Winder/Unwinder Application Software
Contents
1. fe BR os mmostnseoES A WARNING Risk of electric shock f e BANU SKRID PREMIERE SME FEL A o RDRURIGENTODLIAIEZIZ KHR SERGE Read manual before installing i e WaltlOminutesfor capacitor discharge after disconnecting i power supply Warning description 10 A Uw Gm uu g Z W AGG Y Jl GEG OH GOGGGagG rz LLL LLL LLL Y GY EZ ZZ ZZ e Read manual before installing zz MM ULL SUO Mai n fe BG AX WARNING Risk of electric shock e A e 10 eRead manual before installing Wait 10 minutes for capacitor discharge after disconnecting power supply 10 e WaitlOminutesforcapacitordischarge after disconnecting power supply Winder Unwinder Application Software OMRON Checking Before Unpacking e Checking the product e On delivery be sure to check that the delivered product is the Inverter 3G3RX 3G2. amp Print Preview Page Setup A new dialog will appear Put the file name that you want for the project and press the Save button Ez Cm Viele ee me M weg QU Uses Y ortjosonIABIT00703 Userdata 0 l Organize New folder Search Userdata D 3earcn Userdaia L Name Date modified 159 Libraries E Documents 2 Music OMRON i Pictures B Videos LE My Documents 20 03 2013 16 43 File folder do My IPhone 25 04 2013 11 13 File folder A My Music 18 03 2013 15 59 File folder D My Omron 28 05 2013 7 52 File folder LE My Pictures 18 03 2013 15 59 File folder BE My Videos 25 04 2013 11 12 File folder j Omron 06 03 2013 17 39 File folder ProgramData 03 09 2010 15 51 File folder SWSHARE 20 12 2012 19 33 File folder VirtualBox 19 03 2013 11 50 File folder 4 Ml orjos onIABITO07 amp Programs C cx Userdata D G ortjos Nomrtn Filename Winder Application sdd Save as type Drive Files sdd Y Hide Folders 18 Start with the application configuration and inverter parameter settings 30 Winder Unwinder Application Software OMRON DRIVE PROGRAMMING PARAMETERS 4 DRIVE PROGRAMMING PARAMETERS 4 1 Application configuration Follow next steps to configure the basic winder unwinder application parameters m wc Configure digital inputs outputs and analog inputs outputs See section 4 3 Set reel diameter P100 parameter
3. Breaker MCCB or GFI TR Power source O O gt 3 phase or 1 phase per om inverter model L2 i i Sed gt lt ii N L3 Intelligent inputs 24V NOTE For the wiring of intelligent I O and analog inputs be sure to use twisted pair shielded cable Attach the shielded wire for each signal to its respective common terminal at the inverter end only Input impedance of 7 terminals P24 STA 3 wire start Q STP 3 wire stop Jt DC reactor P Braking unit optional Brake resistor optional each intelligent input is 4 7kQO Q Q FIR wire FWWIRV npu Winder m A Hd PIENE Q O O Relay contacts Preset diameter type 1 Form C O C 5 5 configurable as Freeze diameter EE discrete input or I thermistor input AL2 O O Open collector output Reset diameter II Output circuit Thermistor HH P 11 Diameter reached mE fh 5 Not used diva ee GND for logic outputs gt Short bar Source type GND for logic inputs Meter Termination resistor 200Q Change by slide switch Analog monitor Meter Serial communication port output Diameter RS485 ModBus c output voltage L c RJ45 port Optional operator port Pulse train input USB mini B port 24Vdc 32kHz max PC communication port USB power Self power Option port connector GND for analog signals Winder Unwinder Application Software
4. 0 0 6 0 06 06 0 6 06 6 6 6 ITH Winder Unwinder Application Software 37 OMRON Winder Unwinder Application Software 5 4 Reset function timing diagram It resets current diameter In winder mode See below timing diagrams Winder It will reset current diameter to the minimum build up ratio reel diameter Unwinder Input ResetCommand Output MaximumBUR BUR Diameter MinimumBUR Maximum Diameter Minimum Diameter In unwinder mode it will reset current diameter to the maximum build up ratio product diameter Input ResetCommand Output MaximumBUR Maximum Diameter BUR Diameter MinimumBUR Minimum Diameter 38 Winder Unwinder Application Software OMRON WINDER UNWINDER APPLICATION FUNCTIONS 5 5 Diameter completion function It indicates when the job in winder or unwinder mode is complete Winder In winder mode the diameter reached output signal will be activated when current diameter reaches the percentage indicated in Percentage Diameter Completion parameter P112 of the maximum diameter Minimum Build Up Ratio Maximum Build Up Ratio Reel Diameter Product Diameter Diameter indi 0 Ng gt 100 Percentage Diameter 95 00 Completion P112 9500 Output Diameter Reached Winder 1 second Where e Minimum build up ratio 1000 e Minimum build up ratio M
5. A003 Motor base frequency Hz b012 Motor rated current H002 01 Auto tuning parameter H003 Motor capacity selection Introduce motor capacity kW H004 Motor pole number selection Introduce motor pole number P011 Encoder pulses Introduce number of encoder pulses per revolution ppr Before starting the auto tuning set parameter A051 DC injection braking selection to disable 2 After introducing motor parameter settings set H001 01 Static or 02 Rotate and turn on the run command It will start the motor auto tuning omnon POWER RUN WARNING ALARM 3 10Ewo Rey stop RUN RUN RESET KEY ENABLED Note It is recommended to use option 02 rotate autotuning Please be sure that the shaft is free no gear run connected Once the auto tuning process is finished it will appear a message indicating if the auto tuning is ok or not 1 Auto tuning OK Change A051 DC injection braking selection again to enable Auto Tuning OK 2 Auto tuning NOK Verify introduced motor settings For further information please refer to the RX MX2 users manual Auto Tuning NG Note After complete the auto tuning process be sure that with Run FW signal the motor shaft is rotating CW clock wise Winder Unwinder Application Software 23 OMRON Winder Unwinder Application Software 3 2 Parameter settings and Drive Programming application After finishing the autotuning process follow next steps in order to
6. Speed Reference Diameter Reset Function X 03 Speed Offset P111 wo v W VV N Y Y Y Maximum Build Up Ratio P107 Build Up Ratio P130 Taper Tension Reference P1012 1 gt P106 gt Taper Middle Build Up Ratio Tension Reference P119 Taper Tension Minimum BUR P108 3 gt Tension Taper Tension Middle BUR P109 gt gt H Tension Feedback O Terminal RK MX2 PID Taper Tension Maximum BUR P110 9 1 6 Terminology Is the ratio between reel diameter and maximum diameter considering for reel diameter the value 1 For instance an application in which reel diameter is 900mm and maximum diameter is 900mm the ratio is 10 Build Up Ratio BUR SO BUR maximum diameter reel diameter 900mm 90mm 10 Note In this application software the Build Up Ratio is scaled by 1000 So in the last example the minimum build up ratio reel diameter used internally is 1000 1 1000 and for the maximum diameter we will use 10000 10 1000 It is needed to multiply by 1000 the calcu lated Build Up Ratio BUR 18 Winder Unwinder Application Software OMRON PREPARATION AND SYSTEM CONFIGURATION 2 PREPARATION AND SYSTEM CONFIGURATION To prepare the inverters for operation the configuration tool CX Drive is used for setting parameters and to download the Winder Unwinder Application program In
7. Winder mode A077 PID reverse output ON nwinder mode PID reverse output mode A097 Acceleration pattern selection 0 Line Acce s ramp pattern selection A098 Deceleration pattern selection OXLie Decel s ramp pattern selection IC O1 Enable Sensor vector control A044 V f characteristics selection 05 V2 RX 03 SLV MX2 Control method 5013 Electronic thermal characteristics selec 01 Const TRQ Constant torque Motbtonsanttedus tion characteristics b046 Reverse rotation prevention selection 00 OFF Disabled Reverse rotation prevention function Usage rate of regenerative braking func duty for brake unit Please set to 100 96 for brake b090 100 0 96 i tion to work If set to 0 96 transistor disabled b095 Regenerative braking function opera 02 Alws ON Enabled during Renee bananon onsen tion selection stop A081 AVR selection 01 Always OFF AVR selection b130 Verdes PIOUEGHODAUUCHOR Gele 00 OFF Disabled Overvoltage protection function tion during deceleration C091 Debug mode selection 01 Enabled Debug mode selection H002 01 Auto tuning parameter Select final motor data P011 Encoder pulses Pe Number of actual encoder pulses 34 Winder Unwinder Application Software OMRON WINDER UNWINDER APPLICATION FUNCTIONS 5 WINDER UNWINDER APPLICATION FUNCTIONS 5 1 Taper function To compensate physical effects that are difficult to model on the final product winding quality the taper func
8. and implement wiring correctly Not doing so may result in a serious injury due to an electric shock Wiring work must be carried out only by qualified personnel Not doing so may result in a serious injury due to an electric shock Do not change wiring and slide switches SW1 put on or take off Digital Operator and optional devices replace cooling fans while the input power is being supplied Doing so may result in a serious injury due to an electric shock Be sure to ground the unit Not doing so may result in a serious injury due to an electric shock or fire 200 V class type D grounding 400 V class type C grounding Do not remove the terminal block cover during the power supply and 10 minutes after the power shutoff Doing so may result in a serious injury due to an electric shock Do not operate the Digital Operator or switches with wet hands Doing so may result in a serious injury due to an electric shock Inspection of the Inverter must be conducted after the power supply has been turned off Not doing so may result in a serious injury due to an electric shock The main power supply is not necessarily shut off even if the emergency shutoff function is activated 6 Winder Unwinder Application Software OMRON A N CAUTION Do not connect resistors to the terminals PD 1 P N directly Doing so might result in a small scale fire heat generation or damage to the unit Install a stop motion device to ensur
9. and storage Do not store or use the product in the following places Locations subject to direct sunlight e Locations subject to ambient temperature exceeding the specifications Locations subject to relative humidity exceeding the specifications Locations subject to condensation due to severe temperature fluctuations Locations subject to corrosive or flammable gases e Locations subject to exposure to combustibles e Locations subject to dust especially iron dust or salts e Locations subject to exposure to water oil or chemicals Locations subject to shock or vibration e Transporting installation and wiring e Do not drop or apply strong impact on the product Doing so may result in damaged parts or malfunction e Do not hold by the front cover and terminal block cover but hold by the fins during transportation e Do not connect an AC power supply voltage to the control input output terminals Doing so may result in damage to the product e Be sure to tighten the screws on the terminal block securely Wiring work must be done after installing the unit body e Do not connect any load other than a three phase inductive motor to the U V and W output terminals e Take sufficient shielding measures when using the product in the following locations Not doing so may result in damage to the product Locations subject to static electricity or other forms of noise Locations subject to strong magnetic fields Locations close to pow
10. setting in mm Set maximum line speed P101 parameter setting in m min Set winder speed at minimum diameter reel diameter parameter setting in Hz Please follow next example steps to set this parameter from reel diameter maximum line speed and gear box data Motor 4 poles 50 Hz Reel diameter 90 mm Max line speed 175 m min Gear box i22 L 2 zm r z D 3 1415 90mm 282 7Amm rev LineSpeed 175 min 175000 uin reelSpeed inniameter 175000 min 282 74 mm rev 61 8 94rpm ShaftSpeed anaa prm 618 94rpm 2 1237 88rpm 1237 RACE co i U 1 1500rpm Set P113 4126 41 26 Hz Set A004 Shaft speed at minimum diameter offset 41 26 1 15 15 47 44 Hz Speed offset for PID Set Speed offset P111 to the desired percentage for the PID window Set maximum build up ratio To get the maximum build up ratio divide maximum product diameter between reel diameter and multiply the result by 1000 Example 1 Reel diameter 90 mm Product diameter 900 mm MaximumBuildUpRatio P107 A 1000 10000 90mm Example 2 Reel diameter 90 mm Product diameter 700 mm l 700mm MaximumBuildUpRatio P107 1000 7777 90mm Calibrate feedback sensor dancer load cell Verify that you have 0 VDC in the analog input when you have the minimum tension feedback and 10 VDC when you have the maximum tension feedback Calibrate diameter sensor Note Be sure to calibrate the feedback p
11. the following chapters we will show the necessary steps to set up the inverter for a winder unwinder application We will use 3G3RX 3G3MX2 inverter 2 1 Installation and power circuits This manual does not cover how to install the inverters in cabinets how to wire power supply or how to satisfy other application specific requirements Please refer to the RX User s Manual 1560 E2 or MX2 User s Manual 1570 E2 2 2 DIP SWITCH 3G3RX DIP SWITCH There is only one switch in 3G3RX If the switch is ON digital input 1 and 3 are configured as emergency shutoff inputs Factory setting is OFE so just check that the switch is really OFF Slide switch SW1 Slide lever factory deffault OFF OFF lt gt ON 3G3MX2 DIP SWITCHES The switches in MX2 are small and can be difficult to discover They are located just above the control logic connectors MDSW1 is related to RS485 communication and connects a built in 200 termination resistor In this application it should be switched ON in both inverters SFSWI is for configuring digital inputs 3 and 4 as safety inputs This needs to be OFF EDMSW1 is also related to safety and configures digital output 11 as EDM output External Device Monitoring This needs to be OFF MOSWi SFSWa EDMSWa Make sure both SFSW1 and EDMSW1 are OFF i e in the left most position Safety function selector switch EDM function selector switch oFF E ON RR h a Wi
12. upload inverter parameter settings with CX Drive tool download the winder unwinder application case software and save the project 1 Open CX Drive gl oov 2 3G3RX Connect your computer USB port to the RJ 45 3G3RX inverter port with 3G3AX PCACN2 cable or USB CONVERTERCABLE Remove the LCD Digital Operator to access RJ 45 port CX Drive INVERTER USB RS422 Convert Cable 3G3AX PCACN2 or USB CONVERTCABLE LCD Digital Operator 3G3RX 3G3MX2 Use the standard mini USB cable to connect your PC with the 3G3MX2 inverter GX Drive USB Cable A miniB Ans Connector 3G3MX2 3 Use the CX Drive autodetect 9 amp function in order to go online with the 3G3RX 3G3MXG inverter Workspacel CX Drive Drivel File Edit View Drive Tools Window Help 24 Winder Unwinder Application Software omnon APPLICATION CONFIGURATION STEPS 4 A new dialog will appear for autodetect function trying to connect with 3G3RX 3G3MX2 inverter 6 Press mouse right button if you want to change the Drive name A new dialog will appear Winder Unwinder Application Software 25 omnon Winder Unwinder Application Software 7 Introduce the Drive name and press OK button rive Name n mosse Inverter l 3G3RX Comments Type your own comment in here Workspace CX Drive Drivel File Edit View Drive Tools Window He
13. 006 100 0096 build up ratio P110 Taper tension at maximum 0 to 10000 10000 Maximum tension for taper function at maxi BUR 0 096 to 100 0096 100 0096 mum build up ratio 0 to 100 5 Speed offset for final speed reference in 96 of dH a 096 to 10096 596 maximum frequency When diameter reaches this percentage of max 9500 min diameter it will be activated one digital 95 0096 output to indicate that the diameter is almost complete 10000 Minimum tension for taper function at mini 100 0096 mum diameter ex Percentage diameter comple 0 to 10000 BH qe 0 096 to 100 0096 Winder speed at minimum build up ratio This value must be the same as the maximum frequency parameter A004 4420 44 20 Hz Winder speed at minimum 10000 P113 laun 100 00 Hz RX 2 to 50 0 2 to 5 0 MX2 0 to 2500 0 0 to 25 0 RX 2 to 50 0 2 to 5 0 MX2 0 to 2500 0 0 to 25 0 0 to 10000 P127 Li f RX 2 0 2 Proportional value for the minimum diameter MX2 100 1 0 for the dynamic PID function P116 Proportional MinBUR RX 2 0 2 Proportional value for the maximum diameter MX2 100 1 0 for the dynamic PID function os 4 Line speed reference from communications P117 PProportionalGMaxBUR N 32 Winder Unwinder Application Software OMRON DRIVE PROGRAMMING PARAMETERS 4 3 Inputs outputs Digital inputs 4 C004 56 X 00 DP Winder unwinder Winder unwinder mode s
14. 100 1 0 for the dynamic PID function 0 0 to 25 0 Proportional MinBUR Proportional MaxBUR 40 Winder Unwinder Application Software Authorized Distributor Cat No 214E EN 01 Note Specifications subject to change without notice Printed in Europe
15. 21 OMRON Winder Unwinder Application Software 2 4 Encoder connection 3G3AX PG Board Only for 3G3RX inverter DIP switch SWENC DIP switch SWR TM1 oi Connector to the inverter mp gm EN TM1 Terminal arrengement Switch arrangement Switch ON OFF setting Slide the switch from left OFF to right to turn it ON Default settings The default settings factory settings are shown below DIP switch name Settings Default settings ON Disconnection detection enabled when encoder A and B phases are not connected OFF Disconnection detection disabled when encoder A and B phases are not connected ON Disconnection detection enabled when encoder Z phase is not connected OFF OFF Disconnection detection disabled when encoder Z phase is not connected Built in termination resistor between SAP and SAN 150 9 ON enabled OFF Built in termination resistor between SAP and SAN disabled Built in termination resistor between SBP and SBN 150 9 ON enabled OFF Built in termination resistor between SBP and SBN disabled 1 When connecting to multiple units in parallel for pulse train position command inputs turn ON the SWRI and SWR2 of the only one unit located farthest from the master unit 22 Winder Unwinder Application Software OMRON APPLICATION CONFIGURATION STEPS 3 APPLICATION CONFIGURATION STEPS 3 1 Motor autotuning 1 Introduce motor settings
16. 3MX2 model that you ordered Should you find any problems with the product immediately contact your nearest local sales representative or OMRON sales office e Checking the nameplate 3G3RX OMRON 3G3RX A2004 E 1F INVERTER NE18XXX 001 INPUT 90H INPUT 90 QUTPU MADE IN JAPAN omron 3G3MX2 AB001 V1 INVERTER NELOAAX 001 INPUT 50Hz 60H2 200 240 Ph 2 0 1 3 A INPUT 50Hz 60Hz A 0 1 1000 Hz 3Ph 1 2 1 04 e 2013 0 C REM OMR S N 16213606000001 34X2 00001 OMRON Corporation MADE IN JAPAN Winder Unwinder Application Software 11 OMRON e Checking the model 3G3RX 3G3RX A2055 EF F Built in filter E Europe standard Max applicable motor capacity 185 18 5 kW 220 22kW 0 300 30kW 370 37 kW 45 kW Voltage class 2 3 phase 200 V AC 200 V class 4 3 phase 400 V AC 400 V class Enclosure rating A Panel mounting IP20 min or closed wall mounting models B IPOO e Checking the model 3G3MX2 3G3MX2 AB002 EL C IP54 ready for customization E Europe standard Max applicable motor capacity 1 phase 200 VAC 3 phase 200 VAC 3 phase 400 VAC Enclosure rating A IP20 D IP54 includes Class 2 EMC filter 12 Winder Unwinder Application Software OMRON Revision History eA manual revision code appears as a suffix to the catalogue number
17. Cat No I214E EN 01 Winder Unwinder Application Software Version PID Control with Diameter Sensor Model 3G3RX 3G3MX2 CX Drive Version 2 9 3 20 USER S MANUAL a Ld Z Ed lt gt x P P N 2 CS E T E l L N p LN E N P TA ENGEN Tm 1m xt G t Notice OMRON products are manufactured for use according to proper procedures by a qualified operator and only for the purposes described in this manual The following conventions are used to indicate and classify precautions in this manual Always heed the information provided with them Failure to heed pre cautions can result in injury to people or damage to property OMRON Product References All OMRON products are capitalized in this manual The word Unit is also capitalized when it refers to an OMRON product regardless of whether or not it appears in the proper name of the product OMRON 2014 All rights reserved No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means mechanical electronic photocopying recording or otherwise without the prior written permission of OMRON No patent liability is assumed with respect to the use of the information contained herein Moreover because OMRON is con stantly striving to improve its high quality products the information contained in this manual is subject to change without notice E
18. and verify in the output window that the program size is not 0 bytes Z Workspacel CX Drive Drivel Winder Application 363RX A4015 E1F PRG4553 Program Editor 7 E File Edit View Driwe Tools Window R S CBE ee Winder Application Online at Parameter Editor Basic Settings Parameter Access pL Tuning and motor basic data mE Reference Control EX Ea 26 06 2013 15 58 i13 Waming Program Editor Cannot open ithe program n s protected by an access code 25 06 2013 15 58 43 Waming Program Editor Alias cFixLineSpeed 5000000 is not invoked anywhere Main Line 28 Position 1 26 05 2013 15 59 43 Waming Program Editor Alias ASR E diner ite ied jaar ies Tir 30 Position 1 26 06 2013 15 58 43 Waming Program Editor The Diameter Se DOUTE invoked anywt 26 06 2013 15 58 43 Info Program Editor Compilation implied cuna G size 3408 bytes 57 86 of maximum size Mew Tab w ij X kh df Lx x Output Eror List 28 Winder Unwinder Application Software OMRON APPLICATION CONFIGURATION STEPS 14 Download Drive Programming program by pressing the download icon i in the Drive Programming section Z Workspacel CX Drive Drivel Winder Application 3G3RX A4015 E1F PRG4553 Program Editor E File Edit View Drive Tools Window Help II EN L Mex x eas S Oe E T Winder Application O
19. aximum product diameter mm Reel diameter mm 1000 Unwinder In unwinding mode the diameter reached output signal will be activated when current diameter reaches the percentage indi cated in Percentage Diameter Completion parameter P112 of the reel diameter Maximum Build Up Ratio Minimum Build Up Ratio Product Diameter Reel Diameter Input Build Up Ratio Diameter TT 100 Unwinding 0 Percentage Diameter 95 00 Completion P112 9500 E Diameter Reached Unwinder nu 1 second Description When diameter reaches this percentage of max Percentage diameter comple 0 to 10000 9500 min diameter it will be activated one digital tion 0 0096 to 100 0096 95 0096 output to indicate that the diameter is almost complete Winder Unwinder Application Software 39 OMRON Winder Unwinder Application Software 5 6 Dynamic PID function It changes the PID proportional value depending on current calculated diameter ratio PID Proportional ProportionalMinDiameter Proportional ProportionalProductDiameter Diameter Reel Diameter ActualDiameter Product Diameter Parameter gt RX 2 to 50 0 2 to 5 0 RX 2 0 2 Proportional value for the minimum diameter MX2 0 to 2500 MX2 100 1 0 for the dynamic PID function 0 0 to 25 0 RX 2 to 50 0 2 to 5 0 RX 2 0 2 Proportional value for the maximum diameter MX2 0 to 2500 MX2
20. e safety Not doing so might result in a minor injury A holding brake is not a stop motion device designed to ensure safety Be sure to use a specified type of braking resistor regenerative braking unit In case of a braking resistor install a thermal relay that monitors the temperature of the resistor Not doing so might result in a moderate burn due to the heat generated in the braking resistor regenerative braking unit Configure a sequence that enables the Inverter power to turn off when unusual overheating is detected in the braking resistor regenerative braking unit The Inverter has high voltage parts inside which if short circuited might cause damage to itself or other property Place covers on the openings or take other precautions to make sure that no metal objects such as cutting bits or lead wire scraps go inside when installing and wiring Do not touch the Inverter fins braking resistors and the motor which become too hot during the power supply and for some time after the power shutoff Doing so may result in a burn Take safety precautions such as setting up a molded case circuit breaker MCCB that matches the Inverter capacity on the power supply side Not doing so might result in damage to property due to the short circuit of the load Do not dismantle repair or modify this product Doing so may result in an injury Winder Unwinder Application Software 7 OMRON Precautions for Safe Use e Installation
21. e to the machine when using the error retry function because the machine may abruptly start when stopped by an alarm e Be sure to confirm the RUN signal is turned off before resetting the alarm because the machine may abruptly start e Non stop function at momentary power interruption e Do not come close to the machine when selecting restart in the non stop function at momentary power interruption selection b050 because the machine may abruptly start after the power is turned on e Operation stop command e Provide a separate emergency stop switch because the STOP key on the Digital Operator is valid only when function settings are performed e When checking a signal during the power supply and the voltage is erroneously applied to the control input terminals the motor may start abruptly Be sure to confirm safety before checking a signal e Product Disposal e Comply with the local ordinance and regulations when disposing of the product Winder Unwinder Application Software 9 OMRON Warning labels Warning labels are located on the inverter as shown in the following illustration Be sure to follow the instructions ES LL omron O O Oo POWER RUN WARNING ALARM K READ WRITE ESC A iJ amp I FWD REV STOP RUN RUN RESET M E L 7 one r
22. e transport to or through the State of California USA Perchlorate Material special handling may apply See www dtsc ca gov hazardouswaste perchlorate The 3G3AX OP05 has the lithium primary battery with more than 6 ppb of perchlorate Label or mark the above display on the exterior of all outer shipping packages of your products when exporting your products which the 3G3AX OP05 are installed to the State of California USA 8 Winder Unwinder Application Software OMRON e Do not short and charge disassemble heat put into the fire or apply strong impact on the battery The battery may leak explode produce heat or fire Never use the battery which was applied strong impact due to such as fall on the floor it may leak e UL standards establish that the battery shall be replaced by an expert engineer The expert engineer must be in charge of the replacement and also replace the battery according to the method described in this manual e When the display of LCD Digital Operator can not be recognized due to the service life replace the LCD Digital Operator Precautions for Correct Use Installation e Mount the product vertically on a wall with the product s longer sides upright The material of the wall has to be noninflammable such as a metal plate e Main circuit power supply e Confirm that the rated input voltage of the Inverter is the same as AC power supply voltage e Error Retry Function e Do not come clos
23. election mode selection s c006 58 X 02 DP Freeze diameter Besedameerf ndon s owsa O O o ooa Digital outputs Analog inputs O Tension feedback RX MX2 Tension feedback 096 to 10096 dancer load cell Analog outputs AM C028 13 YA 01 DP Actual diameter Actual diameter voltage analog output 4 4 Monitor parameters Parameter No ds mimis Line speed in m min Aus Diameter T Diameter in mm d027 Taper tension reference in 96 5000 50 00 Winder Unwinder Application Software 33 OMRON Winder Unwinder Application Software 4 5 Error codes E51 RX MX2 IDiameter preset value error IDetects if the diameter preset value is lower than minimum build up ratio E60 x RX E70 a Encoder disconnection 3G3AX PG board Detects the encoder disconnection and connection failure x E61 x RX tns Overspeed 3G3AX PG board Detects if the motor rotation has been executed E71 x RX E69 x RX uu 3G3AX PG connection error Detects PG board connection failure E79 x RX 4 6 Other relevant parameters Maximum frequency for Winder to be calculated A004 Maximum frequency depending on Maximum LineSpeed and Reel Diameter See section 4 1 A016 Analog input filter Analog input filter Drive Programming EzSQ selection 02 Always ON Run Winder application program A071 PID selection 01 Enable Enable PID A076 PID feedback selection 01 Input via O PID feedback selection OFF
24. equipment amusement machines vehicles safety equipment and installations subject to separate industry or government regulations e Systems machines and equipment that could present a risk to life or property Please know and observe all prohibitions of use applicable to the products NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS HISK TO LIFE OR PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS AND THAT THE OMRON PRODUCTS ARE PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM PROGRAMMABLE PRODUCTS OMRON shall not be responsible for the user s programming of a programmable product or any consequence thereof 4 Winder Unwinder Application Software OMRON Disclaimers CHANGE IN SPECIFICATIONS Product specifications and accessories may be changed at any time based on improvements and other reasons It is our practice to change model numbers when published ratings or features are changed or when significant construction changes are made However some specifications of the products may be changed without any notice When in doubt special model numbers may be assigned to fix or establish key specifications for your application on your request Please consult with your OMRON representative at any time to confirm actual specifications of purchased products DIMENSIONS AND WEIGHTS Dimensions and weights are nominal and are no
25. er lines e Operation and adjustment e Be sure to confirm the permissible range of motors and machines before operation because the inverter speed can be changed easily from low to high e Provide a separate holding brake if necessary If the Drive Programming stops during multi function output the output status is held Take safety precautions such as stopping peripheral devices If the clock command is used in Drive Programming an unexpected operation may occur due to weak battery Take measures such as detecting a weak battery by a check that the clock data returns to the initial setting and stopping the inverter or programs When the LCD Digital Operator is removed or disconnected Drive Programming is in a waiting status by the clock command e Maintenance and Inspection e Be sure to confirm safety before conducting maintenance inspection or parts replacement e The capacitor service life is influenced by the ambient temperature Refer to Smoothing Capacitor Life Curve described in the manual When a capacitor reaches the end of its service life and does not work as the product you need to replace the capacitor e When disposing of LCD digital operators and wasted batteries follow the applicable ordinances of your local government When disposing of the battery insulate it using tape CREE RC RR EDUC The following display must be indicated when products using lithium primary batteries with more than 6 ppb of perchlorate ar
26. ity is asserted INNO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY REPAIR OR OTHER CLAIMS REGARDING THE PRODUCTS UNLESS OMRON S ANALYSIS CONFIRMS THAT THE PRODUCTS WERE PROPERLY HANDLED STORED INSTALLED AND MAINTAINED AND NOT SUBJECT TO CONTAMINATION ABUSE MISUSE OR INAPPROPRIATE MODIFICATION OR REPAIR Winder Unwinder Application Software 3 OMRON Application Considerations SUITABILITY FOR USE OMRON shall not be responsible for conformity with any standards codes or regulations that apply to the combination of products in the customer s application or use of the products At the customer s request OMRON will provide applicable third party certification documents identifying ratings and limitations of use that apply to the products This information by itself is not sufficient for a complete determination of the suitability of the products in combination with the end product machine system or other application or use The following are some examples of applications for which particular attention must be given This is not intended to be an exhaustive list of all possible uses of the products nor is it intended to imply that the uses listed may be suitable for the products Outdoor use uses involving potential chemical contamination or electrical interference or conditions or uses not described in this manual e Nuclear energy control systems combustion systems railroad systems aviation systems medical
27. located at the lower left of the front and back covers Cat No I214E EN 01 to Revision code Revision code Description 01 April 2014 Original production Related Manuals Cat No Description 1560 E2 RX User s Manual I130E EN RX Quick Start Guide 1570 E2 MX2 User s Manual I129E EN MX2 Quick Start Guide 1579 E2 LCD Digital Operator User s Manual 1580 E2 MX2 RX LX Drive Programming User s Manual Winder Unwinder Application Software 13 OMRON 14 Winder Unwinder Application Software Winder Unwinder Application Software IOVERVIEW isnt UE oncewenscaveasdecsewens seeds DATI INA PUE 3 E e Te T AAR 3 TD GHAI OF ts USER s quad NN 3 BOISE SC EC CC dut tatus E unu 3 1 4 Advantages using the application SO 76 4 L5 vADDHCHUOIMIGOTODE audiuit d OR NEN RU Rate dt 4 ON OE T 4 2 PREPARATION AND SYSTEM CONFIGURATION sss 5 21 NS NN OR and POWEr CICUS NSR 5 LIDE SWC NE 9 23 AGONMCCHONGIACTAI E ote NN tu costi atu 6 2 4 Encoder connection 3G3AX PG Board Only for 3G3RX inverter sesse 8 3 APPLICATION CONFIGURATION STEPS cere 9 BI MOTO UTOR CN 9 3 2 Parameter settings and Drive Programming application sss 10 4 DRIVE PROGRAMMING PARAMETERS eee eene eene enne 17 AD Application ECOUPONS RR EE RE 17 4 2 Application software parameters dudo eee 18 43 THDULS OUIDUIS sepapat anie EE 19 AA Monitor parameters Se 19 RBO TN 20 46 Oiher tele
28. lp Dm GF eS mx ean LE OR Saeed Eile Edit View Drive Tools Window Help DS ae E Ote Transfer from will overwrite the active document with the selected data from 26 Winder Unwinder Application Software OMRON APPLICATION CONFIGURATION STEPS After pressing ok the parameters will start to be transferred Please wait while the parameters are transferred from the drive Close Workspace Save Workspace Save As Workspace lel Save Save As Gil Save AIL as Print Print Prev age Li Page Setup EV TI Winder Unwinder Application Software 27 omnon Winder Unwinder Application Software Go to the folder where you have the driveprogram file Select the file and press Open button Z Open Organize New folder Ir Favorites Name RE Desktop RXDP 0090 WINDER UNWINDER PID CONTROL WITH DIAMETER SENSOR driveprogram 08 07 Downloads El Recent Places aw Libraries Eg Documents a Music O OMRON l Pictures B Videos jE ortjos on IABITOO7C amp Programs C File name RXDP 0090 WINDER UNWINDER CLV WITH DIAMETER SENS All Supported Types prm p v 11 In the project tree go to the section Drive Programming with double click H E Parameter Editor T E Graphs Note It will be showed the DP section without DP winder application source code 13 Compile the program
29. nder Unwinder Application Software 19 OMRON Winder Unwinder Application Software 2 3 Connection diagram 3G3RX connection diagram 3 phase 200 V oh lt 3 phase 400 V AC Short circuit wire To wire the control circuit power supply and main circuit power supply separately be sure to remove the J51 connector wire first DC reactor optional J51 TC T O To Control N power supply STA 3 wire start STP 3 wire stop F R 3 wire FW RV Winder mode Preset diameter Freeze diameter Reset diameter Sequence input common Thermistor Frequency reference Frequency setting unit 500 to 2 kQ power supply B Tension feedback Frequency reference common L panewaw oz CM1 9 oes 9 l P Braking resistor optional L is the common reference for analog input and also for analog output 10kQ op AL2 Relay output 1 Ao 1 QO Common Q Diameter reached Not used Not used Not used Cad Not used e Multi function output common L 3 RS485 communication For termination resistors SN A Analog monitor output AM voltage output Diameter AMI Q Not used FM Digital monitor output PWM output Option 1 Option 2 i 20 Winder Unwinder Application Software OMRON PREPARATION AND SYSTEM CONFIGURATION 3G3MX2 connection diagram
30. nline E 4 Parameter Editor aa Basic Settings Parameter Access Tuning and motor basic data HL Reference Control H Motor Parameters A new dialog will appear showing the status of the downloading process Please wait while the program is transferred to CX Drive EL L 15 After downloading the DP program press the Start P program button or set parameter A017 Drive programming EzSO selection to 02 Always ON 16 Go to the Status Drive Programming section and verify that Tasks are running Double click in the Status gt Drive Programming section Fj TiS OL 1 Running a TA Curentexecuton step Tat G 2 25 Stwusoftsk 2 1 Running Parcel ccs dep ERES 1 Running Current execution step of task 4 Status of task 4 0 Not started W T5L Current execution step of task 5 gm Status of task 5 0 Not started Fj Number of tasks 2 Note This Winder Application software version is using task 1 task 2 and task 3 So verify that three tasks are running Winder Unwinder Application Software 29 omnon Winder Unwinder Application Software 17 Save your project Go to File gt Save As option S Workspacel CX Drive Drivel Winder Applicat E File Edit View Drive Tools Window Help ims lar Open Close 5 C Open Workspace Close Workspace Save Workspace Save As Workspace lel Save Save s Gil Save All
31. red to the end user of the inverter In this users manual you can find WARNING along the instruction WARNINGS indicates that incorrect handling may cause hazardous situation which may result in serious personal injury or death Winder Unwinder Application Software 17 OMRON Winder Unwinder Application Software 1 4 Advantages using the application software Functions supported in this application software Control mode e In this specific application case software winder tension is controlled by RX MX2 standard PID control dancer load cell Diameter sensor calculation A sensor for diameter measurement is needed e Diameter reset preset and freeze functionality Tension profile taper function 3 point tension profile to decrease tension by growing diameter Special digital output functions e Winding job finished job completion Other features 6 Change between winder and unwinder by digital input e Line speeds up to 600m min supported e Diameter monitor e Dynamic PID proportional 1 5 Application diagram Diameter Sensor O2 RX OI MX2 Terminal Reel Diameter in mm P100 Maximum Line Speed P101 Line Speed P127 by communications Build Up Ratio Preset Value P103 Diameter Preset Function X 01 Diameter Diameter Build Up Ratio P130 Diameter Freeze Function X 02 Calculation Diameter in mm P124 39 E
32. roperly If the calibration is not done properly the final speed reference will not be calculated properly Configure the winder application functions described in section 5 Winder Unwinder Application Software 31 OMRON Winder Unwinder Application Software aN N gt 2 2 E O e e pom e gn e 2 e me 3 oO e mg Parameter P100 0 to 65000 mm 42mm Winder unwinder reel diameter in mm Bn 0 to 600 35 P101 Maximum line speed 0 to 600m min m min 35m min Maximum line speed in m min 0 to 10000 2500 l a P102 Tension set point 0 0096 to 100 0096 25 0096 Tension reference 0 P103 Build up ratio preset value 1000 to 15000 BUR 1000 Build up ratio preset value ec ec 2 1 P104 IDiameter filter time 1 0 t ose oie Time used to filter diameter calculation 2 2 P105 Diameter filter time 2 0 Ns ise Osec 0 2sec Time used to filter diameter calculation l 1000 to P106 Taper middle build up ratio MaxBuildUpRatio S S 1500 This value will be used only for winder taper function gt 1000 Its the maximum build up ratio This value is the relation between reel diameter and maximum diameter P107 Maximum build up ratio BUR 6665 gt MinBuildUpRatio P108 Taper tension at minimum 0 to 10000 j j ini BUR 0 096 to 100 0096 1 0 to 10000 10000 Medium tension for taper function at medium i iddle B PIOS aber tension alma DD iia 1000
33. t to be used for manufacturing purposes even when tolerances are shown PERFORMANCE DATA Performance data given in this manual is provided as a guide for the user in determining suitability and does not constitute a warranty It may represent the result of OMRON s test conditions and the users must correlate it to actual application requirements Actual performance is subject to the OMRON Warranty and Limitations of Liability ERRORS AND OMISSIONS The information in this manual has been carefully checked and is believed to be accurate however no responsibility is assumed for clerical typographical or proofreading errors or omissions Winder Unwinder Application Software 5 OMRON Safety Precautions e Indications and meanings of safety information In this user s manual the following precautions and signal words are used to provide information to ensure the safe use of the RX MX2 Inverter The information provided here is vital to safety Strictly observe the precautions provided e Meanings of signal words Indicates an imminently hazardous situation which if not avoided is VAN D A N G R likely to result in serious injury or may result in death Additionally there may be severe property damage Indicates a potentially hazardous situation which if not avoided may C A U T N result in minor or moderate injury or in property damage e Alert symbols in this document DANGER Turn off the power supply
34. tion provides a proportional com pensation of the tension reference related with diameter build up ratio Avoid defects like telescoping and crushed rolls Normally tension will increase as diameter increases contrary compensation is required The cause for this effect is mainly Attack angle of product into roll changing by diameter Gravity effects on final tension due to weight of roll f D Tension Tension Minimum Build Up Ratio P108 Tension Middle Build Up Ratio P109 Tension Product Diameter P110 Build Up Ratio Diameter Minimum Build Up Ratio Middle Build Up Ratio Product Build Up Ratio Reel diameter P106 P107 P 1000 to This value will be used only for Winder taper P106 Tapper middle build up ratio MaxBuildUpRatio 1500 ficia 51000 Its the maximum build up ratio P107 Maximum build up ratio qoe BU 6665 This value is the relation between reel diameter gt MinBuildUpRatio and maximum diameter R P108 Taper tension at minimum 0 to 10000 x 10000 Minimum tension for taper function at mini B 0 096 to 100 0096 100 0096 mum diameter 0 UR 0 to 10000 10000 Medium tension for taper function at medium Pl T le B epee tensionabmigel BURY quce 10000088 100 0096 build up ratio P110 Taper tension at maximum 0 to 10000 10000 Maximum tension for taper function at maxi BUR 0 096 to 100 0096 100 0096 mum build up ratio Note Minimum b
35. uild up ratio value is a fixed value inside the application software 1000 It is not needed to configure it Winder Unwinder Application Software 35 OMRON Winder Unwinder Application Software 5 2 Preset function timing diagram It updates current diameter calculation estimation with the diameter introduced in the preset value parameter while the preset command is activated Input PresetCommand Output MaximumBUR P107 PresetValue P103 BUR Diameter Minimum BUR BUR Build Up Ratio Diameter Ratio Parameter A 6 e P103 Diameter amp BUR preset value 100 to 15000 BUR 1000 Diameter BuildUpRatio for preset value Note Diameter preset value must be introduced in build up ratio units Example Reel diameter 90 mm Preset diameter 450 mm Product diameter max diameter 900 mm 450mm mm PresetBuildUpRatio P103 1000 5000 36 Winder Unwinder Application Software OMRON WINDER UNWINDER APPLICATION FUNCTIONS 5 3 Freeze function timing diagram It freezes current diameter calculation estimation while the Freeze Command input is activated Input Output BUR Diameter FreezeCommand MaximumBUR 6 6 6 6 6 6 6 0 6 Maximum Diameter MinimumBUR Minimum Diameter 6 6 0 6 6 6 6 6 06 6 06 6 06 06 6 06 6 6 6 6 0 eo 6 06 ye 0 0 0 0 0 6
36. vant parameters OAI 20 5 WINDER UNWINDER APPLICATION FUNCTIONS sss ssssssss sss sss s lt 21 TT rc EM 21 2 2 Preset unc hon HW CACHAN EN 22 5 9 Pre JU tot m DAP OTT FAM Nehalem edet nunc ad e aic tor ec tete 23 24 Reser MCN TUIS AON sedes rM RERUM Ud E 24 2 uDTamefer Comp le HOITHRCHOTE oGaseladesten tuto tose pt ederet etna samen wend 25 2 0 DV HAC PID JUROM asistida Ua ge UNE t a AME AO A OE edd 26 OMRON Winder Unwinder Application Software 15 OMRON 16 Winder Unwinder Application Software OMRON Winder Unwinder Application Software 1 OVERVIEW 1 1 Introduction This user s manual explains how to use the Winder Unwinder Application program for 3G3RX 3G3M X2 inverter Be sure to read this user s manual carefully before using this Winder Unwinder Application program and keep it on hand for further reference Real Line Speed Winder gt PR Qt x Z i S I el a ii a UnWinder i Ti E pm 00 089 gi 410v 8i l i M j l S 1 7I PID Control c eI a Si Ov y i s ol 9 KH i PA l i d Si Torque Control Speed Limits S i i 1 cf ANN 1 Start MEM S I AA ALL up sm iam atm mo em m m n m La m m m m e r m r m m e m m Start Stop Tension Reference Tension Reference Stop i CW CCW Preset Diameter Preset Diameter CW CCW Winder Un
37. very precaution has been taken in the preparation of this manual Nevertheless OMRON assumes no responsibility for errors or omissions Neither is any liability assumed for damages resulting from the use of the information contained in this publication OMRON Winder Unwinder Application Software Read and Understand this Manual Please read and understand this manual before using the product Please consult your OMRON representative if you have any questions or comments Warranty and Limitations of Liability WARRANTY OMRON s exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year or other period if specified from date of sale by OMRON OMRON MAKES NO WARRANTY OR REPRESENTATION EXPRESS OR IMPLIED REGARDING NON INFRINGEMENT MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE OF THE PRODUCTS ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE OMRON DISCLAIMS ALL OTHER WARRANTIES EXPRESS OR IMPLIED LIMITATIONS OF LIABILITY OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES LOSS OF PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS WHETHER SUCH CLAIM IS BASED ON CONTRACT WARRANTY NEGLIGENCE OR STRICT LIABILITY In no event shall the responsibility of OMRON for any act exceed the individual price of the product on which liabil
38. winder Reset Diameter Reset Diameter Winder Unwinder Freeze Diameter Freeze Diameter 3G3MX2 3G3MX2 Note In this specific Winder Unwinder Application program the diameter sensor is given through the analog input O2 RX OI MX2 and the tension feedback through analog input O Winder line speed reference must be given through communications 1 2 Handling of this user s manual The contents of this user s manual are subject to change without prior notice No part of this users manual may be reproduced in any form without the publisher s permission If you find any incorrect description missing description or have questions concerning the contents of this users manual please contact the publisher 1 3 Safety instruction Be sure to read this user s manual inverter users manual and appended documents thoroughly before using Winder Unwinder Application program and the inverter Ensure you to understand and follow all safety information precautions and operating and handling instructions for the correct use of the inverter Always use the inverter strictly within the range of specifications described in the inverter user s manual and cor rectly implement maintenance and inspection to prevent fault from occurring When using the inverter together with optional products also read the manual of those products Note that this users manual and the manual for each optional product to be used should be delive
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