Drive

Application
Software

Function Module

Diameter Calculation
Imperial Units

Reference Manual
FM Inertia Compensation

Important User Information

Users of this Reference Manual must be familiar with the application this Function Module is
intended to support and its usage. Function Modules intended usage are as a building blocks for
a created application. The user must be familiar with the programming tools used to implement
this module, the program platform to be used in the application, and the Rockwell Automation
drive products to be controlled in the application.

Because of the variety of uses for the products described in this publication, those responsible for
the application and use of this control equipment must satisfy themselves that all necessary steps
have been taken to assure that each application and use meets all performance and safety
requirements, including any applicable laws, regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown in this guide are intended
solely for purposes of example. Since there are many variables and requirements associated with
any particular installation, Rockwell Automation does not assume responsibility or liability (to
include intellectual property liability) for actual use based upon the examples shown in this
publication.

Rockwell Automation publication SGI-1.1, Safety Guidelines for the Application, Installation, and
Maintenance of Solid-State Control (available from your local Rockwell Automation office),
describes some important differences between solid-state equipment and electromechanical
devices that should be taken into consideration when applying products such as those described
in this publication.

Reproduction of the contents of this copyrighted publication, in whole or in part, without written
permission of Rockwell Automation, is prohibited.

Trademarks
RSLogix5000 is a trademark of Rockwell Automation
PowerFlex is a trademark of Rockwell Automation

Application Software page 2 of 30

 FM Diameter Calculation

Table of Contents

1.0 Precautions ............................................................................................................5

2.0 Definitions ..............................................................................................................6
2.1 Conventions ..........................................................................................................6
2.2 Normalized Quantities...........................................................................................6
2.3 Terminology ..........................................................................................................7
2.3.1 Web .................................................................................................................................... 7
2.3.2 Strip .................................................................................................................................... 7
2.3.3 Drive ................................................................................................................................... 7
2.3.4 Motor Torque....................................................................................................................... 7
2.3.5 Section................................................................................................................................ 7
3.0 Overview .................................................................................................................8
3.1 Diameter effects on surface speed .......................................................................8
3.2 Diameter effects on surface tension......................................................................9
4.0 Functional Description ........................................................................................10
4.1 Overview .............................................................................................................10
4.1.1 Main routine .......................................................................................................................10
4.1.2 DiamPreset routine.............................................................................................................10
4.1.3 DiamCalc routine................................................................................................................10
4.2 Main routine ........................................................................................................10
4.3 DiamPreset routine .............................................................................................11
4.3.1 Preset1Cmmd ....................................................................................................................11
4.3.2 Preset2Cmmd ....................................................................................................................11
4.3.3 Preset3Cmmd ....................................................................................................................11
4.3.4 Preset1Val_in.....................................................................................................................12
4.3.5 Preset2Val_in.....................................................................................................................12
4.3.6 Preset3Val_in.....................................................................................................................12
4.3.7 PresetIncCmmd..................................................................................................................12
4.3.8 PresetDecCmmd................................................................................................................12
4.3.9 PresetIncDecRate_inSec....................................................................................................12
4.3.10 DiamPresetCmmd ..............................................................................................................12
4.3.11 DiamPresetVal_in...............................................................................................................13
4.4 DiamCalc routine ................................................................................................13
4.4.1 CalcEnbl.............................................................................................................................14
4.4.2 CalcEnblThresh_FPM.........................................................................................................15
4.4.3 CalcUpdate_Rev ................................................................................................................15
4.4.4 SpeedLine_FPM.................................................................................................................15
4.4.5 SpeedMotor_Rpm ..............................................................................................................15
4.4.6 GearRatio...........................................................................................................................15
4.4.7 DiamMinEC_in ...................................................................................................................15
4.4.8 DiamFR_in .........................................................................................................................15
4.4.9 DiamMeasEnbl ...................................................................................................................16
4.4.10 DiamMeasInput ..................................................................................................................16
4.4.11 DiamMeasMin_DC .............................................................................................................16
4.4.12 DiamMeasMax_DC ............................................................................................................16
4.4.13 DiamMeasMin_in................................................................................................................16
4.4.14 DiamMeasMax_in...............................................................................................................16
Drive Application Software page 3 of 30
FM Inertia Compensation

4.4.15 DiamPresetCmmd..............................................................................................................16
4.4.16 DiamPresetVal_in ..............................................................................................................16
4.4.17 DiamRate_inRev ................................................................................................................17
4.4.18 DiamIncEnbl.......................................................................................................................17
4.4.19 DiamDecEnbl .....................................................................................................................17
4.4.20 DiamCalc_in.......................................................................................................................17
4.4.21 RadiusCalc_ft.....................................................................................................................17
4.4.22 BuildUpRatio......................................................................................................................18
4.4.23 BuildUpRatioRec................................................................................................................18
4.4.24 DiamMeas_in.....................................................................................................................18
4.4.25 Constant_RPMperFPM ......................................................................................................18
4.4.26 Constant_RPMperFPM ......................................................................................................18
5.0 Setup / Configuration ..........................................................................................19
5.1 Overview.............................................................................................................19
5.2 DiamPreset JSR Instruction................................................................................19
5.2.1 Input Parameters................................................................................................................19
5.2.2 Return Parameters.............................................................................................................19
5.2.3 Default Tags used in Drive Application Software.................................................................20
5.3 DiamCalc JSR Instruction...................................................................................20
5.3.1 Input Parameters................................................................................................................20
5.3.2 Return Parameters.............................................................................................................21
5.3.3 Default Tags used in Drive Application Software.................................................................22
6.0 Tuning / Startup ...................................................................................................23
6.1 Installing the Application Module ........................................................................23
6.2 Drive Tuning & Configuration..............................................................................23
6.3 Offline Tuning / Startup.......................................................................................24
6.4 Online Tuning / Startup.......................................................................................24
6.4.1 Measured Diameter Enable True........................................................................................24
6.4.2 Measured Diameter Enable False (typical configuration).....................................................24
Appendix A - Process Line Command & Status Words..........................................26
Appendix B - Block Diagram .....................................................................................28
Appendix C - Parameter (Tag) Table ........................................................................29

Drive Application Software page 4 of 30

 FM Diameter Calculation

1.0 Precautions

Class 1 LED Product

ATTENTION: Hazard of permanent eye damage exists when using optical transmission
equipment. This product emits intense light and invisible radiation. Do not look into
module ports or fiber optic cable connectors.

General Precautions
ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and
assemblies. Static control precautions are required when installing, testing, servicing or
repairing this assembly. Component damage may result if ESD control procedures are
not followed. If you are not familiar with static control procedures, reference Allen Bradley
publication 8000-4.5.2, Guarding Against Electrostatic Damage or any other applicable
ESD protection handbook.

ATTENTION: An incorrectly applied or installed drive can result in component damage or

a reduction in product life. Wiring or application errors such as under sizing the motor,
incorrect or inadequate AC supply, or excessive surrounding air temperatures may result
in malfunction of the system.

ATTENTION: Only qualified personnel familiar with the PowerFlex 700S AC Drive and
associated machinery the products control should plan, program, configure, or implement
the installation, start-up and subsequent maintenance of the system / product. Failure to
comply may result in personal injury and/or equipment damage.

ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus
capacitors has discharged before performing any work on the drive. Measure the DC bus
voltage at the +DC & DC terminals of the Power Terminal Block (refer to Chapter 1 in the
PowerFlex 700S User Manual for location). The voltage must be zero.

ATTENTION: Risk of injury or equipment damage exists. DPI or SCANport host products
must not be directly connected together via 1202 cables. Unpredictable behavior can
result if two or more devices are connected in this manner.

ATTENTION: Risk of injury or equipment damage exists. Parameters 365 [Encdr0 Loss
Cnfg] - 394 [VoltFdbkLossCnfg] let you determine the action of the drive in response to
operating anomalies. Precautions should be taken to ensure that the settings of these
parameters do not create hazards of injury or equipment damage.

ATTENTION: Risk of injury or equipment damage exists. Parameters 383 [SL CommLoss
Data] - 392 [NetLoss DPI Cnfg] let you determine the action of the drive if communications
are disrupted. You can set these parameters so the drive continues to run. Precautions
should be taken to ensure the settings of these parameters do not create hazards of injury
or equipment damage.

Drive Application Software page 5 of 30

FM Inertia Compensation

2.0 Definitions
A Function Module [FM] is a base program designed to perform a specific function (operation) in
an application. Function Modules are not complete applications and will require additional
programming to control a machine section. The additional programming required for the
application and configuration of the overall application is the responsibility of the user.

An Application Module [AM] is a complete program designed to perform a specific machine

sections application (task). Application Modules are complete programs and only require
configuration setup in order to perform the designated tasks.

2.1 Conventions
The conventions described below are used in programming and documentation of Function
Modules and Application Modules.

1. All FM tags are program scoped.

2. All user connections to the FM are through the Jump to Sub-Routine (JSR)
instruction input and return parameters.
3. Users cannot edit Function Modules.
4. Data format

Data Type RSLogix Type Format Range Example

B = Boolean BOOL x 0 to 1 0 or 1
I = Integer INT x +/- 32767 8947
D = Double INT DINT x +/- 2097151 74364
R = Real (Float) REAL x.x +/-16777215* 3.4 / 13.0
* = Applies to single precision accuracy.

2.2 Normalized Quantities

Often a physical quantity is normalized by dividing the physical quantity by a base quantity
with the same engineering units as the physical quantity. As a result, the normalized quantity
does not have units, but is expressed per-unit. The normalized quantity has a value of 1.0
[per-unit] when the physical quantity has a value equal to the base quantity.

A good example of this is the physical quantity of motor current. The information that the
motor is drawing 40 amps has little significance. The motor nameplate states that the rated
motor current is 30 amps. The motor is drawing 133% current is significant information. In
the previous illustration the quantity of motor amps was normalized to 133%. In per unit, the
quantity is normalized to 1.33.

Drive Application Software page 6 of 30

 FM Diameter Calculation

2.3 Terminology

2.3.1 Web
A web is defined as the material that is being transported through the machine. A
web is sometimes referred to as sheet or strip.

2.3.2 Strip
The strip is defined as the material that is being transported through the machine. A
web is sometimes referred to as sheet or web. The term strip tension is
referencing the tension of the material in the machine.

2.3.3 Drive
The drive is the power device that is transmitting power to the motor. The motor is
connected to a mechanical device that is propelling the material. This manual is
specific to the PowerFlex 700S drive.

2.3.4 Motor Torque

A D.C. Motor has two currents flowing through it. The first current is the flux, also
known as the field current. This is the magnetizing current that allows the motor to
produce torque. The second current is the armature current. This is the actual
torque producing current of the motor.

An A.C. motor has only one current physically flowing through the machine.
However, this current is a combination of both magnetizing and torque producing
current. Motor Torque on an AC motor is the torque producing portion of the total
current flowing through the motor.

2.3.5 Section
A Web Handling Machine is broken up into sections. A section consists of one or
more drives used to propel the material through the line.

An Unwind Section could consist of one drive, one motor, and one spindle

A lead Section could consist of more than one drive and one motor combination.
This could consist of line pacer and then several helper drives. The helper drives
help in transporting the strip through the machine.

Typically when more than one drive is in a section, one drive is the leader and the
other drive is the follower. The follower typically follows the leaders torque
reference.

Drive Application Software page 7 of 30

FM Inertia Compensation

3.0 Overview
Diameter calculation is the process by which a dynamically changing roll diameter is
mathematically calculated during machine operation. In center driven winding and unwinding
applications, the actual diameter of the driven section changes as product is wound about the axis
or unwound from the axis. As the diameter of the driven section changes it is necessary to
change the axial speed and torque in order to maintain constant surface speed and tension on the
product. Diameter calculation can also be used to calculate the change in total reflected inertia.
This is typically used to profile the speed loop gain and in inertia compensation.

3.1 Diameter effects on surface speed

If the rotational speed of the driven section is kept constant, the surface speed will increase
as the diameter of the section increases. To maintain constant surface speed, the rotational
speed must decrease proportional to the increase in roll diameter. If the roll diameter
doubles, the rotational speed must be reduced by half to maintain constant surface speed.

2000
1800
1600
1400
1200
Speed

Motor Speed (Rpm)

1000
Surface Spd (Fpm)
800
600
400
200
0
4 8 12 16 20 24 28 32 36 40 44 48 52
Roll Diameter (in)

RollDiameter(in)
RollDiameter(ft) =
12

LineSpeed(Fpm)
MotorSpeed(Rpm) = *GearRatio
RollDiameter(ft)*p

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 FM Diameter Calculation

3.2 Diameter effects on surface tension

If the torque applied to a driven section is kept constant, the tension applied to the product at
the surface of the roll will decrease as the diameter of the driven section increases. To
maintain constant tension on the product, the torque must be increased proportional to the
change in diameter. If the roll diameter doubles the torque applied must double to maintain
constant product tension at the surface of the roll.

120

100
Torque / Tension

80
Surface Tension (lbs)
60
Motor Torque (lbft)
40

20

0
4 8 12 16 20 24 28 32 36 40 44 48 52
Roll Diameter

RollDiameter(in)
RollDiameter(ft) =
12

RollDiameter(ft)
RollRadius(ft) =
2

RollRadius(ft)*Tension(lbs)
MotorTorque(lbft) =
GearRatio

Drive Application Software page 9 of 30

FM Inertia Compensation

4.0 Functional Description

4.1 Overview
The Diameter Calculation Function Module consists of a program with three routines in
RSLogix 5000. The three routines are the Main, DiamPreset, & DiamCalc. These routines
are dependent on one another and may not be separated. The user may edit the Main
routine to connect signals (tags) and configure the FM. The user cannot edit the DiamPreset
or DiamCalc routines.

4.1.1 Main routine

The Main routine is where the user connects user created controller tags to the input
and output program tags of the FM. These links are created in the Jump to Sub-
Routine (JSR) instructions. One JSR is used to call the DiamPreset routine and
another JSR is used to call the DiamCalc routine.

4.1.2 DiamPreset routine

The DiamPreset routine is used to select and command a preset value to the
diameter calculator. Diameter preset is used to reset the roll diameter to a preset
value such as core diameter as used in winder applications or to the starting roll
diameter as used in unwind applications. If the diameter calculator is not preset to
the correct starting roll diameter, the machine control may not function correctly.

4.1.3 DiamCalc routine

The DiamCalc routine is where the diameter is actually calculated. The diameter is
calculated by measuring the distance of web wound onto the roll for a given number
of roll revolutions. Setting the number of roll revolutions to a whole number, helps
avoid variations in diameter calculation with eccentric rolls.

4.2 Main routine

The Main routine consists of two rungs of ladder logic programming. A rung description
briefly describes the Input and Return (output) parameters of the JSR instructions for each
routine called. Temporary tags have been entered for each input parameter and each return
parameter. The tag names entered in the JSRs are not declared. The user must replace
these tag names with existing project tags or create new tags. The routine will show an error
until all input and return parameters are satisfied. The input parameters may also be entered
as actual values. If an input parameter is set to a value and not a tag, the value cannot be
edited in run mode. Values entered directly in the JSR should be constants that do not
change during machine operation. Specific formatting is required for values entered directly
in the JSR.
NOTE: For Application Module users, the tags in the JSRs are predefined and configured for
operation. No additional integration is necessary.

Data Type Format Example

B = Boolean x 0 or 1
I = Integer x 123
R = Real (Float) x.x 3.4 / 13.0

If any signal scaling is required to interface the FM into the user application, the user may use
the main routine for this programming. Note; any scaling for inputs to the routines should be
done before the JSR and any scaling applied to the return values from the routines should be
done after the JSR.
Below are descriptions of each parameter required for use of the Diameter Calculation FM.

Drive Application Software page 10 of 30

 FM Diameter Calculation

4.3 DiamPreset routine

The diameter preset routine is designed for applications where the diameter calculator will be
preset to one of several preset diameters or where a preset increase/decrease function is
required. If only a single diameter preset is required, this routine and the JSR instruction can
be deleted. If the DiamPreset routine is deleted, the (DiamCalc In15 & In16) inputs
[yDiamPresetCmmd] & [yDiamPresetVal_in] must be controlled by the users custom
programming. If the diameter is not properly preset, the machine section may not be able to
regulate product tension in the process.

Input Parameters
Name Type Range Description
1 Preset1Cmmd BOOL 0 to 1 Preset diameter to Preset1Val_in
2 Preset2Cmmd BOOL 0 to 1 Preset diameter to Preset2Val_in
3 Preset3Cmmd BOOL 0 to 1 Preset diameter to Preset3Val_in
4 Preset1Val_in REAL 0 to 500 Value of Preset 1
5 Preset2Val_in REAL 0 to 500 Value of Preset 2
6 Preset3Val_in REAL 0 to 500 Value of Preset 3
7 PresetIncCmmd BOOL 0 to 1 Manual Diameter Increase
8 PresetDecCmmd BOOL 0 to 1 Manual Diameter Decrease
Manual Diameter Increase/Decrease
9 PresetIncDecRate_inSec REAL 0 to 10
Rate adjustment

Return Parameters
Name Type Range Description
Diameter Preset Command to
1 DiamPresetCmmd BOOL 0 to 1
DiamCalc routine
Diameter Preset Value to DiamCalc
2 DiamPresetVal_in REAL 0 to 500
routine

4.3.1 Preset1Cmmd
This input is the command to the routine to select the Preset1Val_in as the output
DiamPresetVal_in. When this input is high and EnablePresets is high the
DiamPresetCmmd will be set high and the DiamPresetVal_in will be set equal to
Preset1Val_in.
Usage Use this input to activate the value of Preset1Val_in as the preset input to
the DiamCalc routine.

4.3.2 Preset2Cmmd
This input is the command to the routine to select the Preset2Val_in as the output
DiamPresetVal_in. When this input is high and EnablePresets is high the
DiamPresetCmmd will be set high and the DiamPresetVal_in will be set equal to
Preset2Val_in.
Usage Use this input to activate the Preset2Val_in as the preset value of the
DiamCalc routine.

4.3.3 Preset3Cmmd
This input is the command to the routine to select the Preset3Val_in as the output
DiamPresetVal_in. When this input is high and EnablePresets is high the
DiamPresetCmmd will be set high and the DiamPresetVal_in will be set equal to
Preset3Val_in.
Usage Use this input to activate the Preset3Val_in as the preset value of the
DiamCalc routine.
Drive Application Software page 11 of 30
FM Inertia Compensation

4.3.4 Preset1Val_in
The value of Preset1 entered in inches of roll diameter. This value will be sent to the
diameter calculator when Preset1Cmmd is set high.
Usage Set this vale for the smallest roll diameter used when presetting the
diameter calculator in Winder applications. For Unwind applications, set to the
largest diameter used when presetting the diameter calculator.

4.3.5 Preset2Val_in
The value of Preset2 entered in inches of roll diameter. This value will be sent to the
diameter calculator when Preset2Cmmd is set high.
Usage Set this value to the diameter in inches to be used for Preset2Cmmd.

4.3.6 Preset3Val_in
The value of Preset3 entered in inches of roll diameter. This value will be sent to the
diameter calculator when Preset3Cmmd is set high.
Usage Set this value to the diameter in inches to be used for Preset3Cmmd.

4.3.7 PresetIncCmmd
The diameter preset increase input is used to increase the calculated diameter. The
function of this input is inhibited when the EnablePresets input is low. The rate of
change for this increase in diameter is set by the DiamIncDecRate_inSec input.
Usage This input should be connected to a dynamic command that can be set high
when the operator wishes to increase the diameter calculator, using an increase
pushbutton.

4.3.8 PresetDecCmmd
The diameter preset decrease input is used to decrease the calculated diameter.
The function of this input is inhibited when the EnablePresets input is low. The rate
of change for this decrease in diameter is set by the DiamIncDecRate_inSec input.
Usage This input should be connected to a dynamic command that can be set high
when the operator wishes to decrease the diameter calculator, using a decrease
pushbutton.

4.3.9 PresetIncDecRate_inSec
The diameter increase/decrease rate input is set in inches of diameter change per
second. This parameter sets the rate of change for the DiamInc and DiamDec
inputs. To aid in manual adjustment of the calculated diameter, the rate of change
will be increased by 3x when the DiamInc or DiamDec inputs are high for more than 3
seconds. If the inputs are set low and then high again, the 3 second delay will
repeat. This configuration allows for precise adjustment of the diameter preset value
and quick changes if the amount of change to be made is significant.
Usage Adjust this input for a value that allows the operator to accurately adjust the
diameter preset as desired. Recommend initial setting of 0.5 to 1 in/Sec.

4.3.10 DiamPresetCmmd
This return parameter is used to activate the preset function of the DiamCalc routine.
This output will be set high when the EnablePresets is high and one of the preset
inputs are high. This output will command the DiamCalc routine to read the value in
DiamPresetVal_in as the actual diameter.
Usage The tag entered in the DiamPreset JSR instruction for this return parameter
should be entered as an input parameter to the DiamCalc JSR instruction.

Drive Application Software page 12 of 30

 FM Diameter Calculation

4.3.11 DiamPresetVal_in
This return parameter is used as the value to preset the diameter calculation when
the DiamPresetCmmd is high.
Usage - The tag entered in the DiamPreset JSR instruction for this return parameter
should be entered as an input parameter to the DiamCalc JSR instruction.

4.4 DiamCalc routine

The diameter calculation routine is the heart of this function module. The routine includes
programming for the diameter calculator, programming to scale an external measurement of
diameter, and scaled outputs for referencing to the drive and to other function modules. The
module has been configured for operation in Imperial units. All data must be entered in the
units specified by the tags. If the line speed is not directly available in FPM, the user must
scale the line speed reference to FPM. The programming for this may be entered in the main
routine and should be executed before the JSR instruction for the DiamCalc routine.
Example equations for converting the line speed reference to FPM are below.

Note: The change in diameter or actual roll diameter should not be used in the calculation of
Line Speed. The Line Speed input parameter (DiamCalc routine In4) must be an
independent source of line speed, not the spindle rotational speed converted to line speed
(using the calculated diameter).

LineSpeedMtr(Rpm) MinCoreDiam(in)*p
LineSpeed(Fpm) = *
GearRatio 12

LineSpeed(Fpm) = 0.083333*LineSpeed(in/min)

LineSpeed(Fpm) = 3*LineSpeed(Ypm)

LineSpeed(Fpm) = 0.05*LineSpeed(Yph)

LineSpeed(Fpm) = 3.2804*LineSpeed(Mpm)

Typically, line speed reference is used for the diameter calculator line speed input. If the line
speed reference is not available, a line speed feedback signal from an adjacent fixed
diameter drive or a surface tachometer can also be used.

The externally measured diameter may be used for the calculated diameter output. It is
recommended to utilize the Diameter Calculation FM when measuring the actual diameter
with an external device. Using the FM will provide rate of change limits to prevent step
changes in the diameter or errors in the external measurement device from instantaneously
changing the output diameter value used in the speed reference to the machine section. If
the measured diameter output, scaled in inches, is programmed as one of the three preset
inputs, the measured diameter can be used as a preset.

Drive Application Software page 13 of 30

FM Inertia Compensation

Input Parameters
Name Type Range Description
1 CalcEnbl BOOL 0 to 1 Enable the Diameter Calculation
2 CalcEnblThresh_FPM REAL 0 to 50 Diameter Calc low speed thresh hold
3 CalcUpdate_Rev REAL 1 to 200 Number of revolutions per length count
4 SpeedLine_FPM REAL +/- 5000 Line Speed
5 SpeedMotor_RPM REAL +/- 7200 Actual motor speed
6 GearRatio REAL 1 to 100 Motor RPM / Roll RPM
7 DiamMinEC_in REAL 0 to FR Minimum diameter Empty Core
MinEC to
8 DiamFR_in REAL Full Roll diameter
500
9 DiamMeasEnbl BOOL 0 to 1 Use DiamMeas value for actual Diam
10 DiamMeasInput REAL NA Measured diameter input (Raw data)
11 DiamMeasMin_DC REAL NA Raw data minimum
12 DiamMeasMax_DC REAL NA Raw data maximum
13 DiamMeasMin_in REAL 0 to 500 Actual diameter at DiamMeasMin_DC
14 DiamMeasMax_in REAL 0 to 500 Actual diameter at DiamMeasMax_DC
15 yDiamPresetCmmd BOOL 0 to 1 Preset command from DiamPreset
16 yDiamPresetVal_in REAL 0 to 500 Preset value form DiamPreset
17 DiamRate_inRev REAL 0.00 to 1 Max allowed diameter rate of change
18 DiamIncEnbl BOOL 0 to 1 Allow diameter calc to increment
19 DiamDecEnbl BOOL 0 to 1 Allow diameter calc to decrement

Return Parameters
Name Type Range Description
1 DiamCalc_in REAL 0 to 500 Actual calculated diameter
2 RadiusCalc_ft REAL 0 to 21 Actual calculated radius
3 BuildUpRatio REAL 1 to 20 Ratio of actual diameter to min core
4 BuildUpRatioRec REAL 0.05 to 1 (1 / BuildUpRatio)
5 DiamMeas_in REAL 0 to 500 Scaled value of measured diameter
Scaling constant FPM to minimum
6 Constant_RPMperFPM REAL NA
empty core RPM

4.4.1 CalcEnbl
The CalcEnbl input enables the diameter calculator. When the input is low, the
DiamCalc_in output will maintain its last value, unless the Measured Diameter Enable
input parameter (DiamCalc In9) is true. If a preset is commanded, the DiamCalc_in
output will be updated to the preset value. When the input is high, the DiamCalc_in
output will be calculated based on line speed and the number of roll rotations. If the
line speed input is below CalcEnblThresh_FPM, the DiamCalc_in output will be held
at last value, regardless of the CalcEnbl state.
Usage This input should be set high when the section is in run and the line speed
input represents roll surface speed (e.g. web tension control is on (Dancer / Tension /
Torque). The diameter calculator is typically disabled if some form of tension control
is not active.

Drive Application Software page 14 of 30

 FM Diameter Calculation

4.4.2 CalcEnblThresh_FPM
This input adjusts the minimum line speed in FPM that the diameter calculation will
be active. The diameter calculation will be disabled if the line speed is below the
CalcEnbleThresh_FPM. The diameter calculation should be disabled at low line
speed to prevent errors in the calculation.
Usage Typically a setting of 1% to 5% of line speed will work well.

4.4.3 CalcUpdate_Rev
This input adjusts the number of roll revolutions per diameter calculation. The
calculator will measure the length of web accumulated at the set number of
revolutions. A greater number of revolutions will naturally average the roll diameter.
A lower number of revolutions will generate faster updates to the diameter calculator.
Usage Typically set for 1 to 8 revolutions of the roll. Thicker webs ( > 62mils)
should be set lower, and thinner webs ( < 62mils) should be set higher. Using a
whole number of revolutions will help reduce diameter calculation variations due to
roll eccentricity.

4.4.4 SpeedLine_FPM
This is the line speed, translation speed, or surface speed of the roll in FPM.
Usage Connect to the tag that represents line speed scaled in FPM. If the signal is
not available in FPM, see section 4.4 for calculating FPM.

4.4.5 SpeedMotor_Rpm
Actual speed of the driven sections motor (RPM).
Usage Connect to the tag that is the actual motor speed (RPM) of the drive section.

4.4.6 GearRatio
The gear ratio of the machine section.
MotorRevolutions
GearRatio =
RollRevolutions
Usage Connect to the gear ratio tag or set the value of gear ratio in the JSR
instruction.

4.4.7 DiamMinEC_in
The minimum Empty Core diameter in inches. This value is used to limit the
calculated diameter and calculate BuildUpRatio and the FPM to RPM conversion
constant. Enter the smallest diameter of roll cores to be used in the machine. If this
is a coreless machine, enter the starting diameter for the Winder.
Usage Set for the minimum core value.

4.4.8 DiamFR_in
The Full Roll diameter in inches. This value is used to limit the calculated diameter.
If the FR diameter is a changing value and can be set, connect the tag for the value
to this input. If the FR diameter is constant or can not predicted, set the input for the
maximum used in the machine.
Usage - Connect to the Full Roll tag or set the constant value in the JSR.

Drive Application Software page 15 of 30

FM Inertia Compensation

4.4.9 DiamMeasEnbl
This input activates the measured diameter as the actual diameter output
DiamCalc_in. This is set high when the actual diameter is to be measured and the
controller should not calculate the diameter based on roll revolutions and length
wound. Setting this input low does not inhibit usage of measured diameter for a
preset. When set high, the measured diameter rate of change will be limited by
DiamRate_inRev input, the measured diameter will be limited by
DiamMinEC_in/DiamFR_in and the DiamCalc_in output will be held at last state
when the diameter calculator is disabled.
Usage Set high when using measured diameter for actual diameter. Set low when
using measured diameter only for preset and calculated diameter for actual (running)
diameter.

4.4.10 DiamMeasInput
This is the input from the external diameter measurement device.
Usage Connect to the tag for the external measurement device. This should be the
raw data from the device.

4.4.11 DiamMeasMin_DC
This is the minimum value of the measurement device raw data.
Usage Set for the minimum value the measurement device will output.

4.4.12 DiamMeasMax_DC
This is the maximum value of the measurement device raw data.
Usage Set for the maximum value the measurement device will output.

4.4.13 DiamMeasMin_in
This input scales the measured diameter (DiamMeasMin_DC) to inches.
Usage Enter the actual diameter of the measured roll for the DiamMeasMin_DC
value.

4.4.14 DiamMeasMax_in
This input scales the measured diameter (DiamMeasMax_DC) to inches.
Usage Enter the actual diameter of the measured roll for the DiamMeasMax_DC
value.

4.4.15 DiamPresetCmmd
This is the command bit from the DiamPreset routine. When the input is high, the
diameter calculator will be set to the DiamPresetVal_in. Do not set this bit when the
machine section is running.
Usage Connect the yDiamPresetCmmd tag (default) to this input.

4.4.16 DiamPresetVal_in
This is the preset value from the DiamPreset routine. When the DiamPresetCmmd is
high, the DiamPresetVal_in is loaded into the diameter calculator.
Usage Connect the yDiamPresetVal_in tag (default) to this input.

Drive Application Software page 16 of 30

 FM Diameter Calculation

4.4.17 DiamRate_inRev
This input controls the max rate of change for the diameter calculator. The value is
entered in inches per revolution of the spindle (roll). The maximum rate of change
required for the process should entered in the tag. The change in diameter per
revolution is the product thickness * 2. This input is used only for limitation of the
diameter calculator. The formula below calculates the minimum value that should be
used for DiamRate_inRev. Actual values should be at increased at least 5% to avoid
unwanted limitation of the diameter calculator.
Usage Set the input for the maximum rate of change for the application.

MaxWebThickness_mils*2
DiamRate_inRev =
1000

4.4.18 DiamIncEnbl
This input sets the function of the diameter calculator. If the input is low, the diameter
calculator cannot increase. If the input is set high, the diameter calculator can
increase. The setting of this input has not effect on the diameter preset functions.
Usage Set this bit high for winder applications. This bit is typically set low for
unwind applications.

4.4.19 DiamDecEnbl
This input sets the function of the diameter calculator. If the input is low, the diameter
calculator cannot decrease. If the input is set high, the diameter calculator can
decrease. The setting of this input has not effect on the diameter preset functions.
Usage Set this bit high for unwind applications. This bit is typically set low for
Winder applications.

4.4.20 DiamCalc_in
This output is the actual calculated diameter in inches. If DiamMeasEnbl is high, this
is the limited measured diameter value.
Usage This output is typically be used for scaling and calculation in the winder
application and for display of the running diameter.

4.4.21 RadiusCalc_ft
This output is the calculated roll radius in feet.
DiamCalc_in
DiamCalc_in 12in
RadiusCalc_ft = =
24 2
Usage Typically used for calculating required motor torque or converting from FPM
to RPM

Torque _ lbft = Tension _ lb * Radius _ ft

Drive Application Software page 17 of 30

FM Inertia Compensation

4.4.22 BuildUpRatio
This output is a ratio of the actual diameter to the minimum empty core diameter.
DiamCalc_in
BuildUpRatio =
DiamMinEC_in

Usage Typically used to scale the spindle rotational speed reference.

CoreLineSpeedRef_RPM
SpindleSpeed_RPM =
BuildUpRatio

4.4.23 BuildUpRatioRec
This output is the reciprocal ratio of the actual diameter to the minimum empty core
diameter.
1 DiamMinEC_in
BuildUpRatioRec = =
DiamCalc_in DiamCalc_in
DiamMinEC_in

Usage Typically used to scale the spindle rotational speed reference.

SpindleSpeed_RPM = CoreLineSpeedRef_RPM*BuildUpRatioRec

4.4.24 DiamMeas_in
This output is the scaled measured diameter from an external source.
Usage (default) This output is connected to the DiamPreset routine, for use as a
preset to the diameter calculator.

4.4.25 Constant_RPMperFPM
This output is created for use as a pre-calculated scaling constant. The constant is
used in conversions from FPM linear speed ref to RPM motor speed. The change in
roll diameter is not included in the constant and must be applied separately.

LineSpeed_FPM*Constant_RPMperFPM
MotorSpeed_RPM =
BuildUpRatio
GearRatio
Constant_RPMperFPM =
DiamMinEC _ in *
12
Usage Use to convert speed in FPM to motor speed in RPM.

4.4.26 Constant_RPMperFPM
This output is created to convert line speed values in FPM to the corresponding
motor speed at minimum empty core diameter in RPM.

Drive Application Software page 18 of 30

 FM Diameter Calculation

5.0 Setup / Configuration

5.1 Overview
All setup and configuration is done in the Main routine. The Diameter Calculation Function
Module is connected to the balance of the application software by placing application tag
names in the Jump to Sub-Routine (JSR) instructions. One JSR is used to call the
DiamPreset routine and a second JSR is used to call the DiamCalc routine.
When JSR instruction input parameters are configured with tags, which are intended to be
tuned by the user at commissioning, it is recommended that the (z prefix) naming convention
be used for tags of this type.

5.2 DiamPreset JSR Instruction

Note: If only a single diameter preset is required, the DiamPreset routine and JSR instruction
can be deleted. If the DiamPreset routine is deleted, the (DiamCalc In15 & In16) inputs
[yDiamPresetCmmd] & [yDiamPresetVal_in] must be controlled by the users custom
programming. If the diameter is not properly preset, the machine section may not be able to
regulate product tension in the process.

5.2.1 Input Parameters

5.2.1.1 Preset1Cmmd In 1, Preset2Cmmd In 2, Preset3Cmmd In 3
Enter application tags for the Preset Command input parameters (DiamPreset -
In1, In2, and In3). Enter '0' for unused Preset Command input parameters.
5.2.1.2 DiamPreset1Val_in In 4, DiamPreset2Val_in In 5,
DiamPreset3Val_in In 6
Enter application tags for the Preset Value input parameters (DiamPreset - In4,
In5, and In6). If the application tag values are not in units of inches, add a rung to
the Main routine that will scale the tag values to inches. Enter '0.0' for unused
Preset Value input parameters.
Measured diameter can be used as a preset by configuring the tag used for the
DiamCalc JSR instruction Measured Diameter return parameter (DiamCalc
Ret5) for one of the preset values.
5.2.1.3 PresetIncCmmd In 7, PresetDecCmmd In 8
Enter application tags for the Preset Increase/Decrease input parameters
(DiamPreset - In7, In8). Enter '0' if Diameter Increase/Decrease function is not
used.
5.2.1.4 PresetIncDecRate_inSec In 9
Enter an application tag for the Preset Increase/Decrease Rate input parameter
(DiamPreset - In9). If the application tag value is not in units of inches per
second, add a rung to the Main routine that will scale the tag value to inches per
second. If the preset increase/decrease function is not used, enter '0.0' for the
Preset Increase/Decrease Rate input parameter.

5.2.2 Return Parameters

5.2.2.1 DiamPresetCmmd Ret 1
Enter an application tag, for the Diameter Preset Command return parameter
(DiamPreset - Ret1. This tag should be used in the DiamCalc JSR instruction
input parameter (DiamCalc In15).
5.2.2.2 DiamPresetVal_in Ret 2
Enter an application tag, for Diameter Preset Value return parameter (DiamPreset
Ret2). This tag should be used in the DiamCalc JSR instruction input parameter
(DiamCalc In16).

Drive Application Software page 19 of 30

FM Inertia Compensation

5.2.3 Default Tags used in Drive Application Software

5.3 DiamCalc JSR Instruction

5.3.1 Input Parameters

5.3.1.1 CalcEnbl In 1
Enter an application tag for the Diameter Calculator Enable input parameter
(DiamCalc - In1). (See section 4 for guidelines on programming this tag.) If the
Measured Diameter Input is always used, enter '0' for the Diameter Calculator
Enable input parameter.
5.3.1.2 CalcEnblThresh_FPM In 2, CalcUpdate_Rev In 3
Enter an application tag for the Diameter Calculator Enable Threshold and the
Diameter Calculator Update Interval input parameters (DiamCalc In2, In3). If
the Measured Diameter Input is always used, enter 0.0 for both the Diameter
Calculator Threshold and the Diameter Calculator Update Interval. The Diameter
Calculator Threshold and the Diameter Calculator Update Interval are typically
configured with tags that can be tuned on-line.
5.3.1.3 LineSpeed _FPM In 4
Enter an application tag for the Line Speed input parameter (DiamCalc - In4). If
the application tag values are not in units of FPM and RPM, add a rung to the
Main routine that will scale the tag values to FPM and RPM. (See section 4 for
guidelines on programming these tags.)

Drive Application Software page 20 of 30

 FM Diameter Calculation

5.3.1.4 SpeedMotor_RPM In 5, GearRatio In 6

Enter application tags for the Motor Speed and Gear Ratio input parameters
(DiamCalc In5, In6). The Gear Ratio is typically configured with a tag that can
be tuned on-line. Since diameter rate is a function of Motor Speed and Gear
Ratio, Motor Speed and Gear Ratio should always be configured.
5.3.1.5 DiamMinEC_in In 7, DiamFR_in In 8
Enter application tags for the Minimum Empty Core Diameter and Full Roll
Diameter input parameters (DiamCalc In7, In8). The Minimum Empty Core
Diameter and Full Roll Diameter are typically configured with tags that can be
tuned on-line. The Minimum Empty Core Diameter and Full Roll Diameter limit
the magnitude of the Diameter Calculator return parameters. Build-Up Ratio is a
function of Minimum Empty Core Diameter.
5.3.1.6 DiamMeasEnbl In 9, DiamMeasInput In 10, DiamMeasMin_DC
In 11, DiamMeasMax_DC In 12, DiamMeasMin_in In 13,
DiamMeasMax_in In 14
Enter application tags for Measured Diameter Enable, Measured Diameter Input
[Data Counts], Minimum Measured Diameter [Data Counts], Maximum Measured
Diameter [Data Counts], Minimum Measured Diameter [Inches], Maximum
Measured Diameter [Inches] input parameters (DiamCalc In9, In10, In11, In12,
In13, In14). If a Measured Diameter signal is not used, enter 0 for Measured
Diameter Enable, 0.0 for Measured Diameter Input, 1.0 for both Minimum
Measured Diameters, and 2.0 for both Maximum Measured Diameters. When a
Measured Diameter signal is used, Minimum and Maximum Diameter tags are
typically configured with tags that can be tuned on-line.
5.3.1.7 DiamPresetCmmd In 15, DiamPreset Val_in In 16
Enter application tags for Diameter Preset Command and Diameter Preset Value
input parameters (DiamCalc In15, In16). If the DiamPreset routine is used,
enter the tags used as return parameters in the DiamPreset JSR instruction. If
the DiamPreset routine is not used, enter the appropriate application tags.
Measured diameter can be used as a preset by configuring the tag used for the
Measured Diameter input parameter (DiamCalc Ret5).
5.3.1.8 DiamRate_inRev In 17, DiamIncEnbl In 18, DiamDecEnbl In 19
Enter application tags for Diameter Rate Limit, Diameter Calculator Increase
Enable and Diameter Calculator Decrease Enable input parameters. These
parameters are typically configured with tags that can be tuned on-line.

5.3.2 Return Parameters

5.3.2.1 DiamCalc_in Ret 1, RadiusCalc_ft Ret 2
Enter application tags, for the Calculated Diameter and Calculated Radius return
parameters.
5.3.2.2 BuildUpRatio Ret 3, BuildUpRatioRec Ret 4
Enter application tags, for the Normalized Diameter and Reciprocal of Normalized
Diameter return parameters (DiamCalc Ret3, Ret4).
5.3.2.3 DiamMeas_in Ret 5
Enter an application tag, for the Measured Diameter return parameter (DiamCalc
Ret5). If the Measured Diameter is used to preset the Diameter Calculator and
the Diameter Preset routine is used, enter this tag name for the one of the Preset
Value input parameters. If the Measured Diameter is used to preset the Diameter
Calculator and the Diameter Preset routine is not used, enter this tag name for the
Diameter Preset Value input parameter (DiamCalc In16).
5.3.2.4 Constant_RPMperFPM Ret 6
Enter an application tag, for the Calibration Constant return parameter.

Drive Application Software page 21 of 30

FM Inertia Compensation

5.3.3 Default Tags used in Drive Application Software

Drive Application Software page 22 of 30

 FM Diameter Calculation

6.0 Tuning / Startup

6.1 Installing the Application Module
Perform the following operations in the order listed to ensure proper signal connections between
the DriveLogix controller and the PowerFlex 700S firmware.

1. Download the RSLogix 5000 [.acd] file to the DriveLogix controller

2. Download the DriveExecutive [.dno] file to the PowerFlex 700S

Note, order of these events are critical as the DriveLogix controller must send the Peer
Communication format to the PowerFlex 700S firmware before the PowerFlex 700S will
accept all the configuration settings provided in the DriveExecutive file. Manually setting the
Peer Communication format in the drive will not be effective until configured in DriveLogix. If
this sequence of operation is not followed, the DriveLogix controller may not communicate
with the PowerFlex 700S.

6.2 Drive Tuning & Configuration

For basic commissioning of the application, the drive must first be tuned to regulate the
motor. The following steps will guide you through the basic requirements of drive tuning
when using an application module.
1. Set param 153 bit 8 high. This will set the start/stop control to 3 wire for
operation via the HIM. When the start up is complete this must be set to low for
2 wire operation from DriveLogix.
2. From the HIM, select the Start-Up function and follow the directions. In this
section you will perform the following steps.
a. Motor Control
i. FOC for Induction Motor
ii. PMag for Permanent Magnet Motor
b. Motor Data Enter all motor data for the attached motor, check # poles
c. Feedback Config Select feedback type
d. Pwr Circuit Diag
e. Direction Test (NOTE, the motor will run) recommend always changing
wires and not software, this is for maintenance purposes, if the program
is restored it will default to the standard direction setting.
f. Motor Tests (NOTE, the motor will run)
g. Inertia Measure (NOTE, the motor will run)
h. Speed Limits
i. Select +/- Speed Ref
ii. Fwd Speed Limit
iii. Rev Speed Limit
iv. Abs Overspd Lim Max over speed past the Fwd and Rev
Speed Limit. This is where the drive will fault
i. Do not complete the remainder of the Start-Up procedure in the drive
j. Scroll down to Done/Exit
3. Tune the speed regulator. Depending on the inertia of the machine and other
factors, the speed regulator bandwidth (param 90) should be set for 15 to 50
radians.
4. Set param 153 bit 8 Low. This will set the start/stop control to 2 wire for
operation via DriveLogix

Drive Application Software page 23 of 30

FM Inertia Compensation

6.3 Offline Tuning / Startup

Verify that the number and order of JSR input parameters and JSR return parameters agree
with the JSR rung comment and section 4 of this user manual.
Verify that the data type of all JSR instruction input and return parameters agree with the data
type described in the JSR instruction rung comment and section 4 of this user manual. If
immediate values are used for input parameters, the immediate value data type can be
controlled by using or excluding a decimal point. For example, if the JSR instruction input
parameter is designated as type REAL, and the desired value is zero, use 0.0 in the JSR
instruction input parameter. An Input entered a 0 is used as an INTEGER value.
Check the value of all JSR instruction input parameter tags. If the tag is calculated by other
Logix instructions, verify that the tag will be calculated in the correct engineering units. If the
tag is not calculated by other Logix instruction, preset the tag per section 4 of this user
manual.

6.4 Online Tuning / Startup

6.4.1 Measured Diameter Enable True

With the Logix controller in run, verify that the Measured Diameter return parameter
(DiamCalc Ret5) agrees with the actual diameter.
If the Measured Diameter return parameter (DiamCalc Ret5) is not accurate:
1. Check that the value of the following input parameters:
Measured Diameter Input (DiamCalc - In10)
Minimum Measured Diameter (DiamCalc - In11)
Maximum Measured Diameter (DiamCalc - In12)
Minimum Measured Diameter (DiamCalc - In13)
Maximum Measured Diameter (DiamCalc - In14)
Preset the Diameter Calculator to the actual diameter drive (The diameter can only
be preset with the Diameter Calculator Enable input parameter (DiamCalc In1)
false.) and run the drive (The diameter rate limit is zero when the motor speed is
zero.) Verify that Calculated Diameter return parameter (DiamCalc - Ret1) tracks the
actual diameter.
If the Calculated Diameter return parameter (DiamCalc - Ret1) does not change with
actual diameter:
1. Verify that the value of the Diameter Increase Enable, Diameter Decrease
Enable and the Diameter Rate Limit (DiamCalc In17, In18, and In19) will allow
the diameter to ramp to the measured value.
2. Verify that the Motor Speed and Gear Ratio input parameters (DiamCalc In5,
In6) are entered correctly.

6.4.2 Measured Diameter Enable False (typical configuration)

Preset the Diameter Calculator to the actual diameter (the diameter can only be
preset with the Diameter Calculator Enable input parameter (DiamCalc In1) false).
After diameter preset is complete, set the Diameter Calculator Enable input true.
Run the drive at a line speed greater than the Diameter Calculator Enable Threshold
(DiamCalc In2). Verify that the Calculated Diameter return parameter (DiamCalc -
Ret1) tracks the actual diameter.
If the Calculated Diameter return parameter (DiamCalc - Ret1) does not change with
actual diameter:
1. Verify that the Diameter Calculator Enable input parameter (DiamCalc In1) is
true.
2. Verify that the value of the Diameter Increase Enable, Diameter Decrease Enable
and the Diameter Rate Limit (DiamCalc In17, In18, and In19) will allow the
diameter to ramp to the measured value.
3. Verify that the Motor Speed and Gear Ratio input parameters (DiamCalc In5,
In6) are entered correctly.
Drive Application Software page 24 of 30
 FM Diameter Calculation

If the Calculated Diameter return parameter (DiamCalc - Ret1) is not accurate:

1. Hand tach the roll surface and verify that the correct value of Line Speed
(DiamCalc - In4). Finally, monitor motor speed and verify the correct value of
Motor Speed (DiamCalc In5).
Note: The diameter calculator is only as accurate as the Line Speed and Motor
Speed input parameters (DiamCalc In4, In5). For example, if a line speed
reference signal is used for the Line Speed input parameter, lead section speed
errors, lead section calibration errors, dancer loop velocity, and/or material stretch will
contribute to differences between the actual surface speed of the roll and the Line
Speed input parameter value.

If the Calculated Diameter return parameter (DiamCalc - Ret1) is accurate but is

fluctuating:
1. Increase the Diameter Calculator Update Interval (DiamCalc In3) and use a
whole number of revolutions. Using a whole number of revolutions for the
Diameter Calculator Update Interval will help reduce fluctuations due to roll
eccentricity.

Drive Application Software page 25 of 30

FM Inertia Compensation

Appendix A - Process Line Command & Status Words

The following table is a functional list of the Process Line command word
[wDLx_DrvCmmdProcLn]

Bit Input Signal Description

00 Clear Fault Clear all Faults
01 Run (2 Wire) 1 = Start, transition to 0 = Stop
02 Reserved
03 Coast Stop not supported in rev 110101
04 Jog Forward Jog in Forward direction
05 Jog Reverse Jog in Reverse direction
06 Reverse Rotation (Under Wind) Under wind selection
07 Tension Control Enable Activates selected mode of Tension Control
User determines how and when to activate
08 Stall Tension
Stall Tension
09 Tension Control Selects Tension Control Mode - Tension
10 Torque Control Selects Tension Control Mode - Torque
11 Dancer Control Selects Tension Control Mode - Dancer
12 Torque Trim Selects Trim type Torque is trimmed
13 Speed Trim Selects Trim type Speed is trimmed
14 Draw Trim Off Zeros the Draw trim signal
15 Torque Follower Control Special Control mode for torque follower
16 Diam Preset 1 Commands preset 1 for Diam Calc
17 Diam Preset 2 Commands preset 2 for Diam Calc
18 Diam Preset 3 Commands preset 3 for Diam Calc
19 Diam Preset Increase Manual increase for Diameter Calc
20 Diam Preset Decrease Manual decrease for Diameter Calc
21 Diam Calc Increase Enable Releases Diameter Clac for Increase
22 Diam Calc Decrease Enable Releases Diameter Calc for Decrease
23 Reserved
24 Reserved
25 Reserved
26 Reserved
27 Reserved
28 Reserved
29 Torque Mem Enable Memorizes running torque
Boosts the memorized torque by user set
30 Torque Mem Boost Enable
percentage.
Boosts the memorized torque by user set
31 Torque Mem Knife Cut
percentage.

Drive Application Software page 26 of 30

 FM Diameter Calculation

The following table is a functional list of the Process Line status word
[DLx_DrvStatProcLn]

Bit Output Signal Description

00 Fault Drive Fault or a System Fault
01 Running Drive is Running / not stopping
02 Reserved
03 Motor Ctrl On Motor is being control (Motor POWER)
04 Reserved
05 Jogging section Jogging
06 Rotational Reverse Under Wind
07 Tension Control On Selected mode of Tension control is enabled
08 Zero Speed Below Zero Line speed set point
09 Diameter Calculation Active Future
10 Reserved
11 Reserved
12 Reserved
13 Reserved
14 Reserved
15 Reserved
16 Enable Loss Fault Drive Enable lost
17 Fail to Run fault Drive failed to start
18 Communication fault NA not support
19 Message fault NA not support
20 Motor Overload Fault Overload alarm from drive
21 Motor Overtemperature Flt Over temperature alarm from drive
22 Motor Blower Loss Fault Motor blower has stopped or tripped off
23 Reserved
24 Reserved
25 Reserved
26 Reserved
27 Reserved
28 Reserved
29 Reserved
Use in line control logic to command a
30 Operate Permissive
coordinated line ramp stop.
Loss of permissive resets start command.
31 On Permissive The drive will coast stop or ramp stop
depending on configuration

Drive Application Software page 27 of 30

 DiamPresetCmmd

DiamMeasEnbl
LineSpeedRef_FPM
X
12 / 0 0
DIV_03.Dest DiamCalc_in
FM Inertia Compensation

/
RollSpeed_RPM 1 1
3.14 Ramp

Drive Application Software page 28 of 30

DiamMeasured_in

DiamPresetVal_in

Calculator Enable
Appendix B - Block Diagram

LineSpeedRef_FPM & DiamCalcAvtive

CalcEnableThresh_FPM
>
DiamIncEnable
&
0
0
RollSpeed_FPM +- 1
DiamRate_inRev */
DiamDecEnable
&
0
0

1
 FM Diameter Calculation

Appendix C - Parameter (Tag) Table

Input Tags for Diameter Calculation Function Module

User
Name Type Source Tag from Routine Default
Value
DiamPreset Routine
Preset1Cmmd Bx wDLx_DrvCmmdProcLn.16 NA 0
Preset2Cmmd Bx wDLx_DrvCmmdProcLn.17 NA 0
Preset3Cmmd Bx wDLx_DrvCmmdProcLn.18 NA 0
Preset1Val_in R x.x zDLx_DiamPreset1Val_in NA 4.0
Preset2Val_in R x.x zDLx_DiamPreset2Val_in NA 6.0
Preset3Val_in R x.x zDLx_DiamPreset2Val_in NA 9.0
PresetIncCmmd Bx wDLx_DrvCmmdProcLn.19 NA 0
PresetDecCmmd Bx wDLx_DrvCmmdProcLn.19 NA 0
zDLx_DiamPresetIncDecRate_
PresetIncDecRate_inSec R x.x NA 0.0
inSec
DiamCalc Routine
CalcEnbl Bx DLx_DrvStatProcLn.7 NA 0
CalcEnblThresh_FPM R x.x zDLx_CalcEnblThresh_FPM NA 5.0
CalcUpdate_Rev R x.x zDLx_CalcUpdate_Rev NA 2.0
SpeedLine_FPM R x.x DLx_LineSpdRf_FPM RunJogSpdRf NA
SpeedMotor_RPM R x.x SpeedMotor_RPM Main scaled to (RPM) NA
GearRatio R x.x zDLx_GearRatio NA 5.0
DiamMinEC_in R x.x zDLx_DiamMinEC_in NA 4.0
DiamFR_in R x.x zDLx_DiamFR_in NA 30.0
DiamMeasEnbl Bx None NA 0
DiamMeasInput R x.x None NA 0.0
DiamMeasMin_DC R x.x None NA 1.0
DiamMeasMax_DC R x.x None NA 2.0
DiamMeasMin_in R x.x None NA 1.0
DiamMeasMax_in R x.x None NA 2.0
yDiamPresetCmmd Bx DiamPresetCmmd DiamPreset NA
yDiamPresetVal_in R x.x DiamPresetVal_in DiamPreset NA
DiamRate_inRev R x.x zDLx_DiamRate_inRev NA 0.25
DiamIncEnbl Bx wDLx_DrvCmmdProcLn.21 NA 0
DiamDecEnbl Bx wDLx_DrvCmmdProcLn.22 NA 0

Drive Application Software page 29 of 30

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Americas: Rockwell Automation, 6040 Ponders Court, Greenville, SC 29615-4617 USA, Tel: (1) 864.297.4800, Fax: (1) 864.281.2433
Europe: Rockwell Automation, Brhlstrae 22, D-74834 Elztal-Dallau, Germany, Tel: (49) 6261 9410, Fax: (49) 6261 17741
Asia Pacific: Rockwell Automation, 55 Newton Road, #11-01/02 Revenue House, Singapore 307987, Tel: (65) 351 6723, Fax: (65) 355 1733

U.S. Allen-Bradley Drives Technical Support

Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives

Publication: 9329-RM001B-EN-E March 2003

Copyright 2003 Rockwell Automation. All rights reserved. Printed in USA