9m/s2 or less for the FR-A840-04320(160K) or higher. Available for the Ethernet models only.

C on

tr ol

s pe

ci fic

at io

ns

Control method Soft-PWM control, high carrier frequency PWM control (selectable among V/F control, Advanced magnetic flux vector control, Real sensorless vector control), Optimum excitation control, and vector control

Output frequency range 0.2 to 590 Hz (The upper-limit frequency is 400 Hz (200 Hz for the SND rating) under Advanced magnetic flux vector control, Real sensorless vector control, and vector control.)

Frequency setting resolution

Analog input 0.015 Hz/60 Hz (0 to 10 V/12 bits for terminals 2 and 4) 0.03 Hz/60 Hz (0 to 5 V/11 bits or 0 to 20 mA/approx. 11 bits for terminals 2 and 4, 0 to 10 V/12 bits for terminal 1) 0.06 Hz/60 Hz (0 to 5 V/11 bits for terminal 1)

Digital input 0.01 Hz Frequency accuracy

Analog input Within 0.2% of the max. output frequency (25C 10C) Digital input Within 0.01% of the set output frequency

Voltage/frequency characteristics Base frequency can be set from 0 to 590 Hz. Constant-torque/variable-torque pattern can be selected.

Starting torque SLD Rating:120% 0.3 Hz, LD Rating:150% 0.3 Hz, SND Rating:150% 0.3 Hz, ND Rating:200% 0.3 Hz, HD Rating:250% 0.3 Hz (Real sensorless vector control, vector control)

Torque boost Manual torque boost Acceleration/deceleration time setting

0 to 3600 s (acceleration and deceleration can be set individually), linear or S-pattern acceleration/deceleration mode, backlash countermeasures acceleration/deceleration can be selected.

DC injection brake (induction motor) Operation frequency (0 to 120 Hz), operation time (0 to 10 s), operation voltage (0 to 30%) variable

Stall prevention operation level

Activation range of stall prevention operation (SLD rating: 0 to 120%, LD rating: 0 to 150%, SND rating: 0 to 220%, ND rating: 0 to 220%, HD rating: 0 to 280%). Whether to use the stall prevention or not can be selected. (V/F control, Advanced magnetic flux vector control)

Torque limit level Torque limit value can be set (0 to 400% variable). (Real sensorless vector control, vector control )

O pe

ra tio

n sp

ec ifi

ca tio

ns

Frequency setting signal

Analog input Terminals 2 and 4: 0 to 10 V, 0 to 5 V, 4 to 20 mA (0 to 20 mA) are available. Terminal 1: -10 to +10 V, -5 to +5 V are available.

Digital input Input using the setting dial of the operation panel or parameter unit Four-digit BCD or 16-bit binary (when used with option FR-A8AX)

Start signal Forward and reverse rotation or start signal automatic self-holding input (3-wire input) can be selected.

Input signals (twelve terminals)

Low-speed operation command, Middle-speed operation command, High-speed operation command, Second function selection, Terminal 4 input selection, Jog operation selection, Selection of automatic restart after instantaneous power failure, Flying start, Output stop, Start self- holding selection, Forward rotation command, Reverse rotation command, Inverter reset The input signal can be changed using Pr.178 to Pr.189 (input terminal function selection).

Pulse train input 100k pulses/s

Operational functions

Dancer feedback speed control, tension sensor feedback speed control, tension sensorless torque control, tension sensor feedback torque control, winding diameter calculation, initial winding diameter calculation, actual line speed detection, reduction ratio setting, maximum/minimum winding diameter setting, winding diameter / winding length storage, line speed acceleration/deceleration function, dancer roll break detection, tension PI gain tuning, speed control proportional gain compensation, reel change function, taper function, inertia compensation function, mechanical loss compensation function, maximum and minimum frequency settings, multi-speed operation, acceleration/deceleration pattern, thermal protection, DC injection brake, starting frequency, JOG operation, output stop (MRS), stall prevention, regeneration avoidance, DC feeding, frequency jump, rotation display, automatic restart after instantaneous power failure, retry function, carrier frequency selection, fast-response current limit, forward/ reverse rotation prevention, operation mode selection, slip compensation, droop control, speed smoothing control, auto tuning, applied motor selection, gain tuning, RS-485 communication, Ethernet communication, dancer control, cooling fan operation selection, stop selection (deceleration stop/coasting), power-failure deceleration stop function, PLC function, life diagnosis, maintenance timer, current average monitor, multiple rating, speed control, torque control, pre-excitation, torque limit, test run, 24 V power supply input for control circuit, safety stop function

O ut

pu t s

ig na

l Open collector output (five terminals) Relay output (two terminals)

Inverter running, Up to frequency, Instantaneous power failure/undervoltage, Overload warning, Output frequency detection, Fault The output signal can be changed using Pr.190 to Pr.196 (output terminal function selection). Fault codes of the inverter can be output (4 bits) from the open collector.

Pulse train output (FM type) 50k pulses/s

In di

ca tio

n Fo

r m et

er

Pulse train output (FM type)

Max. 2.4 kHz: one terminal (output frequency) The monitor item can be changed using Pr.54 FM/CA terminal function selection.

Current output (CA type)

Max. 20 mADC: one terminal (output frequency) The monitor item can be changed using Pr.54 FM/CA terminal function selection.

Voltage output Max. 10 VDC: one terminal (output frequency) The monitor item can be changed using Pr.158 AM terminal function selection.

Operation panel (FR-DU08)

Operating status

Output frequency, Output current, Output voltage, Frequency setting value The monitor item can be changed using Pr.52 Operation panel main monitor selection.

Fault record A fault record is displayed when a fault occurs. Past 8 fault records and the conditions immediately before the fault (output voltage/current/ frequency/cumulative energization time/year/month/date/time) are saved.

Protective/ warning function

Protective function

Overcurrent trip during acceleration, Overcurrent trip during constant speed, Overcurrent trip during deceleration or stop, Regenerative overvoltage trip during acceleration, Regenerative overvoltage trip during constant speed, Regenerative overvoltage trip during deceleration or stop, Inverter overload trip (electronic thermal relay function), Motor overload trip (electronic thermal relay function), Heat sink overheat, Instantaneous power failure, Undervoltage, Input phase loss, Stall prevention stop, Brake transistor alarm detection, Upper limit fault detection, Lower limit fault detection, Output side earth (ground) fault overcurrent, Output short circuit, Output phase loss, External thermal relay operation, PTC thermistor operation, Option fault, Communication option fault, Parameter storage device fault, PU disconnection, Retry count excess, Parameter storage device fault, CPU fault, Operation panel power supply short circuit/RS-485 terminals power supply short circuit, 24 VDC power fault, Abnormal output current detection, Inrush current limit circuit fault, Communication fault (inverter), Analog input fault, USB communication fault, Safety circuit fault, Overspeed occurrence, Speed deviation excess detection, Signal loss detection, Encoder phase fault, 4 mA input fault, PID signal fault, Option fault, Opposite rotation deceleration fault, Internal circuit fault, Encoder pulse number setting error, Overload trip, Ethernet communication fault

Warning function

Fan alarm, Stall prevention (overcurrent), Stall prevention (overvoltage), Regenerative brake pre-alarm, Electronic thermal relay function pre-alarm, PU stop, Speed limit indication, Parameter copy, Safety stop, Maintenance signal output, USB host error, Operation panel lock, Password locked, Parameter write error, Copy operation error, 24 V external power supply operation, Load fault warning, Ethernet communication fault

En vi

ro nm

en t

Surrounding air temperature

-10C to +50C (non-freezing) (LD, SND, ND, HD ratings) -10C to +40C (non-freezing) (SLD rating)

Surrounding air humidity 95% RH or less (non-condensing) (With circuit board coating (conforming to IEC60721-3-3: 1994 3C2/3S2)) 90% RH or less (non-condensing) (Without circuit board coating)

Storage temperature -20C to +65C Atmosphere Indoors (without corrosive gas, flammable gas, oil mist, dust and dirt, etc.) Altitude/vibration Maximum 2500 m , 5.9 m/s2 or less at 10 to 55 Hz (directions of X, Y, Z axes)

Application examples

APPENDIX 243

11

11.6 Application examples This section shows examples of major applications of the FR-A800-R2R inverters which have the dedicated functions for Roll to Roll applications. Each example provides the overview and the example setting of relevant parameters.

11.6.1 Dancer feedback speed control with roll diameter compensation for printers

This is useful for winding paper rolls for printers. The roll diameter compensation function and the dancer feedback speed control enhance the speed and quality of winding.

Requirements for this application High-speed winding is always required in this application. Furthermore, paper rolls must be wound with less sagging and unevenness. Therefore, fluctuation of dancer rolls must be reduced to a minimum.

Control overview The FR-A800-R2R inverter for the intermediate roller controls the total line speed of paper rolls. The tension of the paper to be wound is constantly maintained by the dancer roll. Another FR-A800-R2R inverter is used to control the speed of the winding shaft. The inverter keeps the tension of the paper constant for winding by identifying the dancer roll in the same position. The use of the roll diameter compensation function maintains the circumferential speed of the paper roll during winding. FR-A800-R2R inverters have the following additional functions as compared with the FR-A800 inverter standard models.

Purpose Inverter features Prevention of sagging and unevenness The inverter minimizes speed fluctuation to prevent sagging and unevenness.

Increase speed Higher responsivity can be expected under Vector control using encoders (internal response: 300 rad/ s).

Cost reduction A dancer roll controller is included in the inverter.

Additional function Description Dancer feedback speed control function

To keep the position of the dancer roll, PID control is performed for speed control of the winding shaft.

Analog output signal for dancer tension control

Taper function: To change a load applied to the dancer roll, analog signals as tension control commands are output to an electro-pneumatic converter.

Roll diameter compensation function

After the winding roll diameter is calculated, the motor speed is controlled based on data of the diameter so that circumferential speed of the winding roll are kept constant. This function reduces hunting in dancer feedback speed control. Roll diameter calculators and PID calculators do not need to be added externally.

Tension PI gain tuning By automatically adjusting the tension PI gain for dancer PID control, time required for adjustment is significantly cut down. Anyone can start the system easily.

Speed control proportional gain compensation function

Speed control proportional gain can be changed based on the value determined by roll diameter calculation.

Application examples

244 APPENDIX

To keep the line speed constant, the winding speed decreases with increasing the roll diameter. The FR-A800-R2R inverter automatically calculates the winding speed by calculating roll diameter.

Dancer feedback speed control (PID control) is performed to compensate the frequency so that measurements shown on the displacement gauge (non-contact potentiometer) remains the same.

Example setting of parameters The following shows mechanical specifications and parameter settings required for configuring the system shown as the application example. The parameter settings are examples for a 15 kW motor and the 18.5 kW inverter used for the winding

shaft.

Item Specification Item Specification Minimum roll diameter 100 mm Accumulated amount 300 mm Maximum roll diameter 1000 mm Roll diameter storage Enabled Gear ratio 1/3 Tension setting output Required Maximum speed of the actual line 200 m/min Taper control Enabled

Dancer signal 0 to 10 V input Roll diameter at taper start 800 mm

Line speed command Analog signal, 0 to 10 V input (60 seconds cushion time enabled at acceleration/deceleration)

Taper ratio 40%

Initial roll diameter calculation Enabled Taper ratio setting Analog signal, 0 to 10 V input

Pr. Parameter name Initial value

Setting value Remarks

1 Maximum frequency 120 Hz 70 Hz

Set about 110% of the maximum speed (the maximum speed refers to the motor speed for the minimum-diameter roll at the maximum line speed) (the amount of dancer compensation: about 10%). = Maximum line speed / ( Minimum diameter Gear ratio) = 200 103 / ( 100 1/3) / 30 63.66 Hz 1.1 70 Hz

Printing unit

Displacement gauge

Encoder

FR-A800-R2R FR-A800-R2R

Line speed setting 2

Encoder

1

Line speed (0 to 10 V) 2AM

FR-A8AP 1

Dancer position (0 to 10 V)

Dancer/tension control selection X114 RL

(Non-contact potentiometer)

2

JOG

FM

AM

Actual line speed monitoring

Dancer tension command

Actual line speed monitoring

FR-A8AP

Taper ratio 4

SF- V5RU

Encoder SF-

V5RU

Actual line speed (single phase)

Intermediate shaft (reference axis)

Winding shaft

Air cylinder

Electro-pneumatic converter

FR-A800-R2R 2 (0 to 10 V) 1 (0 to 10 V) 4 (0 to 10 V)

RL RM CS

Line speed

Dancer/tension control selection (X114) AM

RUN

Dancer tension command

Winding diameter calculation completion at star signal (Y232)

Dancer signal Taper ratio

Stored winding diameter clear signal (X109) External thermal relay signal (OH)

Application examples

APPENDIX 245

11

7 Acceleration time 15 s 0 s Use these parameters to improve trackability of the dancer feedback speed control.8 Deceleration time 15 s 0 s

9 Electronic thermal O/L relay Inverter rated current

0 A Setting for a specific motor for Vector control (motor with built-in thermal protector).

10 DC injection brake operation frequency 3 Hz 0.5 Hz

18 High speed maximum frequency 120 Hz 70 Hz

52 Operation panel main monitor selection 0 22

Set "22" (Roll diameter) for monitoring. Or use any of Pr.774 to Pr.776 when using the 3-line monitor screen on the PU. Other monitor items related to this application and their setting values are as follows: 26 (Line speed command), 27 (Actual line speed), 28 (Dancer compensation speed), 29 (Winding length), 52 (PID set point), 53 (PID measured value), and 54 (PID deviation).

71 Applied motor 0 30 30: Setting for the Mitsubishi Electric Vector control dedicated motor SF-V5RU.

72 PWM frequency selection 2 15

73 Analog input selection 1 10 10: Terminal 2 input between 0 to 10 V for the line speed and terminal 1 input between 0 to 10 V for the dancer signal with reversible polarity.

80 Motor capacity 9999 15 kW

Set these parameters according to the motor. 81 Number of motor poles 9999 4 (poles) 83 Rated motor voltage 200 V 164 V 84 Rated motor frequency 9999 51 128 PID action selection 0 40 40: Dancer control enabled (reverse action) 129 PID proportional band 100% 100% Performing tension PI gain tuning allows setting these

parameters.130 PID integral time 1 s 10 s

133 PID action set point 500% 550%

Set Pr.52 = "86" (Terminal 1 input after calibration in %) to check the upper and lower limit of the dancer roll position. Set the target position (neutral position) in this parameter according to the check result.

134 PID differential time 9999 9999

To improve trackability of a mechanical extraneous disturbance (variation), set 0.01 seconds at first, and change the setting to a slightly larger value as required. (Set the minimum possible value because setting a too large value causes hunting.)

158 AM terminal function selection 1 19 19: Analog output signal for dancer tension control

180 RL terminal function selection 0 114 114: Tension control selection (X114) signal ON (Setting "114" is required for tension control.)

181 RM terminal function selection 1 109 109: Stored winding diameter clear (X109) signal ON (Setting "109" clears the stored roll diameter.)

186 CS terminal function selection 6 7 7: External thermal relay input (OH) signal (Setting "7" is required for signals input from the SF-V5RU thermal protector.)

190 RUN terminal function selection 0 232 232: Winding diameter calculation completion at start (Y232) signal (positive logic)

267 Terminal 4 input selection 0 2 2: Terminal 4 input between 0 to 10 V for the taper ratio setting

350 Line speed command voltage/ current bias 0% 0%

351 Line speed command bias 0 m/min 0 m/min Use Pr.358 to set the increment.

352 Line speed command voltage/ current gain 50% 100%

353 Line speed command gain 0 m/min 200 m/min Use Pr.358 to set the increment. Max. line speed: 200 m/min 358 Line speed unit 0 0 0: m/min (increment of the maximum line speed)

360 Line speed command value 0 m/min 0 m/min If setting Pr.361 to "8", set a line speed command value in this parameter.

361 Line speed command input selection 9999 0

362 Actual line speed input selection 0 0 0: Signals for the actual line speed are not input (the actual line

speed is determined by calculating from the line speed setting).

363 Dancer / tension sensor feedback input selection 9999 5 5: Dancer signals input via terminal 1.

369 Number of encoder pulses 1024 2048

Pr. Parameter name Initial value

Setting value Remarks

Application examples

246 APPENDIX

393 Line speed command acceleration/deceleration reference

1000 m/min 100 m/min

394 First acceleration time for line speed command 15 s 0 s Setting must be lower than the acceleration/deceleration rate of

the line speed command (input via terminals 2 and 5). (In this example, setting these parameters are not required as the cushion time is considered for the line speed command.)395 First deceleration time for line

speed command 15 s 0 s

430

Dancer tension setting / taper function enable/disable selection for tension sensor feedback speed control 2

100% 100%

622 Line speed command for starting 0 m/min 0 m/min Setting this parameter avoids intermittent operation after the

initial roll diameter calculation is completed.

641 Speed control proportional gain 1 9999 60% By adjusting the speed control proportional gain, response

improvement is achievable according to the roll diameter. Pr.644 (proportional gain for the maximum roll diameter) and Pr.641 (proportional gain for the minimum roll diameter) are used for determination of the setting of Pr.642 and Pr.643. Pr.642 = /5 + Pr.641 Pr.643 = 8 /15 + Pr.641 ( = Pr.644 - Pr.641)

642 Speed control proportional gain 2 9999 80%

643 Speed control proportional gain 3 9999 120%

644 Speed control proportional gain 4 9999 200%

645 Winding diameter storage selection 0 1

When "1" (storing roll diameters enabled) is set, the input of the Stored winding diameter clear (X109) signal is required. The storing of roll diameters (writing in EEPROM) is conducted when the inverter power or the X114 signal turns OFF. Note that storing is not conducted when the RES signal is input. Therefore, avoid inputting the RES signal frequently without storing the roll diameters. For the input of the RES signal by necessity such as a reset of the inverter fault, it is recommended to configure the sequence that the RES signal will be input after the X114 signal turns OFF and before the X114 signal turns ON again.

647 Operation time with stored winding diameter 0 s 0.01 s

Be sure to set this parameter when storing roll diameters is set to enabled (the value of the stored roll diameter is not applied to any setting if this parameter is not set).

800 Control method selection 20 0 0: Vector control (speed control)

821 Speed control integral time 1 0.333 s 0 s Set 0 seconds to disable the integral so that the inverter acts as a proportional amplifier.

868 Terminal 1 function assignment 0 9999 9999: Function disabled. (Setting "9999" is required to prevent compensation for the dancer signal voltage input from being added when the X114 signal is OFF.)

C2 (902)

Terminal 2 frequency setting bias frequency 0 Hz 0 Hz

Use these parameters to correct the offset of the line speed commands.C3

(902) Terminal 2 frequency setting bias 0% 3%

C6 (904)

Terminal 4 frequency setting bias 20% 0% Use this parameter to correct the taper ratio setting.

C7 (905)

Terminal 4 frequency setting gain 100% 40%

1003 Notch filter frequency 0 100 Hz Use this parameter to decrease whining sound of a motor when stopped.

1004 Notch filter depth 0 2

1219 Tension PI gain tuning start/ status 0 1 1: Tension PI gain tuning starts.

1222 Target amplitude 9999 1% Set the target amplitude for the limit cycle. Start tuning with a small value and gradually increase the value while making sure that tuning causes no problem.

1230 Winding/unwinding selection 0 0 0:Winding, 1: Unwinding 1235 Maximum winding diameter 1 2 mm 1000 mm 1236 Minimum winding diameter 1 1 mm 100 mm 1243 Gear ratio numerator 1 1 Set the gear ratio of the unwinding shaft as a accurately as

possible.1244 Gear ratio denominator 1 3

1245 Sampling time for winding diameter calculation 9999 0.1 s Setting is recommended when the results of the roll diameter

calculation change significantly.

Pr. Parameter name Initial value

Setting value Remarks

Application examples

APPENDIX 247

11

Adjustment parameter. The parameter number in parentheses is the one for use with the LCD operation panel and the parameter unit.

1246 Line speed at winding diameter calculated value activation 1 m/min 1 m/min

1247 Winding diameter change increment amount limit 9999 0.2 mm

Setting Pr.1247 = "9999 (initial value)" disables the roll diameter calculation. Be sure to change the setting from the initial value for the roll diameter calculation.

1249 Number of averaging for winding diameter calculation 4 4 Use this parameter to enable the primary delay filter relative to

the result of the roll diameter calculation.

1251 Winding diameter compensation speed filter time constant

0 s 0.1 s

1252 Dancer lower limit position 400% 500%

1253 Initial winding diameter calculation deadband 1.0% 10%

1254 Initial winding diameter calculation deadband 2 9999 0%

Use this parameter to prevent the dancer roll from moving too much when the normal operation starts after the initial roll diameter calculation is completed.

1255 Accumulated amount 9999 270 mm

The setting value can be calculated from the setting of Pr.1253 Initial winding diameter calculation deadband (10%) and the accumulated amount (300 mm) as follows: 300 mm 0.9 = 270 mm

1258 Integral term limit at start 2.5% 1.5% Use these parameters to adjust winding speed for the initial roll diameter calculation.1259 PID term limit at start 2.5% 1.5%

1285 Taper setting analog input selection 9999 4 4: The taper ratio is input through terminal 4.

1286 Winding diameter at taper start 9999 800 mm 1287 Taper ratio setting 0% 9999 9999: The taper ratio is set through the analog input terminal.

Pr. Parameter name Initial value

Setting value Remarks

Application examples

248 APPENDIX

11.6.2 Dancer feedback speed control with roll diameter compensation for wire drawing machines

This is useful for winding wire using a wire drawing machine. The dancer feedback speed control with roll diameter compensation function in the inverter enable high-speed winding for high-inertia loads.

Requirements for this application High-speed winding for high-inertia loads and the stability of a dancer roll are required in this application.

Control overview The wire drawing section pulls the wire at a constant speed to make the wire thinner. Tension of wire to be wound is maintained constant by the dancer roll. For the winding shaft, the inverter provides dancer feedback speed control to keep the dancer roll position, achieving constant tension winding. In addition, using the roll diameter compensation function, the circumferential speed of the winding bobbin is kept constant. FR-A800-R2R inverters have the following additional functions as compared with the FR-A800 inverter standard models.

Purpose Inverter features Stability of dancer roll The inverter minimizes speed fluctuation to prevent sagging and unevenness. Winding for high-inertia loads Higher responsivity can be expected under Vector control using encoders (internal response: 300 rad/s). Cost reduction A dancer roll controller is included in the inverter.

Additional function Description Dancer feedback speed control function The winding shaft rotation speed is controlled to keep the dancer roll position constant.

Roll diameter compensation function

After the winding roll diameter is calculated, the motor speed is controlled based on data of the diameter so that circumferential speed of the winding roll are kept constant. This function reduces hunting in dancer feedback speed control. Roll diameter calculators and PID calculators do not need to be added externally.

Tension PI gain tuning By automatically adjusting the tension PI gain for dancer PID control, time required for adjustment is significantly cut down. Anyone can start the system easily.

Speed control proportional gain compensation function

Speed control proportional gain can be changed based on the value determined by roll diameter calculation.

Displacement gauge

Non-contact potentiometer

FR-A800-R2RFR-A800-R2R

Line speed (0 to 10 V) 2AM

1

JOG

Dancer/tension control selection (X114) RL

Dancer signal

Dancer signal

Dancer position (0 to 10 V)

Actual line speed (single phase)

Line speed setting (0 to 10V)

Encoder

FR-A800-R2RFR-A800-R2R

2 2 2

Brake unit

Brake resistor

Encoder

Brake resistor

Brake resistor

Brake unit

Brake unit

Brake resistor

Brake unit

Intermediate shaft (reference axis)

Intermediate shaftIntermediate shaft Winding shaft

FR-A8AP FR-A8AP FR-A8AP

FR-A8AP 1 1

SF- V5RU

Encoder SF-

V5RU

Encoder SF-

V5RU

Encoder SF-

V5RU

Application examples

APPENDIX 249

11

Example setting of parameters The following shows mechanical specifications and parameter settings required for configuring the system shown as the application example. The parameter settings are examples for a 7.5 kW motor and the 11 kW inverter used for the winding

shaft.

Item Specification Item Specification Minimum roll diameter 280 mm

Line speed command Analog signal, 0 to 10 V input (90 seconds cushion time enabled at acceleration/deceleration)Maximum roll diameter 400 mm

Gear ratio 1/1.2 Initial roll diameter calculation Disabled

Maximum speed of the actual line 2000 m/min Roll diameter storage Enabled

Dancer signal 0 to 10 V input Tension setting output Required

Pr. Parameter name Initial value

Setting value Remarks

7 Acceleration time 15 s 0.1 s Use these parameters to improve trackability of the dancer feedback speed control. (In this example, 0.1 seconds is applied to avoid the influence of external noises. Setting a larger value worsen the trackability.)

8 Deceleration time 15 s 0.1 s

9 Electronic thermal O/L relay Inverter rated current

0 A Setting for a specific motor for Vector control (motor with built- in thermal protector).

10 DC injection brake operation frequency 3 Hz 0 Hz

52 Operation panel main monitor selection 0 22

Set "22" (Roll diameter) for monitoring. Or use any of Pr.774 to Pr.776 when using the 3-line monitor screen on the PU. Other monitor items related to this application and their setting values are as follows: 26 (Line speed command), 27 (Actual line speed), 28 (Dancer compensation speed), 29 (Winding length), 52 (PID set point), 53 (PID measured value), and 54 (PID deviation).

71 Applied motor 0 30 30: Setting for the Mitsubishi Electric Vector control dedicated motor SF-V5RU.

73 Analog input selection 1 10 10: Terminal 2 input between 0 to 10 V for the line speed and terminal 1 input between 0 to 10 V for the dancer signal with reversible polarity.

79 Operation mode selection 0 2 2: External operation mode only. 80 Motor capacity 9999 7.5 kW

Set these parameters according to the motor. 81 Number of motor poles 9999 4 (poles) 83 Rated motor voltage 200 V 164 V 84 Rated motor frequency 9999 51 Hz

128 PID action selection 0 41

41: Dancer control enabled (forward action) (Compensation direction of the dancer signal is reversed since the lower limit of the dancer signal output is 8 V and the upper limit is 2 V.)

129 PID proportional band 100% 250% Performing tension PI gain tuning allows setting these parameters.130 PID integral time 1 s 5 s

133 PID action set point 500% 550%

Set Pr.52 = "86" (Terminal 1 input after calibration in %) to check the upper and lower limit of the dancer roll position. Set the target position (neutral position) in this parameter according to the check result.

134 PID differential time 9999 0.05 s

To improve trackability of a mechanical extraneous disturbance (variation), set 0.01 seconds at first, and change the setting to a slightly larger value as required. (Set the minimum possible value because setting a too large value causes hunting.)

180 RL terminal function selection 0 114 114: Tension control selection (X114) signal ON (Setting "114" is required for tension control.)

181 RM terminal function selection 1 109 109: Stored winding diameter clear (X109) signal ON (Setting "109" clears the stored roll diameter.)

Application examples

250 APPENDIX

186 CS terminal function selection 6 7 7: External thermal relay input (OH) signal (Setting "7" is required for signals input from the SF-V5RU thermal protector.)

242 Terminal 1 added compensation amount (terminal 2) 100% 0%

Setting 0% is required to disable additional input to the dancer signal (compensation for addition via terminal 1) while the X114 signal is OFF and the normal operation is carried out.

350 Line speed command voltage/ current bias 0% 0%

351 Line speed command bias 0 m/min 0 m/min Use Pr.358 to set the increment.

352 Line speed command voltage/ current gain 50% 100%

353 Line speed command gain 0 m/min 2000 m/min Use Pr.358 to set the increment. Max. line speed: 2000 m/ min

358 Line speed unit 0 0 0: m/min (increment of the maximum line speed)

360 Line speed command value 0 m/min 0 m/min If setting Pr.361 to "8", set a line speed command value in this parameter.

361 Line speed command input selection 9999 0

362 Actual line speed input selection 0 0 0: Signals for the actual line speed are not input (the actual line speed is determined by calculating from the line speed setting).

363 Dancer / tension sensor feedback input selection 9999 5 5: Dancer signals input via terminal 1.

369 Number of encoder pulses 1024 2048

393 Line speed command acceleration/deceleration reference

1000 m/min 100 m/min

394 First acceleration time for line speed command 15 s 0.5 s Setting must be lower than the acceleration/deceleration rate

of the line speed command (input via terminals 2 and 5). (In this example, setting these parameters are not required as the cushion time is considered for the line speed command. However, 0.5 seconds is set as a precaution against noise.)

395 First deceleration time for line speed command 15 s 0.5 s

622 Line speed command for starting 0 m/min 0 m/min Setting this parameter avoids intermittent operation after the initial roll diameter calculation is completed.

641 Speed control proportional gain 1 9999 100% By adjusting the speed control proportional gain, response improvement is achievable according to the roll diameter. Pr.644 (proportional gain for the maximum roll diameter) and Pr.641 (proportional gain for the minimum roll diameter) are used for determination of the setting of Pr.642 and Pr.643. Pr.642 = /5 + Pr.641 Pr.643 = 8 /15 + Pr.641 ( = Pr.644 - Pr.641)

642 Speed control proportional gain 2 9999 140% 643 Speed control proportional gain 3 9999 200%

644 Speed control proportional gain 4 9999 300%

645 Winding diameter storage selection 0 1

When "1" (storing roll diameters enabled) is set, the input of the Stored winding diameter clear (X109) signal is required. The storing of roll diameters (writing in EEPROM) is conducted when the inverter power or the X114 signal turns OFF. Note that storing is not conducted when the RES signal is input. Therefore, avoid inputting the RES signal frequently without storing the roll diameters. For the input of the RES signal by necessity such as a reset of the inverter fault, it is recommended to configure the sequence that the RES signal will be input after the X114 signal turns OFF and before the X114 signal turns ON again.

647 Operation time with stored winding diameter 0 s 0.01 s

Be sure to set this parameter when storing roll diameters is set to enabled (the value of the stored roll diameter is not applied to any setting if this parameter is not set).

800 Control method selection 20 0 0: Vector control (speed control)

821 Speed control integral time 1 0.333 s 0 s Set 0 seconds to disable the integral so that the inverter acts as a proportional amplifier.

822 Speed setting filter 1 9999 0.5 s Set this parameter when noise is superimposed on the input analog signals.

1003 Notch filter frequency 0 50 Hz Use this parameter to decrease whining sound of a motor when stopped.

1004 Notch filter depth 0 2

Pr. Parameter name Initial value

Setting value Remarks

Application examples

APPENDIX 251

11

Adjustment parameter.

1219 Tension PI gain tuning start/ status 0 1 1: Tension PI gain tuning starts.

1222 Target amplitude 9999 1% Set the target amplitude for the limit cycle. Start tuning with a small value and gradually increase the value while making sure that tuning causes no problem.

1230 Winding/unwinding selection 0 0 0:Winding, 1: Unwinding 1235 Maximum winding diameter 1 2 mm 400 mm Set the initial roll diameter as accurately as possible.

(Unwinding roll: maximum diameter / Winding roll: minimum diameter).1236 Minimum winding diameter 1 1 mm 280 mm

1243 Gear ratio numerator 1 10 Set the gear ratio of the unwinding shaft as accurately as possible.1244 Gear ratio denominator 1 12

1245 Sampling time for winding diameter calculation 9999 0.1 s Setting is recommended when the results of the roll diameter

calculation change significantly.

1247 Winding diameter change increment amount limit 9999 0.1 mm

Setting Pr.1247 = "9999 (initial value)" disables the roll diameter calculation. Be sure to change the setting from the initial value for the roll diameter calculation.

1249 Number of averaging for winding diameter calculation 4 4 Use this parameter to enable the primary delay filter relative

to the result of the roll diameter calculation.

1251 Winding diameter compensation speed filter time constant 0 s 0.1 s

1255 Accumulated amount 9999 9999 9999: Initial roll diameter calculation disabled.

Pr. Parameter name Initial value

Setting value Remarks

Application examples

252 APPENDIX

11.6.3 Tension sensorless torque control with roll diameter compensation for printers

This is useful for winding paper rolls for printers. Torque control by the inverter with tension control, inertia compensation, and mechanical loss compensation enables the winding of paper rolls without dancer rolls and tension controllers.

Requirements for this application This control method is suitable for a winding application where a reasonable finish is required in about half the dancer-roll- winding machine speed.

Control overview The FR-A800-R2R inverter is used for roll winding machines. The inverter controls the motor output torque according to the calculated diameter of a paper roll to make paper tension constant. When the paper feed speed of the printer is increased (or decreased), the inverter changes the torque command value according to the inertia of the paper roll to give the acceleration (or deceleration) torque to keep a constant tension. A taper ratio can be also set to prevent the roll from getting too tight. FR-A800-R2R inverters have the following additional functions as compared with the FR-A800 inverter standard models.

To make the tension constant, the torque is controlled according to the changing roll diameter. Motor torque (T) = Tension (F) Roll diameter (D) / 2

Purpose Inverter features Cost reduction Dancer rolls and tension controllers are not required for the winding system (tension control).

Constant tension Tension is kept steady during operation including acceleration/deceleration (by inertia compensation and mechanical loss compensation).

Additional function Description Roll diameter calculation function, tension control

The inverter controls the motor output torque according to the changing diameter of a paper roll to make paper tension constant.

Taper function Tension is reduced when the roll diameter increases in order to prevent the roll from getting too tight. Various taper ratio settings are enabled using parameters.

Inertia compensation function Paper tension is kept constant by adding the acceleration/deceleration torque even when the paper feeding speed increases/decreases.

Mechanical loss compensation function

The torque command, which is calculated in consideration of the mechanical loss amount, is given to avoid tension changes due to mechanical losses.

FR-A800-R2R

X112

X114 STF/STR

Nip roll Tension (F)

1

X111

Speed limit Start command

1

Tension command FR-A8AZ

Intermediate shaft Winding shaft

Inertia compensation deceleration signal

6

Dancer/tension control selection

Encoder

FR-A8AP

Roll diameter (D)

Torque (T)

Inertia compensation acceleration signal

X109Stored winding diameter clear signal Stall mode trigger signal X123

2Line speed

SF- V5RU

FR-A800-R2R

Encoder

FR-A8AP

AM Y237 Y238

SF- V5RU

X114

Dancer/tension control selection

Printing unit

Application examples

APPENDIX 253

11

Example setting of parameters The following shows mechanical specifications and parameter settings required for configuring the system shown as the application example. The parameter settings are examples for a 7.5 kW motor and the 11 kW inverter used for the winding

shaft.

Item Specification Item Specification

Minimum roll diameter 100 mm Initial roll diameter calculation Disabled

Maximum roll diameter 300 mm Roll diameter storage Enabled Gear ratio 1/1.2 Tension command 0 to 300 N Maximum speed of the actual line 400 m/min Tension setting output Required

Pr. Parameter name Initial value

Setting value RemarksIntermediate

shaft Winding

shaft 7 Acceleration time 15 s 0 s 8 Deceleration time 15 s 0 s

9 Electronic thermal O/L relay Inverter rated current

0

10 DC injection brake operation frequency 3 Hz 0.5 Hz 0 Hz

12 DC injection brake operation voltage 4% 2.5%

52 Operation panel main monitor selection 0 27 22

Set "22" (Roll diameter) or "27" (Actual line speed) for monitoring. Or use any of Pr.774 to Pr.776 when using the 3- line monitor screen on the PU. Other monitor items related to this application and their setting values are as follows: 26 (Line speed command), 81 (Tension command after taper compensation), 82 (Winding diameter compensation torque command), 83 (Inertia compensation), and 84 (Mechanical loss compensation).

71 Applied motor 0 30 30: Setting for the Mitsubishi Electric Vector control dedicated motor SF-V5RU.

73 Analog input selection 1 1 10 10: Terminal 2 input between 0 to 10 V for the line speed with reversible polarity.

80 Motor capacity 9999 7.5 kW

Set these parameters according to the motor. 81 Number of motor poles 9999 4 (poles) 83 Rated motor voltage 200 V 164 V 84 Rated motor frequency 9999 51 Hz 95 Online auto tuning selection 0 0 2 2: Magnetic flux observer (continuous tuning) 128 PID action selection 0 40 0 129 PID proportional band 100% 9999 100% 130 PID integral time 1 s 9999 1 s 134 PID differential time 9999 9999 9999

158 AM terminal function selection 1 26 1 26 (for intermediate shaft): Line speed command value

180 RL terminal function selection 0 114 114: Tension control selection (X114) signal ON (Setting "114" is required for tension control.)

181 RM terminal function selection 1 1 109 109: Stored winding diameter clear (X109) signal ON (Setting "109" clears the stored roll diameter.)

182 RH terminal function selection 2 2 123 123: Stall mode trigger signal (X123) signal ON (Setting "123" triggers the stall mode.)

184 AU terminal function selection 4 4 111 To use the inertia compensation function, assign the Inertia compensation acceleration (X111) signal and the Inertia compensation deceleration (X112) signal.189 RES terminal function selection 62 62 112

193 OL terminal function selection 3 237 3 To use the inertia compensation function, assign the Line speed acceleration (Y237) signal and the Line speed deceleration (Y238) signal to affected output terminals on the inverter for the intermediate roller to output these signal to the inverter for the winding shaft.

194 FU terminal function selection 4 238 4

Application examples

254 APPENDIX

270 Acceleration/deceleration time during stall condition 15 s 15 s Set the acceleration/deceleration time during stall

mode.

350 Line speed command voltage/ current bias 0% 0%

351 Line speed command bias 0 m/min 0 m/min Use Pr.358 to set the increment.

352 Line speed command voltage/ current gain 50% 50% 100%

353 Line speed command gain 0 m/min 400 m/min Use Pr.358 to set the increment. Max. line speed: 400 m/min

358 Line speed unit 0 0 0: m/min (increment of the maximum line speed)

360 Line speed command value 0 m/min 0 m/min If setting Pr.361 to "8", set a line speed command value in this parameter.

361 Line speed command input selection 9999 3 3: Input via terminal 2

362 Actual line speed input selection 0 0 0: Signals for the actual line speed are not input (the actual line speed is determined by calculating from the line speed setting).

363 Dancer / tension sensor feedback input selection 9999 9999 Leave the setting "9999 (initial value)" (No

function) since tension feedback is not required. 369 Number of encoder pulses 1024 2048

393 Line speed command acceleration/deceleration reference

1000 m/min 250 m/min The line accelerates to 250 m/min in 5 seconds.

394 First acceleration time for line speed command 15 s 5 s Setting must be lower than the acceleration/

deceleration rate of the line speed command (input via terminals 2 and 5).395 First deceleration time for line

speed command 15 s 5 s

645 Winding diameter storage selection 0 0 1

When "1" (storing roll diameters enabled) is set, the input of the Stored winding diameter clear (X109) signal is required. The storing of roll diameters (writing in EEPROM) is conducted when the inverter power or the X114 signal turns OFF. Note that storing is not conducted when the RES signal is input. Therefore, avoid inputting the RES signal frequently without storing the roll diameters. For the input of the RES signal by necessity such as a reset of the inverter fault, it is recommended to configure the sequence that the RES signal will be input after the X114 signal turns OFF and before the X114 signal turns ON again.

647 Operation time with stored winding diameter 0 s 0.01 s

Be sure to set this parameter when storing roll diameters is set to enabled (the value of the stored roll diameter is not applied to any setting if this parameter is not set).

800 Control method selection 20 0 2 0: Vector control (speed control) 2: Vector control (switchover between speed control and torque control)

803 Constant output range torque characteristic selection 0 0 To limit output torque in the constant power range,

set "1" (constant torque).

804 Tension / Torque command source selection 0 0

Tension command given by analog input via terminal 1 on the inverter (0 to 10 VDC) or terminal 6 on the FR-A8AZ (0 to 10 VDC)

807 Speed limit selection 0 0 2 2: Speed limit command given by analog voltage input via terminal 1

821 Speed control integral time 1 0.333 s 0.333 s 0.333 s 868 Terminal 1 function assignment 0 0 5 5: Forward/reverse rotation speed limit (Pr.807=2) 1230 Winding/unwinding selection 0 1 0 0:Winding, 1: Unwinding 1235 Maximum winding diameter 1 2 mm 80 mm 300 mm Set the initial roll diameter as accurately as

possible. (Unwinding roll: maximum diameter / Winding roll: minimum diameter).1236 Minimum winding diameter 1 1 mm 80 mm 100 mm

1243 Gear ratio numerator 1 10 Set the gear ratio of the unwinding shaft as accurately as possible.1244 Gear ratio denominator 1 12

1245 Sampling time for winding diameter calculation 9999 0.1 Set a sampling time for the roll diameter

calculation.

1246 Line speed at winding diameter calculated value activation 1 m/min 1 m/min Set the line speed command value to start the roll

diameter calculation.

Pr. Parameter name Initial value

Setting value RemarksIntermediate

shaft Winding

shaft

Application examples

APPENDIX 255

11

Adjustment parameter.

1247 Winding diameter change increment amount limit 9999 9999 1 mm

Setting Pr.1247 = "9999 (initial value)" disables the roll diameter calculation. Be sure to change the setting from the initial value for the roll diameter calculation.

1249 Number of averaging for winding diameter calculation 4 4

Use this parameter to enable the primary delay filter relative to the result of the roll diameter calculation.

1255 Accumulated amount 9999 9999 9999: Initial roll diameter calculation disabled. 1284 Taper mode selection 0 0 1 1 (for winding shaft): Linear taper profile 1286 Winding diameter at taper start 9999 9999 240 mm Set the roll diameter to start taper control. 1287 Taper ratio setting 0% 0% 20% Set the taper ratio.

1401 Tension command increment 0 1 1: Setting increment: 0.1 N, setting range: 0 to 1000 N

1402 Tension command input voltage bias 0% 0%

Set the tension command in the range of 0 to 300 N.

1403 Tension command bias 0 N 0 N

1404 Tension command input voltage gain 100% 100%

1405 Tension command gain 1000 N 300 N

1406 Commanded tension reduction scaling factor during stall condition

20% 20% Commanded tension during stall mode = Tension command value Pr.1406

1407 Speed limit during stall condition 1 Hz 1 Hz Set the speed limit to be used during stall mode.

1410 Motor inertia 0 0 0.01 Set the motor inertia for the inertia compensation function.

1411 Empty reel inertia 0 0 0.01 Set the empty reel inertia for the inertia compensation function.

1412 Roll width 0 0 50 mm Set the roll width for the inertia compensation function.

1413 Material specific gravity 0 0 1.4 Set the specific gravity of the material for the inertia compensation function.

1414 First acceleration time for inertia compensation 15 s 15 s 5 s Set the acceleration time for the inertia

compensation function.

1415 First deceleration time for inertia compensation 15 s 15 s 5 s Set the deceleration time for the inertia

compensation function.

1419 Mechanical loss setting frequency bias 1000% 1001.5%

Set the frequency and the compensation value for each setting of mechanical loss.

For setting, start measuring mechanical loss with an empty reel attached at low speeds, and gradually increase the set speed to find the speed requiring mechanical loss compensation.

1420 Mechanical loss setting frequency 1 9999 9999 1.33 Hz

1421 Mechanical loss 1 1000% 1000% 1001.5%

1422 Mechanical loss setting frequency 2 9999 9999 2 Hz

1423 Mechanical loss 2 1000% 1000% 1002%

1424 Mechanical loss setting frequency 3 9999 9999 4.67 Hz

1425 Mechanical loss 3 1000% 1000% 1002.5%

1426 Mechanical loss setting frequency 4 9999 9999 23.33 Hz

1427 Mechanical loss 4 1000% 1000% 1003%

1428 Mechanical loss setting frequency 5 9999 9999 50 Hz

1429 Mechanical loss 5 1000% 1000% 1004%

Pr. Parameter name Initial value

Setting value RemarksIntermediate

shaft Winding

shaft

Application examples

256 APPENDIX

11.6.4 Tension sensor feedback torque control with roll diameter compensation for fabric inspection machines

This is useful for a small winding system formed by the small number of shafts (rollers) and no controllers, for example, a fabric inspection machine. As tension of material rolls can be controlled by the R2R inverters only, winding/unwinding of materials is possible without programmable controllers.

Requirements for this application Highly responsive tension control using feedback from tension sensors is required for the above-mentioned winding system.

Control overview The FR-A800-R2R inverter is used for every driving roller in the winding system. The inverter controls the motor output torque based on tension data fed back from a tension sensor to make fabric tension constant. FR-A800-R2R inverters have the following additional functions as compared with the FR-A800 inverter standard models.

Purpose Inverter features

Cost reduction Tension control with no programmable controllers improves the maintainability of the winding system and reduces to the total man-hour count to develop the system.

Responsivity enhancement The responsivity of the R2R inverter performing tension control is high as tension data is fed back to the inverter directly from a tension sensor.

Additional function Description

Tension control The inverter controls the motor output torque according to the changing diameter of a fabric roll to make fabric tension constant.

Inertia compensation function Fabric tension is kept constant by adding the acceleration/deceleration torque even when the fabric feeding speed increases/decreases.

Mechanical loss compensation function

The torque command, which is calculated in consideration of the mechanical loss amount, is given to avoid tension changes due to mechanical losses.

Two-way operation The operation can be switched automatically between winding and unwinding.

Application examples

APPENDIX 257

11

Example setting of parameters The following shows mechanical specifications and parameter settings required for configuring the system shown as the

application example. The parameter settings are examples for a 7.5 kW motor and the 11 kW inverter used for each roller.

Item Specification Item Specification Minimum roll diameter 100 mm Tension feedback signal 0 to 10 V / 0 to 300 N input Maximum roll diameter 800 mm Tension setting output Required

Gear ratio 1/3 Initial roll diameter calculation Disabled

Maximum speed of the actual line 300 m/min Roll diameter storage Enabled

Minimum tension 100 N Intermediate shaft (Nip roll) diameter 200 mm

Maximum tension 300 N

Pr. Parameter name Initial value

Setting value RemarksUnwinding

shaft Intermediate

shaft Winding

shaft 7 Acceleration time 15 s 0.1 s 15 s 0.1 s 8 Deceleration time 15 s 0.1 s 15 s 0.1 s

9 Electronic thermal O/L relay Inverter rated current 0 Setting for a Vector control dedicated motor

(with built-in thermal protectors).

10 DC injection brake operation frequency 3 Hz 0 Hz

11 DC injection brake operation time 0.5 s 0 s 0.5 s 0 s

30 Regenerative function selection 0 1 Set "1" when using the FR-ABR.

X126

X112

X111

STF/STR

Tension control selection

Inertia compensation acceleration

X114

Two-way operation

Inertia compensation deceleration

Start command

X109

Stored winding diameter clear

Winding length clear X117

1

2

Line speed

Tension feedback

Y233

Target winding diameter achieved

Winding/ unwinding completion

Y234

FR-A800-R2R

Encoder

FR-A8AP

SF- V5RU

X114

LX X126

STF/STR

Emergency stop

Two-way operation X92

Tension control selection

Pre-excitation

Start command 1Line speed

Y237 (Line speed

acceleration)

AM

Input to inverter controlling unwinding shaft

From intermediate shaft

Y238 (Line speed

deceleration)

X126

X112

X111

Y238

Y237

STF/STR

Tension control selection

Inertia compensation acceleration

X114

Two-way operation

Inertia compensation deceleration

Start command

X109

Stored winding diameter clear

Winding length clear X117

2

Tension feedback

Tension command 6

Y233

1

Target winding diameter achieved

Winding/unwinding completion

Y234

FR-A800-R2R

Encoder

FR-A8AP

SF- V5RU

FR-A800-R2R

Encoder

Tension sensorTension sensor Nip roll

FR-A8AP

SF- V5RU

Unwinding shaft Winding shaft

Intermediate shaft

FR-A8AZ Tension command 6 FR-A8AZ

Application examples

258 APPENDIX

52 Operation panel main monitor selection 0 22 0

Set "22" (Roll diameter) for monitoring. Or use any of Pr.774 to Pr.776 when using the 3-line monitor screen on the PU. Other monitor items related to this application and their setting values are as follows: 26 (Line speed command), 27 (Actual line speed), 81 (Tension command after taper compensation), 82 (Winding diameter compensation torque command), 83 (Inertia compensation), and 84 (Mechanical loss compensation).

70 Special regenerative brake duty 0% 6%

Setting is required when the FR-ABR is used (setting value: 10% for the 7.5K inverter or lower, 6% for the 11K inverter or higher). (When the SF-V5RU motor is used, the inverter of the next larger capacity is supposed to be used.)

71 Applied motor 0 30 30: Setting for the Mitsubishi Electric Vector control dedicated motor SF-V5RU.

73 Analog input selection 1 0 0: Terminal 2 input between 0 to 10 V and terminal 1 input between 0 to 10 V

79 Operation mode selection 0 0 3 0 3 (for intermediate roller): External/PU combined operation mode 1

80 Motor capacity 9999 kW 7.5 kW Set these parameters according to the motor.

81 Number of motor poles 9999 4 (poles) 83 Rated motor voltage 200 V 164 V 84 Rated motor frequency 9999 51 Hz

95 Online auto tuning selection 0 2 0 2 2: Magnetic flux observer (continuous tuning)

129 PID proportional band 100% 50% 0% 50% Setting increment: 0.1% 130 PID integral time 1 s 2 s 300 s 2 s Setting increment: 0.1 second

158 AM terminal function selection 1 1 26 1 26 (for intermediate roller): Line speed

command value 180 RL terminal function selection 0 92 92: Emergency stop (X92) signal

181 RM terminal function selection 1 117

117: Winding length clear (X117) signal (Turning the signal ON clears the winding length.)

182 RH terminal function selection 2 109

109: Stored winding diameter clear (X109) signal (Turning the signal ON clears the stored roll diameter.)

183 RT terminal function selection 3 114 114: Tension control selection (X114) signal (Turning the signal ON is required for tension control.)

184 AU terminal function selection 4 23 23: Pre-excitation (LX) signal

187 MRS terminal function selection 24 126 126: Two-way operation (X126) signal

188 STOP terminal function selection 25 111 To use the inertia compensation function,

assign the Inertia compensation acceleration (X111) signal and the Inertia compensation deceleration (X112) signal.189 RES terminal function

selection 62 112

350 Line speed command voltage/current bias 0 0

351 Line speed command bias 0 0 Use Pr.358 to set the increment.

352 Line speed command voltage/current gain 50% 92% 100% 92%

Line speed commands are input to the inverter for the intermediate shaft (roller) via terminal 1 and output to the inverters for the winding roll and the unwinding roll via terminal AM. The setting value for the winding roll and the unwinding roll is smaller than the one for the intermediate shaft because it has been calibrated considering a voltage drop.

Pr. Parameter name Initial value

Setting value RemarksUnwinding

shaft Intermediate

shaft Winding

shaft

Application examples

APPENDIX 259

11

353 Line speed command gain 0 m/min 300 m/min Use Pr.358 to set the increment. Max. line speed: 300 m/min

358 Line speed unit 0 0 0: m/min (increment of the maximum line speed)

360 Line speed command value 0 0 If setting Pr.361 to "8", set a line speed command value in this parameter.

361 Line speed command input selection 9999 5 5: Input via terminal 1

362 Actual line speed input selection 0 0

0: Signals for the actual line speed are not input (the actual line speed is determined by calculating from the line speed setting).

369 Number of encoder pulses 1024 2048

393 Line speed command acceleration/deceleration reference

1000 m/min 300 m/min Acceleration/deceleration speed and time: 300 m/min for 30 seconds (same as the setting of the intermediate shaft)394 First acceleration time for line

speed command 15 s 10 s 30 s 10 s

395 First deceleration time for line speed command 15 s 10 s 30 s 10 s

645 Winding diameter storage selection 0 1 0 1

When "1" (storing roll diameters enabled) is set, the input of the Stored winding diameter clear (X109) signal is required.

800 Control method selection 20 1 0 1 0: Speed control, 1: Torque control 802 Pre-excitation selection 0 1 1: Servo lock

803 Constant output range torque characteristic selection 0 1 0 1 To limit output torque in the constant power

range, set "1" (constant torque).

804 Tension / Torque command source selection 0 0 0 0 0: Tension command given by analog input

via terminal 6 on the FR-A8AZ

807 Speed limit selection 0 1 1: Speed limited by the setting of Pr.808 or Pr.809

808 Forward rotation speed limit/ speed limit 60 Hz 120 Hz Set the forward rotation speed limit.

823 Speed detection filter 1 0.001 s 0.001 s 0.01 s 0.001 s The setting of 0.01 seconds for the intermediate shaft is for noise precautions.

868 Terminal 1 function assignment 0 0

1072 Tension reverse selection 0 1 0 0 Set the intermediate shaft to "1" (tension direction reversed) for back tension.

1136 Tension sensor feedback voltage/current bias 0% 0%

0.0% (0 V) corresponds to 0 N and 100.0% (10 V) corresponds to 300.0 N when Pr.1401 is set to "1" (0.1 N).

1137 Tension sensor feedback bias 0 N 0 N

1138 Tension sensor feedback voltage/current gain 100% 100% 0% 100%

1139 Tension sensor feedback gain 100 N 300 N 0 N 300 N

1230 Winding/unwinding selection 0 1 0 0 0: Winding, 1: Unwinding

1231 Material thickness d1 9999 0.3 mm Set this parameter for the roll diameter calculation from the material thickness.

1235 Maximum winding diameter 1 2 mm 800 mm 200 mm 800 mm Set the initial roll diameter as accurately as possible. (Unwinding roll: maximum diameter / Winding roll: minimum diameter).1236 Minimum winding diameter 1 1 mm 100 mm 200 mm 100 mm

1243 Gear ratio numerator 1 1 Set the gear ratio of the unwinding/winding shaft as accurately as possible.1244 Gear ratio denominator 1 3

1245 Sampling time for winding diameter calculation 9999 0.1 s 9999 0.1 s

Setting is recommended when the results of the roll diameter calculation change significantly.

1246 Line speed at winding diameter calculated value activation

1 0 Set the line speed command value to start the roll diameter calculation.

1247 Winding diameter change increment amount limit 9999 2 mm 9999 2 mm

Setting Pr.1247 = "9999 (initial value)" disables the roll diameter calculation. Be sure to change the setting from the initial value for the roll diameter calculation.

Pr. Parameter name Initial value

Setting value RemarksUnwinding

shaft Intermediate

shaft Winding

shaft

Application examples

260 APPENDIX

Adjustment parameter.

1249 Number of averaging for winding diameter calculation 4 5

Use this parameter to enable the primary delay filter relative to the result of the roll diameter calculation.

1401 Tension command increment 0 1 0 1 1: Setting increment: 0.1 N, setting range: 0 to 1000 N

1405 Tension command gain 100 N 300 N 100 N 300 N 0 V corresponds to 0 N and 10 V corresponds to 300 N.

1410 Motor inertia 0 kgm2 0 kgm2

Set these parameters to control tension changes due to inertia torque during acceleration/deceleration.

1411 Empty reel inertia 0 kgm2 0.01 kgm2

1412 Roll width 0 mm 50 mm 1413 Material specific gravity 0 g/cm3 1.7 g/cm3

1414 First acceleration time for inertia compensation 15 s 5 s

1415 First deceleration time for inertia compensation 15 s 5 s

1418 Inertia compensation cushion time 0 s 0 s

1419 Mechanical loss setting frequency bias 1000% 1001.5%

Set the frequency and the compensation value for each setting of mechanical loss.

Use these parameters when mechanical losses are large or variable due to hard acceleration/deceleration.

1420 Mechanical loss setting frequency 1 9999 1 Hz

1421 Mechanical loss 1 1000% 1001.5%

1422 Mechanical loss setting frequency 2 9999 6.67 Hz

1423 Mechanical loss 2 1000% 1002%

1424 Mechanical loss setting frequency 3 9999 16.67 Hz

1425 Mechanical loss 3 1000% 1002.5%

1426 Mechanical loss setting frequency 4 9999 50 Hz

1427 Mechanical loss 4 1000% 1003.5%

1428 Mechanical loss setting frequency 5 9999 93.33 Hz

1429 Mechanical loss 5 1000% 1004.5%

Pr. Parameter name Initial value

Setting value RemarksUnwinding

shaft Intermediate

shaft Winding

shaft

Parameters (functions) and instruction codes under different control methods

APPENDIX 261

11

11.7 Parameters (functions) and instruction codes under different control methods

The following parameters and instruction codes are changed or added in the FR-A800-R2R inverter as compared to the FR- A800 series standard inverter. The availability of the parameters and instruction codes is shown by control method. For information on the availability of other parameters by control method and instruction codes, refer to the Instruction Manual (Detailed) of the FR-A800 inverter.

Instruction codes are used to read and write parameters by using the Mitsubishi inverter protocol via RS-485 communication. (For the details of the RS-485 communication, refer to the Instruction Manual (Detailed) of the FR-A800 inverter.)

Function availability under each control method is as follows: : Available : Not available : Available with some restrictions

For "parameter copy", "parameter clear", and "all parameter clear", "" indicates the function is available, and "" indicates the function is not available.

Communication parameters that are not cleared by parameter clear or all clear (H5A5A or H55AA) via communication. When a communication option is installed, parameter clear (lock release) during password lock (Pr.297 Password lock/unlock 9999) can

be performed only from the communication option. Reading and writing via the PU connector are available. The parameter is used for gain adjustment during servo lock. Available under tension sensor feedback torque control.

The function of the parameter with the following mark is available when the option is connected. FR-A8AP, FR-A8AL, FR-A8TP, FR-A8APR, FR-A8APS, FR-A8AR, FR-A8AX, FR-A8AY, FR-A8AZ, FR-A8NC, FR-A8NCE, FR-A8ND, FR-A8NP

Pr. Name

Instruction code Control method Parameter

R ea

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cl ea

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0 Torque boost 00 80 0

1 Maximum frequency 01 81 0

2 Minimum frequency 02 82 0

3 Base frequency 03 83 0

4 Multi-speed setting (high speed) 04 84 0

5 Multi-speed setting (middle speed) 05 85 0

6 Multi-speed setting (low speed) 06 86 0

7 Acceleration time 07 87 0

8 Deceleration time 08 88 0

9 Electronic thermal O/L relay 09 89 0

10 DC injection brake operation frequency 0A 8A 0

11 DC injection brake operation time 0B 8B 0

12 DC injection brake operation voltage 0C 8C 0

13 Starting frequency 0D 8D 0

14 Load pattern selection 0E 8E 0

15 Jog frequency 0F 8F 0

16 Jog acceleration/deceleration time 10 90 0

17 MRS input selection 11 91 0

18 High speed maximum frequency 12 92 0

19 Base frequency voltage 13 93 0

20 Acceleration/deceleration reference frequency 14 94 0

21 Acceleration/deceleration time increments 15 95 0

22 Stall prevention operation level (Torque limit level) 16 96 0

23 Stall prevention operation level compensation factor at double speed 17 97 0

24 Multi-speed setting (speed 4) 18 98 0

V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

262 APPENDIX

25 Multi-speed setting (speed 5) 19 99 0

26 Multi-speed setting (speed 6) 1A 9A 0

27 Multi-speed setting (speed 7) 1B 9B 0

28 Multi-speed input compensation selection 1C 9C 0

29 Acceleration/deceleration pattern selection 1D 9D 0

30 Regenerative function selection 1E 9E 0

31 Frequency jump 1A 1F 9F 0

32 Frequency jump 1B 20 A0 0

33 Frequency jump 2A 21 A1 0

34 Frequency jump 2B 22 A2 0

35 Frequency jump 3A 23 A3 0

36 Frequency jump 3B 24 A4 0

37 Speed display 25 A5 0

41 Up-to-frequency sensitivity 29 A9 0

42 Output frequency detection 2A AA 0

43 Output frequency detection for reverse rotation 2B AB 0

44 Second acceleration/deceleration time 2C AC 0

45 Second deceleration time 2D AD 0

46 Second torque boost 2E AE 0

47 Second V/F (base frequency) 2F AF 0

48 Second stall prevention operation level 30 B0 0

49 Second stall prevention operation frequency 31 B1 0

50 Second output frequency detection 32 B2 0

51 Second electronic thermal O/L relay 33 B3 0

52 Operation panel main monitor selection 34 B4 0

54 FM/CA terminal function selection 36 B6 0

55 Frequency monitoring reference 37 B7 0

56 Current monitoring reference 38 B8 0

57 Restart coasting time 39 B9 0

58 Restart cushion time 3A BA 0

60 Energy saving control selection 3C BC 0

65 Retry selection 41 C1 0

66 Stall prevention operation reduction starting frequency 42 C2 0

67 Number of retries at fault occurrence 43 C3 0

68 Retry waiting time 44 C4 0

69 Retry count display erase 45 C5 0

70 Special regenerative brake duty 46 C6 0

71 Applied motor 47 C7 0

72 PWM frequency selection 48 C8 0

73 Analog input selection 49 C9 0

74 Input filter time constant 4A CA 0

75 Reset selection/disconnected PU detection/PU stop selection 4B CB 0

76 Fault code output selection 4C CC 0

77 Parameter write selection 4D CD 0

78 Reverse rotation prevention selection 4E CE 0

79 Operation mode selection 4F CF 0

Pr. Name

Instruction code Control method Parameter

R ea

d

W rit

e

Ex te

nd ed

C op

y

C le

ar

A ll

cl ea

r

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

APPENDIX 263

11

80 Motor capacity 50 D0 0

81 Number of motor poles 51 D1 0

82 Motor excitation current 52 D2 0

83 Rated motor voltage 53 D3 0

84 Rated motor frequency 54 D4 0

85 Excitation current break point 55 D5 0

86 Excitation current low-speed scaling factor 56 D6 0

89 Speed control gain (Advanced magnetic flux vector) 59 D9 0

90 Motor constant (R1) 5A DA 0

91 Motor constant (R2) 5B DB 0

92 Motor constant (L1) 5C DC 0

93 Motor constant (L2) 5D DD 0

94 Motor constant (X) 5E DE 0

95 Online auto tuning selection 5F DF 0

96 Auto tuning setting/status 60 E0 0

100 Second acceleration time for line speed command 00 80 1

101 Second deceleration time for line speed command 01 81 1

102 Third acceleration time for line speed command 02 82 1

103 Third deceleration time for line speed command 03 83 1

110 Third acceleration/deceleration time 0A 8A 1

111 Third deceleration time 0B 8B 1

112 Third torque boost 0C 8C 1

113 Third V/F (base frequency) 0D 8D 1

114 Third stall prevention operation level 0E 8E 1

115 Third stall prevention operation frequency 0F 8F 1

116 Third output frequency detection 10 90 1

117 PU communication station number 11 91 1

118 PU communication speed 12 92 1

119 PU communication stop bit length / data length 13 93 1

120 PU communication parity check 14 94 1

121 Number of PU communication retries 15 95 1

122 PU communication check time interval 16 96 1

123 PU communication waiting time setting 17 97 1

124 PU communication CR/LF selection 18 98 1

125 Terminal 2 frequency setting gain frequency 19 99 1

126 Terminal 4 frequency setting gain frequency 1A 9A 1

127 PID control automatic switchover frequency 1B 9B 1

128 PID action selection 1C 9C 1

129 PID proportional band 1D 9D 1

130 PID integral time 1E 9E 1

131 PID upper limit 1F 9F 1

132 PID lower limit 20 A0 1

133 PID action set point 21 A1 1

Pr. Name

Instruction code Control method Parameter

R ea

d

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Ex te

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C op

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C le

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A ll

cl ea

r

Sp ee

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To rq

ue

co nt

ro l

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

264 APPENDIX

134 PID differential time 22 A2 1

135 Integral clamp (positive polarity) 23 A3 1

136 Integral clamp (negative polarity) 24 A4 1

137 PID upper/lower limit hysteresis width 25 A5 1

140 Backlash acceleration stopping frequency 28 A8 1

141 Backlash acceleration stopping time 29 A9 1

142 Backlash deceleration stopping frequency 2A AA 1

143 Backlash deceleration stopping time 2B AB 1

144 Speed setting switchover 2C AC 1

145 PU display language selection 2D AD 1

147 Acceleration/deceleration time switching frequency 2F AF 1

148 Stall prevention level at 0 V input 30 B0 1

149 Stall prevention level at 10 V input 31 B1 1

150 Output current detection level 32 B2 1

151 Output current detection signal delay time 33 B3 1

152 Zero current detection level 34 B4 1

153 Zero current detection time 35 B5 1

154 Voltage reduction selection during stall prevention operation 36 B6 1

155 RT signal function validity condition selection 37 B7 1

156 Stall prevention operation selection 38 B8 1

157 OL signal output timer 39 B9 1

158 AM terminal function selection 3A BA 1

159 DA1 output sign selection 3B BB 1

160 User group read selection 00 80 2

161 Frequency setting/key lock operation selection 01 81 2

162 Automatic restart after instantaneous power failure selection 02 82 2

163 First cushion time for restart 03 83 2

164 First cushion voltage for restart 04 84 2

165 Stall prevention operation level for restart 05 85 2

166 Output current detection signal retention time 06 86 2

167 Output current detection operation selection 07 87 2

168 Parameter for manufacturer setting. Do not set.

169 170 Watt-hour meter clear 0A 8A 2

171 Operation hour meter clear 0B 8B 2

172 User group registered display/batch clear 0C 8C 2

173 User group registration 0D 8D 2 174 User group clear 0E 8E 2 178 STF terminal function selection 12 92 2

179 STR terminal function selection 13 93 2

180 RL terminal function selection 14 94 2

181 RM terminal function selection 15 95 2

182 RH terminal function selection 16 96 2

Pr. Name

Instruction code Control method Parameter

R ea

d

W rit

e

Ex te

nd ed

C op

y

C le

ar

A ll

cl ea

r

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

APPENDIX 265

11

183 RT terminal function selection 17 97 2

184 AU terminal function selection 18 98 2

185 JOG terminal function selection 19 99 2

186 CS terminal function selection 1A 9A 2

187 MRS terminal function selection 1B 9B 2

188 STOP terminal function selection 1C 9C 2

189 RES terminal function selection 1D 9D 2

190 RUN terminal function selection 1E 9E 2

191 SU terminal function selection 1F 9F 2

192 IPF terminal function selection 20 A0 2

193 OL terminal function selection 21 A1 2

194 FU terminal function selection 22 A2 2

195 ABC1 terminal function selection 23 A3 2

196 ABC2 terminal function selection 24 A4 2

232 Multi-speed setting (speed 8) 28 A8 2

233 Multi-speed setting (speed 9) 29 A9 2

234 Multi-speed setting (speed 10) 2A AA 2

235 Multi-speed setting (speed 11) 2B AB 2

236 Multi-speed setting (speed 12) 2C AC 2

237 Multi-speed setting (speed 13) 2D AD 2

238 Multi-speed setting (speed 14) 2E AE 2

239 Multi-speed setting (speed 15) 2F AF 2

240 Soft-PWM operation selection 30 B0 2

241 Analog input display unit switchover 31 B1 2

242 Terminal 1 added compensation amount (terminal 2) 32 B2 2

243 Terminal 1 added compensation amount (terminal 4) 33 B3 2

244 Cooling fan operation selection 34 B4 2

245 Rated slip 35 B5 2

246 Slip compensation time constant 36 B6 2

247 Constant-power range slip compensation selection 37 B7 2

249 Earth (ground) fault detection at start 39 B9 2

250 Stop selection 3A BA 2

251 Output phase loss protection selection 3B BB 2

252 Override bias 3C BC 2

253 Override gain 3D BD 2

255 Life alarm status display 3F BF 2 256 Inrush current limit circuit life display 40 C0 2 257 Control circuit capacitor life display 41 C1 2 258 Main circuit capacitor life display 42 C2 2 259 Main circuit capacitor life measuring 43 C3 2

260 PWM frequency automatic switchover 44 C4 2

261 Power failure stop selection 45 C5 2

262 Subtracted frequency at deceleration start 46 C6 2

263 Subtraction starting frequency 47 C7 2

264 Power-failure deceleration time 1 48 C8 2

265 Power-failure deceleration time 2 49 C9 2

266 Power failure deceleration time switchover frequency 4A CA 2

267 Terminal 4 input selection 4B CB 2

Pr. Name

Instruction code Control method Parameter

R ea

d

W rit

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Ex te

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C op

y

C le

ar

A ll

cl ea

r

Sp ee

d co

nt ro

l

To rq

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co nt

ro l

Sp ee

d co

nt ro

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To rq

ue

co nt

ro l

V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

266 APPENDIX

268 Monitor decimal digits selection 4C CC 2

269 Parameter for manufacturer setting. Do not set.

270 Acceleration/deceleration time during stall condition 4E CE 2

271 Second acceleration time for inertia compensation 4F CF 2

272 Second deceleration time for inertia compensation 50 D0 2

276 Line speed monitoring reference 54 D4 2

278 Actual line speed voltage/current gain 56 D6 2

279 Actual line speed gain 57 D7 2

280 Actual line speed voltage/current bias 58 D8 2

281 Actual line speed bias 59 D9 2

282 Actual line speed pulse input bias 5A DA 2

283 Actual line speed pulse input gain 5B DB 2

284 Actual line speed input filter time constant 5C DC 2

285 Overspeed detection frequency (Speed deviation excess detection frequency)

5D DD 2

286 Droop gain 5E DE 2

287 Droop filter time constant 5F DF 2

288 Droop function activation selection 60 E0 2

289 Inverter output terminal filter 61 E1 2

290 Monitor negative output selection 62 E2 2

291 Pulse train I/O selection 63 E3 2

294 UV avoidance voltage gain 66 E6 2

295 Frequency change increment amount setting 67 E7 2

296 Password lock level 68 E8 2

297 Password lock/unlock 69 E9 2

298 Frequency search gain 6A EA 2

299 Rotation direction detection selection at restarting 6B EB 2

300 BCD input bias 00 80 3

301 BCD input gain 01 81 3

302 BIN input bias 02 82 3

303 BIN input gain 03 83 3

304 Digital input and analog input compensation enable/disable selection

04 84 3

305 Read timing operation selection 05 85 3

306 Analog output signal selection 06 86 3

307 Setting for zero analog output 07 87 3

308 Setting for maximum analog output

08 88 3

309 Analog output signal voltage/current switchover

09 89 3

310 Analog meter voltage output selection

0A 8A 3

311 Setting for zero analog meter voltage output

0B 8B 3

Pr. Name

Instruction code Control method Parameter

R ea

d

W rit

e

Ex te

nd ed

C op

y

C le

ar

A ll

cl ea

r

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

APPENDIX 267

11

312 Setting for maximum analog meter voltage output

0C 8C 3

313 DO0 output selection 0D 8D 3

314 DO1 output selection 0E 8E 3

315 DO2 output selection 0F 8F 3

316 DO3 output selection 10 90 3

317 DO4 output selection 11 91 3

318 DO5 output selection 12 92 3

319 DO6 output selection 13 93 3

320 RA1 output selection 14 94 3

321 RA2 output selection 15 95 3

322 RA3 output selection 16 96 3

323 AM0 0V adjustment 17 97 3

324 AM1 0mA adjustment 18 98 3

326 Motor temperature feedback reference

1A 9A 3

329 Digital input unit selection 1D 9D 3

331 RS-485 communication station number 1F 9F 3

332 RS-485 communication speed 20 A0 3

333 RS-485 communication stop bit length / data length 21 A1 3

334 RS-485 communication parity check selection 22 A2 3

335 RS-485 communication retry count 23 A3 3

336 RS-485 communication check time interval 24 A4 3

337 RS-485 communication waiting time setting 25 A5 3

338 Communication operation command source 26 A6 3

339 Communication speed command source 27 A7 3

340 Communication startup mode selection 28 A8 3

341 RS-485 communication CR/LF selection 29 A9 3

342 Communication EEPROM write selection 2A AA 3

343 Communication error count 2B AB 3

345 DeviceNet address 2D AD 3

346 DeviceNet baud rate 2E AE 3

349 Communication reset selection

31 B1 3

350 Line speed command voltage/current bias 32 B2 3

351 Line speed command bias 33 B3 3

352 Line speed command voltage/current gain 34 B4 3

353 Line speed command voltage/current gain 35 B5 3

354 Line speed command pulse input bias 36 B6 3

Pr. Name

Instruction code Control method Parameter

R ea

d

W rit

e

Ex te

nd ed

C op

y

C le

ar

A ll

cl ea

r

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

268 APPENDIX

355 Line speed command pulse input gain 37 B7 3

356 Line speed command digital input bias 38 B8 3

357 Line speed command digital input gain 39 B9 3

358 Line speed unit 3A BA 3

359 Encoder rotation direction

3B BB 3

360 Line speed command value 3C BC 3

361 Line speed command input selection 3D BD 3

362 Actual line speed input selection 3E BE 3

363 Dancer / tension sensor feedback input selection 3F BF 3

364

Dancer tension setting input selection / taper function enable/ disable selection for tension sensor feedback speed control 1

40 C0 3

365 Tension command value (RAM) 41 C1 3

366 Tension command value (RAM, EEPROM) 42 C2 3

367 Speed feedback range

43 C3 3

368 Feedback gain 44 C4 3

369 Number of encoder pulses 45 C5 3

374 Overspeed detection level 4A CA 3

376 Encoder signal loss detection enable/disable selection

4C CC 3

380 Acceleration S-pattern 1 50 D0 3

381 Deceleration S-pattern 1 51 D1 3

382 Acceleration S-pattern 2 52 D2 3

383 Deceleration S-pattern 2 53 D3 3

384 Input pulse division scaling factor 54 D4 3

385 Frequency for zero input pulse 55 D5 3

386 Frequency for maximum input pulse 56 D6 3

393 Line speed command acceleration/ deceleration reference 5D DD 3

394 First acceleration time for line speed command 5E DE 3

395 First deceleration time for line speed command 5F DF 3

398 Draw rate 62 E2 3

406 High resolution analog input selection

06 86

407 Motor temperature detection filter 07 87

408 Motor thermistor selection 08 88

413 Encoder pulse division ratio 0D 8D 4

414 PLC function operation selection 0E 8E 4 415 Inverter operation lock mode setting 0F 8F 4

416 Pre-scale function selection 10 90 4

417 Pre-scale setting value 11 91 4

418 Extension output terminal filter

12 92 4

422 Position control gain 16 96 4

Pr. Name

Instruction code Control method Parameter

R ea

d

W rit

e

Ex te

nd ed

C op

y

C le

ar

A ll

cl ea

r

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

APPENDIX 269

11

423 Dancer / tension sensor feedback detection level 17 97 4

424 Dancer / tension sensor feedback input offset 18 98 4

425 Break detection waiting time 19 99 4

426 Dancer tension setting bias 1A 9A 4

427 Dancer tension setting gain 1B 9B 4

428 Command pulse selection 1C 9C 4

430

Dancer tension setting / taper function enable/disable selection for tension sensor feedback speed control 2

1E 9E 4

432 Pulse train torque command bias 20 A0 4

433 Pulse train torque command gain 21 A1 4

434 IP address 1 22 A2 4

435 IP address 2 23 A3 4

447 Digital torque command bias 2F AF 4

448 Digital torque command gain 30 B0 4

450 Second applied motor 32 B2 4

451 Second motor control method selection 33 B3 4

453 Second motor capacity 35 B5 4

454 Number of second motor poles 36 B6 4

455 Second motor excitation current 37 B7 4

456 Rated second motor voltage 38 B8 4

457 Rated second motor frequency 39 B9 4

458 Second motor constant (R1) 3A BA 4

459 Second motor constant (R2) 3B BB 4

460 Second motor constant (L1) 3C BC 4

461 Second motor constant (L2) 3D BD 4

462 Second motor constant (X) 3E BE 4

463 Second motor auto tuning setting/ status 3F BF 4

464 PID proportional band for values below set point 40 C0 4

465 PID integral time for values below set point 41 C1 4

466 PID differential time for values below set point 42 C2 4

467 Second PID proportional band 43 C3 4

468 Second PID integral time 44 C4 4

469 Second PID differential time 45 C5 4

470 Second PID proportional band for values below set point 46 C6 4

471 Second PID integral time for values below set point 47 C7 4

472 Second PID differential time for values below set point 48 C8 4

473 Third PID proportional band 49 C9 4

474 Third PID integral time 4A CA 4

475 Third PID differential time 4B CB 4

476 Third PID proportional band for values below set point 4C CC 4

477 Third PID integral time for values below set point 4D CD 4

Pr. Name

Instruction code Control method Parameter

R ea

d

W rit

e

Ex te

nd ed

C op

y

C le

ar

A ll

cl ea

r

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

270 APPENDIX

478 Third PID differential time for values below set point 4E CE 4

479 Fourth PID proportional band 4F CF 4

480 Fourth PID integral time 50 D0 4

481 Fourth PID differential time 51 D1 4

482 Fourth PID proportional band for values below set point 52 D2 4

483 Fourth PID integral time for values below set point 53 D3 4

484 Fourth PID differential time for values below set point 54 D4 4

485 Integral control activation 55 D5 4

486 Deviation A 56 D6 4

487 Deviation B 57 D7 4

488 Deviation C1 58 D8 4

489 Deviation C2 59 D9 4

490 PID gain A 5A DA 4

491 PID gain B 5B DB 4

492 PID gain C1 5C DC 4

493 PID gain C2 5D DD 4

494 PID gain D 5E DE 4

495 Remote output selection 5F DF 4

496 Remote output data 1 60 E0 4 497 Remote output data 2 61 E1 4 498 PLC function flash memory clear 62 E2 4

500 Communication error execution waiting time

00 80 5

501 Communication error occurrence count display

01 81 5

502 Stop mode selection at communication error 02 82 5

503 Maintenance timer 1 03 83 5

504 Maintenance timer 1 warning output set time 04 84 5

505 Speed setting reference 05 85 5

516 S-pattern time at a start of acceleration 10 90 5

517 S-pattern time at a completion of acceleration 11 91 5

518 S-pattern time at a start of deceleration 12 92 5

519 S-pattern time at a completion of deceleration 13 93 5

539 MODBUS RTU communication check time interval 27 A7 5

541 Frequency command sign selection

29 A9 5

542 Communication station number (CC- Link)

2A AA 5

543 Baud rate selection (CC-Link) 2B AB 5

544 CC-Link extended setting 2C AC 5

547 USB communication station number 2F AF 5

548 USB communication check time interval 30 B0 5

549 Protocol selection 31 B1 5

Pr. Name

Instruction code Control method Parameter

R ea

d

W rit

e

Ex te

nd ed

C op

y

C le

ar

A ll

cl ea

r

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

APPENDIX 271

11

550 NET mode operation command source selection 32 B2 5

551 PU mode operation command source selection 33 B3 5

552 Frequency jump range 34 B4 5

553 PID deviation limit 35 B5 5

554 PID signal operation selection 36 B6 5

555 Current average time 37 B7 5

556 Data output mask time 38 B8 5

557 Current average value monitor signal output reference current 39 B9 5

560 Second frequency search gain 3C BC 5

561 PTC thermistor protection level 3D BD 5

563 Energization time carrying-over times 3F BF 5 564 Operating time carrying-over times 40 C0 5

565 Second motor excitation current break point 41 C1 5

566 Second motor excitation current low- speed scaling factor 42 C2 5

569 Second motor speed control gain 45 C5 5

570 Multiple rating setting 46 C6 5 571 Holding time at a start 47 C7 5

573 4 mA input check selection 49 C9 5

574 Second motor online auto tuning 4A CA 5

598 Undervoltage level 62 E2 5

599 X10 terminal input selection 63 E3 5

600 First free thermal reduction frequency 1 00 80 6

601 First free thermal reduction ratio 1 01 81 6

602 First free thermal reduction frequency 2 02 82 6

603 First free thermal reduction ratio 2 03 83 6

604 First free thermal reduction frequency 3 04 84 6

606 Power failure stop external signal input selection 06 86 6

607 Motor permissible load level 07 87 6

608 Second motor permissible load level 08 88 6

609 PID measured tension monitor filter 09 89 6

610 PID measured tension monitor increment 0A 8A 6

611 Acceleration time at a restart 0B 8B 6

617 Reverse rotation excitation current low-speed scaling factor 11 91 6

620 Line speed bias for reel change 14 94 6

621 Allowable deviation from target line speed 15 95 6

622 Line speed command for starting 16 96 6

635 Line speed command added compensation value voltage/current bias

23 A3 6

636 Line speed command added compensation value bias 24 A4 6

637 Line speed command added compensation value voltage/current gain

25 A5 6

Pr. Name

Instruction code Control method Parameter

R ea

d

W rit

e

Ex te

nd ed

C op

y

C le

ar

A ll

cl ea

r

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

272 APPENDIX

638 Line speed command added compensation value gain 26 A6 6

639 Speed control proportional term applied diameter 1 27 A7 6

640 Speed control proportional term applied diameter 2 28 A8 6

641 Speed control proportional gain 1 29 A9 6

642 Speed control proportional gain 2 2A AA 6

643 Speed control proportional gain 3 2B AB 6

644 Speed control proportional gain 4 2C AC 6

645 Winding diameter storage selection 2D AD 6

646 Stored winding diameter 2E AE 6

647 Operation time with stored winding diameter 2F AF 6

648 Target winding diameter 30 B0 6

650 Terminal 4 input compensation selection 32 B2 6

653 Speed smoothing control 35 B5 6

654 Speed smoothing cutoff frequency 36 B6 6

655 Analog remote output selection 37 B7 6

656 Analog remote output 1 38 B8 6 657 Analog remote output 2 39 B9 6 658 Analog remote output 3 3A BA 6 659 Analog remote output 4 3B BB 6

663 Control circuit temperature signal output level 3F BF 6

665 Regeneration avoidance frequency gain 41 C1 6

668 Power failure stop frequency gain 44 C4 6

673 SF-PR slip amount adjustment operation selection 49 C9 6

674 SF-PR slip amount adjustment gain 4A CA 6

675 User parameter auto storage function selection 4B CB 6

679 Second droop gain 4F CF 6

680 Second droop filter time constant 50 D0 6

681 Second droop function activation selection 51 D1 6

682 Second droop break point gain 52 D2 6

683 Second droop break point torque 53 D3 6

684 Tuning data unit switchover 54 D4 6

686 Maintenance timer 2 56 D6 6

687 Maintenance timer 2 warning output set time 57 D7 6

688 Maintenance timer 3 58 D8 6

689 Maintenance timer 3 warning output set time 59 D9 6

690 Deceleration check time 5A DA 6

692 Second free thermal reduction frequency 1 5C DC 6

693 Second free thermal reduction ratio 1 5D DD 6

694 Second free thermal reduction frequency 2 5E DE 6

695 Second free thermal reduction ratio 2 5F DF 6

696 Second free thermal reduction frequency 3 60 E0 6

Pr. Name

Instruction code Control method Parameter

R ea

d

W rit

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Ex te

nd ed

C op

y

C le

ar

A ll

cl ea

r

Sp ee

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nt ro

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To rq

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co nt

ro l

Sp ee

d co

nt ro

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To rq

ue

co nt

ro l

V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

APPENDIX 273

11

699 Input terminal filter 63 E3 6

707 Motor inertia (integer) 07 87 7

724 Motor inertia (exponent) 18 98 7

744 Second motor inertia (integer) 2C AC 7

745 Second motor inertia (exponent) 2D AD 7

750 Motor temperature detection level

32 B2 7

751 Reference motor temperature 33 B3 7

753 Empty reel inertia (integer) 35 B5 7

754 Empty reel inertia (exponent) 36 B6 7

755 Cumulative pulse clear signal selection

37 B7 7

756 Cumulative pulse division scaling factor

38 B8 7

757 Control terminal option-Cumulative pulse division scaling factor

39 B9 7

758 Cumulative pulse storage

3A BA 7

774 Operation panel monitor selection 1 4A CA 7

775 Operation panel monitor selection 2 4B CB 7

776 Operation panel monitor selection 3 4C CC 7

778 4 mA input check filter 4E CE 7

799 Pulse increment setting for output power 63 E3 7

800 Control method selection 00 80 8

801 Output limit level 01 81 8

802 Pre-excitation selection 02 82 8

803 Constant output range torque characteristic selection 03 83 8

804 Tension / Torque command source selection 04 84 8

805 Torque command value (RAM) 05 85 8

806 Torque command value (RAM,EEPROM) 06 86 8

807 Speed limit selection 07 87 8

808 Forward rotation speed limit/speed limit 08 88 8

809 Reverse rotation speed limit/reverse- side speed limit 09 89 8

810 Torque limit input method selection 0A 8A 8

811 Set resolution switchover 0B 8B 8

812 Torque limit level (regeneration) 0C 8C 8

813 Torque limit level (3rd quadrant) 0D 8D 8

814 Torque limit level (4th quadrant) 0E 8E 8

815 Torque limit level 2 0F 8F 8

816 Torque limit level during acceleration 10 90 8

817 Torque limit level during deceleration 11 91 8

818 Easy gain tuning response level setting 12 92 8

819 Easy gain tuning selection 13 93 8

820 Speed control P gain 1 14 94 8

821 Speed control integral time 1 15 95 8

822 Speed setting filter 1 16 96 8

Pr. Name

Instruction code Control method Parameter

R ea

d

W rit

e

Ex te

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C op

y

C le

ar

A ll

cl ea

r

Sp ee

d co

nt ro

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co nt

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Sp ee

d co

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To rq

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V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

274 APPENDIX

823 Speed detection filter 1

17 97 8

824 Torque control P gain 1 (current loop proportional gain) 18 98 8

825 Torque control integral time 1 (current loop integral time) 19 99 8

826 Torque setting filter 1 1A 9A 8

827 Torque detection filter 1 1B 9B 8

828 Model speed control gain 1C 9C 8

829 Taper ratio setting input filter time constant 1D 9D 8

830 Speed control P gain 2 1E 9E 8

831 Speed control integral time 2 1F 9F 8

832 Speed setting filter 2 20 A0 8

833 Speed detection filter 2

21 A1 8

834 Torque control P gain 2 22 A2 8

835 Torque control integral time 2 23 A3 8

836 Torque setting filter 2 24 A4 8

837 Torque detection filter 2 25 A5 8

838 DA1 terminal function selection 26 A6 8

839 DA1 output filter 27 A7 8

840 Torque bias selection 28 A8 8

841 Torque bias 1 29 A9 8

842 Torque bias 2 2A AA 8

843 Torque bias 3 2B AB 8

844 Torque bias filter 2C AC 8

845 Torque bias operation time 2D AD 8

846 Torque bias balance compensation 2E AE 8

847 Fall-time torque bias terminal 1 bias 2F AF 8

848 Fall-time torque bias terminal 1 gain 30 B0 8

849 Analog input offset adjustment 31 B1 8

850 Brake operation selection 32 B2 8

851 Control terminal option-Number of encoder pulses

33 B3 8

852 Control terminal option-Encoder rotation direction

34 B4 8

853 Speed deviation time

35 B5 8

854 Excitation ratio 36 B6 8

855 Control terminal option-Signal loss detection enable/disable selection

37 B7 8

857 DA1-0V adjustment 39 B9 8

858 Terminal 4 function assignment 3A BA 8

859 Torque current/Rated PM motor current 3B BB 8

860 Second motor torque current/Rated PM motor current 3C BC 8

862 Encoder option selection

3E BE 8

863 Control terminal option-Encoder pulse division ratio

3F BF 8

864 Torque detection 40 C0 8

Pr. Name

Instruction code Control method Parameter

R ea

d

W rit

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Ex te

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C le

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A ll

cl ea

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Sp ee

d co

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To rq

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co nt

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V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

APPENDIX 275

11

865 Low speed detection 41 C1 8

866 Torque monitoring reference 42 C2 8

867 AM output filter 43 C3 8

868 Terminal 1 function assignment 44 C4 8

869 Current output filter 45 C5 8

870 Speed detection hysteresis 46 C6 8

872 Input phase loss protection selection 48 C8 8

873 Speed limit 49 C9 8

874 OLT level setting 4A CA 8

875 Fault definition 4B CB 8

876 Thermal protector input 4C CC 8

877 Speed feed forward control/model adaptive speed control selection 4D CD 8

878 Speed feed forward filter 4E CE 8

879 Speed feed forward torque limit 4F CF 8

880 Load inertia ratio 50 D0 8

881 Speed feed forward gain 51 D1 8

882 Regeneration avoidance operation selection 52 D2 8

883 Regeneration avoidance operation level 53 D3 8

884 Regeneration avoidance at deceleration detection sensitivity 54 D4 8

885 Regeneration avoidance compensation frequency limit value 55 D5 8

886 Regeneration avoidance voltage gain 56 D6 8

888 Free parameter 1 58 D8 8 889 Free parameter 2 59 D9 8

891 Cumulative power monitor digit shifted times 5B DB 8

892 Load factor 5C DC 8

893 Energy saving monitor reference (motor capacity) 5D DD 8

894 Control selection during commercial power-supply operation 5E DE 8

895 Power saving rate reference value 5F DF 8

896 Power unit cost 60 E0 8

897 Power saving monitor average time 61 E1 8

898 Power saving cumulative monitor clear 62 E2 8

899 Operation time rate (estimated value) 63 E3 8

C0 (900)

FM/CA terminal calibration 5C DC 1

C1 (901)

AM terminal calibration 5D DD 1

C2 (902)

Terminal 2 frequency setting bias frequency 5E DE 1

C3 (902)

Terminal 2 frequency setting bias 5E DE 1

125 (903)

Terminal 2 frequency setting gain frequency 5F DF 1

C4 (903)

Terminal 2 frequency setting gain 5F DF 1

C5 (904)

Terminal 4 frequency setting bias frequency 60 E0 1

Pr. Name

Instruction code Control method Parameter

R ea

d

W rit

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Ex te

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C op

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C le

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A ll

cl ea

r

Sp ee

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To rq

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co nt

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Sp ee

d co

nt ro

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To rq

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co nt

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V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

276 APPENDIX

C6 (904)

Terminal 4 frequency setting bias 60 E0 1

126 (905)

Terminal 4 frequency setting gain frequency 61 E1 1

C7 (905)

Terminal 4 frequency setting gain 61 E1 1

C12 (917)

Terminal 1 bias frequency (speed) 11 91 9

C13 (917)

Terminal 1 bias (speed) 11 91 9

C14 (918)

Terminal 1 gain frequency (speed) 12 92 9

C15 (918)

Terminal 1 gain (speed) 12 92 9

C16 (919)

Terminal 1 bias command (torque) 13 93 9

C17 (919)

Terminal 1 bias (torque) 13 93 9

C18 (920)

Terminal 1 gain command (torque) 14 94 9

C19 (920)

Terminal 1 gain (torque) 14 94 9

C29 (925)

Motor temperature detection calibration (analog input)

19 99 9

C30 (926)

Terminal 6 bias frequency (speed)

1A 9A 9

C31 (926) Terminal 6 bias (speed) 1A 9A 9

C32 (927)

Terminal 6 gain frequency (speed)

1B 9B 9

C33 (927) Terminal 6 gain (speed) 1B 9B 9

C34 (928)

Terminal 6 bias command (torque)

1C 9C 9

C35 (928) Terminal 6 bias (torque) 1C 9C 9

C36 (929)

Terminal 6 gain command (torque)

1D 9D 9

C37 (929) Terminal 6 gain (torque) 1D 9D 9

C8 (930)

Current output bias signal 1E 9E 9

C9 (930)

Current output bias current 1E 9E 9

C10 (931)

Current output gain signal 1F 9F 9

C11 (931)

Current output gain current 1F 9F 9

C38 (932)

Terminal 4 bias command (torque) 20 A0 9

C39 (932)

Terminal 4 bias (torque) 20 A0 9

C40 (933)

Terminal 4 gain command (torque) 21 A1 9

Pr. Name

Instruction code Control method Parameter

R ea

d

W rit

e

Ex te

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C op

y

C le

ar

A ll

cl ea

r

Sp ee

d co

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To rq

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co nt

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Sp ee

d co

nt ro

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To rq

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co nt

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V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

APPENDIX 277

11

C41 (933)

Terminal 4 gain (torque) 21 A1 9

977 Input voltage mode selection 4D CD 9 989 Parameter copy alarm release 59 D9 9

990 PU buzzer control 5A DA 9

991 PU contrast adjustment 5B DB 9

992 Operation panel setting dial push monitor selection 5C DC 9

994 Droop break point gain 5E DE 9

995 Droop break point torque 5F DF 9

997 Fault initiation 61 E1 9

999 Automatic parameter setting 63 E3 9

1000 Direct setting selection 00 80 A

1003 Notch filter frequency 03 83 A

1004 Notch filter depth 04 84 A

1005 Notch filter width 05 85 A

1006 Clock (year) 06 86 A 1007 Clock (month, day) 07 87 A 1008 Clock (hour, minute) 08 88 A

1015 Integral stop selection at limited manipulated amount 0F 8F A

1016 PTC thermistor protection detection time 10 90 A

1018 Monitor with sign selection 12 92 A

1019 Analog meter voltage negative output selection

13 93 A

1020 Trace operation selection 14 94 A

1021 Trace mode selection 15 95 A

1022 Sampling cycle 16 96 A

1023 Number of analog channels 17 97 A

1024 Sampling auto start 18 98 A

1025 Trigger mode selection 19 99 A

1026 Number of sampling before trigger 1A 9A A

1027 Analog source selection (1ch) 1B 9B A

1028 Analog source selection (2ch) 1C 9C A

1029 Analog source selection (3ch) 1D 9D A

1030 Analog source selection (4ch) 1E 9E A

1031 Analog source selection (5ch) 1F 9F A

1032 Analog source selection (6ch) 20 A0 A

1033 Analog source selection (7ch) 21 A1 A

1034 Analog source selection (8ch) 22 A2 A

1035 Analog trigger channel 23 A3 A

1036 Analog trigger operation selection 24 A4 A

1037 Analog trigger level 25 A5 A

1038 Digital source selection (1ch) 26 A6 A

1039 Digital source selection (2ch) 27 A7 A

1040 Digital source selection (3ch) 28 A8 A

1041 Digital source selection (4ch) 29 A9 A

1042 Digital source selection (5ch) 2A AA A

1043 Digital source selection (6ch) 2B AB A

1044 Digital source selection (7ch) 2C AC A

1045 Digital source selection (8ch) 2D AD A

1046 Digital trigger channel 2E AE A

1047 Digital trigger operation selection 2F AF A

Pr. Name

Instruction code Control method Parameter

R ea

d

W rit

e

Ex te

nd ed

C op

y

C le

ar

A ll

cl ea

r

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

278 APPENDIX

1048 Display-off waiting time 30 B0 A

1049 USB host reset 31 B1 A

1072 Tension reverse selection 48 C8 A

1103 Deceleration time at emergency stop 03 83 B

1106 Torque monitor filter 06 86 B

1107 Running speed monitor filter 07 87 B

1108 Excitation current monitor filter 08 88 B

1109 PROFIBUS communication command source selection

09 89 B

1110 PROFIBUS format selection 0A 8A B

1113 Speed limit method selection 0D 8D B

1114 Torque command reverse selection 0E 8E B

1115 Speed control integral term clear time 0F 8F B

1116 Constant output range speed control P gain compensation 10 90 B

1117 Speed control P gain 1 (per-unit system) 11 91 B

1118 Speed control P gain 2 (per-unit system) 12 92 B

1119 Model speed control gain (per-unit system) 13 93 B

1121 Per-unit speed control reference frequency 15 95 B

1134 PID upper limit manipulated value 22 A2 B

1135 PID lower limit manipulated value 23 A3 B

1136 Tension sensor feedback voltage/ current bias 24 A4 B

1137 Tension sensor feedback bias 25 A5 B

1138 Tension sensor feedback voltage/ current gain 26 A6 B

1139 Tension sensor feedback gain 27 A7 B

1140 Signed winding diameter compensation torque command selection

28 A8 B

1141 Line speed command acceleration/ deceleration pattern 29 A9 B

1142 Line speed command acceleration start S-curve time 2A AA B

1143 Line speed command acceleration completion S-curve time 2B AB B

1144 Line speed command deceleration start S-curve time 2C AC B

1145 Line speed command deceleration completion S-curve time 2D AD B

1146 Line speed command input filter time constant 2E AE B

1147 Line speed command maximum value 2F AF B

1148 PID manipulated line speed bias 30 B0 B

1149 PID manipulated line speed gain 31 B1 B

1150 User parameters 1 32 B2 B

1151 User parameters 2 33 B3 B

1152 User parameters 3 34 B4 B

1153 User parameters 4 35 B5 B

1154 User parameters 5 36 B6 B

1155 User parameters 6 37 B7 B

Pr. Name

Instruction code Control method Parameter

R ea

d

W rit

e

Ex te

nd ed

C op

y

C le

ar

A ll

cl ea

r

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

APPENDIX 279

11

1156 User parameters 7 38 B8 B

1157 User parameters 8 39 B9 B

1158 User parameters 9 3A BA B

1159 User parameters 10 3B BB B

1160 User parameters 11 3C BC B

1161 User parameters 12 3D BD B

1162 User parameters 13 3E BE B

1163 User parameters 14 3F BF B

1164 User parameters 15 40 C0 B

1165 User parameters 16 41 C1 B

1166 User parameters 17 42 C2 B

1167 User parameters 18 43 C3 B

1168 User parameters 19 44 C4 B

1169 User parameters 20 45 C5 B

1170 User parameters 21 46 C6 B

1171 User parameters 22 47 C7 B

1172 User parameters 23 48 C8 B

1173 User parameters 24 49 C9 B

1174 User parameters 25 4A CA B

1175 User parameters 26 4B CB B

1176 User parameters 27 4C CC B

1177 User parameters 28 4D CD B

1178 User parameters 29 4E CE B

1179 User parameters 30 4F CF B

1180 User parameters 31 50 D0 B

1181 User parameters 32 51 D1 B

1182 User parameters 33 52 D2 B

1183 User parameters 34 53 D3 B

1184 User parameters 35 54 D4 B

1185 User parameters 36 55 D5 B

1186 User parameters 37 56 D6 B

1187 User parameters 38 57 D7 B

1188 User parameters 39 58 D8 B

1189 User parameters 40 59 D9 B

1190 User parameters 41 5A DA B

1191 User parameters 42 5B DB B

1192 User parameters 43 5C DC B

1193 User parameters 44 5D DD B

1194 User parameters 45 5E DE B

1195 User parameters 46 5F DF B

1196 User parameters 47 60 E0 B

1197 User parameters 48 61 E1 B

1198 User parameters 49 62 E2 B

1199 User parameters 50 63 E3 B

1211 Tension PI gain tuning timeout time 0B 8B C

1215 Limit cycle output upper limit 0F 8F C

1217 Limit cycle hysteresis 11 91 C

1219 Tension PI gain tuning start/status 13 93 C 1222 Target amplitude 16 96 C

1223 Manipulated amount for operation 17 97 C

1226 Tension PI gain tuning response level setting 1A 9A C

1227 Dancer / tension sensor feedback input filter time constant 1B 9B C

Pr. Name

Instruction code Control method Parameter

R ea

d

W rit

e

Ex te

nd ed

C op

y

C le

ar

A ll

cl ea

r

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

280 APPENDIX

1230 Winding/unwinding selection 1E 9E C

1231 Material thickness d1 1F 9F C

1232 Material thickness d2 20 A0 C

1233 Material thickness d3 21 A1 C

1234 Material thickness d4 22 A2 C

1235 Maximum winding diameter 1 23 A3 C

1236 Minimum winding diameter 1 24 A4 C

1237 Maximum winding diameter 2 25 A5 C

1238 Minimum winding diameter 2 26 A6 C

1239 Maximum winding diameter 3 27 A7 C

1240 Minimum winding diameter 3 28 A8 C

1241 Maximum winding diameter 4 29 A9 C

1242 Minimum winding diameter 4 2A AA C

1243 Gear ratio numerator 2B AB C

1244 Gear ratio denominator 2C AC C

1245 Sampling time for winding diameter calculation 2D AD C

1246 Line speed at winding diameter calculated value activation 2E AE C

1247 Winding diameter change increment amount limit 2F AF C

1248 Winding diameter change limit disable time 30 B0 C

1249 Number of averaging for winding diameter calculation 31 B1 C

1250 Winding diameter compensation speed filtering waiting time 32 B2 C

1251 Winding diameter compensation speed filter time constant 33 B3 C

1252 Dancer lower limit position 34 B4 C

1253 Initial winding diameter calculation deadband 35 B5 C

1254 Initial winding diameter calculation deadband 2 36 B6 C

1255 Accumulated amount 37 B7 C

1256 Speed control P gain at start 38 B8 C

1257 Speed control integral time at start 39 B9 C

1258 Integral term limit at start 3A BA C

1259 PID term limit at start 3B BB C

1262 Winding length increment 3E BE C

1263 Stored winding length (lower 4 digits) 3F BF C

1264 Winding length detection (lower 4 digits) 40 C0 C

1265 Line multi-speed setting (high-speed) 41 C1 C

1266 Line multi-speed setting (middle- speed) 42 C2 C

1267 Line multi-speed setting (low-speed) 43 C3 C

1268 Line multi-speed setting (speed 4) 44 C4 C

1269 Line multi-speed setting (speed 5) 45 C5 C

1270 Line multi-speed setting (speed 6) 46 C6 C

1271 Line multi-speed setting (speed 7) 47 C7 C

1272 Line multi-speed setting (speed 8) 48 C8 C

1273 Line multi-speed setting (speed 9) 49 C9 C

1274 Line multi-speed setting (speed 10) 4A CA C

1275 Line multi-speed setting (speed 11) 4B CB C

1276 Line multi-speed setting (speed 12) 4C CC C

Pr. Name

Instruction code Control method Parameter

R ea

d

W rit

e

Ex te

nd ed

C op

y

C le

ar

A ll

cl ea

r

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

APPENDIX 281

11

1277 Line multi-speed setting (speed 13) 4D CD C

1278 Line multi-speed setting (speed 14) 4E CE C

1279 Line multi-speed setting (speed 15) 4F CF C

1280 Winding diameter monitoring reference 50 D0 C

1281 Commanded tension monitoring reference 51 D1 C

1282 Tension command cushion time 52 D2 C

1283 Cushion time reference tension 53 D3 C

1284 Taper mode selection 54 D4 C

1285 Taper setting analog input selection 55 D5 C

1286 Winding diameter at taper start 56 D6 C

1287 Taper ratio setting 57 D7 C

1288 Data table winding diameter 1 58 D8 C

1289 Data table taper ratio 1 59 D9 C

1290 Data table winding diameter 2 5A DA C

1291 Data table taper ratio 2 5B DB C

1292 Data table winding diameter 3 5C DC C

1293 Data table taper ratio 3 5D DD C

1294 Data table winding diameter 4 5E DE C

1295 Data table taper ratio 4 5F DF C

1296 Data table winding diameter 5 60 E0 C

1297 Data table taper ratio 5 61 E1 C

1298 Stored winding length (upper 4 digits) 62 E2 C

1299 Stored winding length increment 63 E3 C

1346 Winding length detection (upper 4 digits) 2E AE D

1348 P/PI control switchover frequency 30 B0 D

1349 Emergency stop operation selection 31 B1 D

1382 PID set point cushion time 52 D2 D

1383 PID torque control manipulated tension bias [N] 53 D3 D

1384 PID torque control manipulated tension gain [N] 54 D4 D

1401 Tension command increment 01 81 E

1402 Tension command input voltage bias 02 82 E

1403 Tension command bias 03 83 E

1404 Tension command input voltage gain 04 84 E

1405 Tension command gain 05 85 E

1406 Commanded tension reduction scaling factor during stall condition 06 86 E

1407 Speed limit during stall condition 07 87 E

1409 Tension command cushion time during stall condition 09 89 E

1410 Motor inertia 0A 8A E

1411 Empty reel inertia 0B 8B E

1412 Roll width 0C 8C E

1413 Material specific gravity 0D 8D E

1414 First acceleration time for inertia compensation 0E 8E E

1415 First deceleration time for inertia compensation 0F 8F E

1418 Inertia compensation cushion time 12 92 E

1419 Mechanical loss setting frequency bias 13 93 E

1420 Mechanical loss setting frequency 1 14 94 E

Pr. Name

Instruction code Control method Parameter

R ea

d

W rit

e

Ex te

nd ed

C op

y

C le

ar

A ll

cl ea

r

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

Sp ee

d co

nt ro

l

To rq

ue

co nt

ro l

V /F

V /F

V /F

Ma gn

eti c f

lux Ma

gn eti

c f lux

Ma gn

eti c f

lux

Vector Sensorless

Parameters (functions) and instruction codes under different control methods

282 APPENDIX

1421 Mechanical loss 1 15 95 E

1422 Mechanical loss setting frequency 2 16 96 E

1423 Mechanical loss 2 17 97 E

1424 Mechanical loss setting frequency 3 18 98 E

1425 Mechanical loss 3 19 99 E

1426 Mechanical loss setting frequency 4 1A 9A E

1427 Mechanical loss 4 1B 9B E

1428 Mechanical loss setting frequency 5 1C 9C E

1429 Mechanical loss 5 1D 9D E

1480 Load characteristics measurement mode 50 D0 E

1481 Load characteristics load reference 1 51 D1 E

1482 Load characteristics load reference 2 52 D2 E

1483 Load characteristics load reference 3 53 D3 E

1484 Load characteristics load reference 4 54 D4 E

1485 Load characteristics load reference 5 55 D5 E

1486 Load characteristics maximum frequency 56 D6 E

1487 Load characteristics minimum frequency 57 D7 E

1488 Upper limit warning detection width 58 D8 E

1489 Lower limit warning detection width 59 D9 E

1490 Upper limit fault detection width 5A DA E

1491 Lower limit fault detection width 5B DB E

1492 Load status detection signal delay time / load reference measurement waiting time

5C DC E

1499 Parameter for manufacturer setting. Do not set.

Pr. Name

Instruction code Control method Parameter

R ea

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Ex te

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C le

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A ll

cl ea

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co nt

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Sp ee

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To rq

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co nt

ro l

V /F

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Vector Sensorless

Index

APPENDIX 283

11

11.8 Index

A Acceleration/deceleration time selection for line speed command (X105 signal, X106 signal) .................................................. 79, 227 Acceleration/deceleration time setting for line speed command. 79 Actual line speed (monitoring) .................................................. 218 Actual line speed 2 (monitoring) ............................................... 218 Actual line speed detection signal..................................... 199, 227 Analog input signals and pulse train input signals ...................... 47 Analog output signal for dancer tension control (monitoring).... 218 Analog output signal function for dancer tension control .......... 108 Average current load detection ..................................................... 8

B Break detection (Y231 signal) ............................. 89, 127, 180, 230

D Dancer compensation line speed (monitoring) ......................... 218 Dancer compensation speed (monitoring) ................................ 218 Dancer position / tension feedback detection (Y235 signal)............................................................... 88, 126, 230 Dancer roll position detection signal ......................................... 227 Dancer roll target position signal......................................... 85, 227 Dancer signal input selection ...................................................... 85

I Inertia compensation................................................................. 157 Inertia compensation (monitoring) ............................................ 218 Inertia compensation acceleration (X111 signal) ...................... 157 Inertia compensation deceleration (X112 signal) ...................... 157 Inertia compensation second acceleration/deceleration time (X113 signal)............................................................................. 157 Initial winding diameter calculation at a start (dancer feedback speed control) ........................................................................... 208 Initial winding diameter calculation at a start (tension sensorless torque control) ........................................................................... 212 Input signal list .......................................................................... 227 Integral term activation selection (X103 signal) ................ 100, 227

L Line speed acceleration (Y237 signal)...................................... 157 Line speed at winding diameter calculated value activation ..... 204 Line speed command.......................................................... 67, 227 Line speed command (monitoring) ........................................... 218 Line speed command acceleration/deceleration pattern ............ 82 Line speed command input......................................................... 67 Line speed command input (compensation) ............................... 76 Line speed command input by analog input ............................... 67 Line speed deceleration (Y238 signal)...................................... 157 Line speed pulse (monitoring)................................................... 218

M Measured winding diameter input (X122 signal) ....................... 212 Mechanical loss compensation ................................................. 163 Mechanical loss compensation (monitoring)............................. 218 Mechanical loss compensation function ................................... 163 Minimum/maximum winding diameter selection (X107 signal, X108 signal) ........................................ 203, 206, 227 Monitor list................................................................................. 218

O Offset displacement storage (X102 signal) ................. 88, 126, 227 Operation command source and speed command source (Pr.338, 339) ............................................................................. 233 Output signal list ....................................................................... 230

P PID action selection (Pr.128) .............................................. 65, 177 PID compensation disabled (X116 signal) .................. 65, 177, 227 PID gain switchover (X120 signal, X121 signal) ............... 101, 227 PID integral term reset input (X100 signal) ............................... 100 PID lower limit (FDN signal) ................................ 89, 127, 180, 230 PID measured tension (monitoring) .......................................... 218 PID offset displacement ...................................................... 88, 126 PID torque control actual tension.............................................. 218 PID torque control manipulated tension.................................... 218 PID upper limit (FUP signal) ............................... 89, 127, 180, 230

R Reel change (X104 signal)........................................................ 106

S SND rating .................................................................................... 8 Speed control proportional gain disabled (X124 signal) ..................................................................... 216, 227 Speed control proportional gain selection according to the winding diameter calculation result ........................................................ 216 Stall mode function ................................................................... 165 Stall mode trigger (X123 signal)................................................ 165 Stored winding diameter clear (X109 signal) .................... 213, 227

T Taper function ........................................................................... 151 Target winding diameter achieved (Y233 signal) .............. 208, 230 Tension control selection (X114 signal) ...... 65, 139, 177, 194, 227 Tension PI gain tuning ................................................................ 91 Tension sensor feedback torque control function selection ...... 177 Terminal 1 input voltage (monitoring) ....................................... 218

W Winding diameter (monitoring).................................................. 218 Winding diameter calculation and winding diameter compensation function ..................................................................................... 195 Winding diameter calculation completion (Y232 signal) ............................................................. 208, 212, 230 Winding diameter calculation completion signal ............... 208, 212 Winding diameter calculation using actual line speed (actual line speed method) .......................................................................... 199 Winding diameter compensation selection (X115 signal) . 197, 227 Winding diameter compensation speed (monitoring)................ 218 Winding diameter compensation torque command (monitoring)............................................................................... 218 Winding length (monitoring) ...................................................... 218 Winding length clear (X117 signal) ................................... 213, 227 Winding/unwinding shaft selection...................................... 67, 178

284

REVISIONS *The manual number is given on the bottom left of the back cover.

Revision date *Manual number Revision Jan. 2016 IB(NA)-0600622ENG-A First edition Jun. 2016 IB(NA)-0600622ENG-B Added

Calibration parameters for the compensation value added to the line speed command (Pr.635 to Pr.638)

Oct. 2017 IB(NA)-0600622ENG-C Added PID upper/lower limit hysteresis width (Pr.137) Empty reel inertia (integer/exponent) (Pr.753, Pr.754) Parameters related to cumulative pulse (Pr.755 to Pr.758) Winding length increment selection (cm/mm) (Pr.1262 = "4, 5") Parameters related to stored winding length (Pr.1298, Pr.1299) Winding length detection (upper 4 digits) (Pr.1346)

Aug. 2018 IB(NA)-0600622ENG-D Added Parameters (Pr.85, Pr.86, Pr.565, Pr.566, Pr.617, Pr.675, Pr.801, Pr.1348,

Pr.1349, Pr.1480 to Pr.1492) Parameter setting range (Pr.14, Pr.52, Pr.75, Pr.178 to Pr.189, Pr.190 to

Pr.196, Pr.288, Pr.414, Pr.502, Pr.681, Pr.774 to Pr.776, Pr.803, Pr.992) Tension sensor feedback torque control Speed control of intermediate shafts Application examples

Jun. 2019 IB(NA)-0600622ENG-E Added Parameters (Pr.1134, Pr.1135, Pr.1140) Monitoring of the wiring length (upper 4 digits) supported by

FR Configurator2. Functions available during tension sensor feedback torque control (Pr.424,

Pr.553, Pr.554, RL signal, PID signal, Y48 signal) Edited Parameter initial setting (Pr.353) Parameter setting range (Pr.54, Pr.365, Pr.366, Pr.1137, Pr.1139, Pr.1281,

Pr.1283, Pr.1403, Pr.1405) May 2021 IB(NA)-0600622ENG-F Added

Parameters (Pr.398, Pr.609, Pr.610, Pr.1141 to Pr.1149, Pr.1382 to Pr.1384)

Edited Parameter initial setting (Pr.1148) Parameter setting range (Pr.52, Pr.54, Pr.158, Pr.774 to Pr.776, Pr.992,

Pr.1027 to Pr.1034) Nov. 2021 IB(NA)-0600622ENG-G Added

Speed control of reference shaft

IB(NA)-0600622ENG-G

Roll to Roll Function

800-R2R

IN VER

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800 Plus

IN STR

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TIO N

M A

N U

A L (R

O LL TO

R O

LL FU N

C TIO

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ROLL TO ROLL FUNCTION MANUAL FR-A820-00046(0.4K)-04750(90K)-R2R FR-A840-00023(0.4K)-06830(280K)-R2R FR-A842-07700(315K)-12120(500K)-R2R

The FR-A800-R2R inverter has dedicated functions for roll to roll applications, in addition to the functions of the standard type FR-A800 inverter. This Roll to Roll Function Manual explains the functions dedicated to the FR-A800-R2R inverter. For the functions not found in this Function Manual, refer to the Instruction Manual of the FR-A800 inverter. In addition to this Roll to Roll Func

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