Mitsubishi Electric 800 Plus Series User manual

for Roll to Roll
INVERTER
FR-A800 Plus
The optimum functions for roll to roll applications are added.
• System simplification
•
Wide range of applications
• Easy startup and adjustment
FACTORY AUTOMATION
L(NA)06101ENG-A (1603) MEE
HEAD OFFICE: TOKYO BLDG., 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN
Mitsubishi Electric Corporation Nagoya Works is a factory certified for ISO14001 (standards for
environmental management systems)and ISO9001(standards for quality assurance management systems)

Features
Standard specifications
Outline dimensions
Roll to roll function related parameters
Warranty
Support
6
22
27
29
34
35
Contents
2
3
1
2
3
4
5
6
Global Player
GLOBAL IMPACT OF
MITSUBISHI ELECTRIC
We bring together the best minds to
create the best technologies. At
Mitsubishi Electric, we understand
that technology is the driving force of
change in our lives. By bringing
greater comfort to daily life, maximiz-
ing the efficiency of businesses and
keeping things running across
society, we integrate technology and
innovation to bring changes for the
better.
Mitsubishi Electric is involved in many areas including the following
Energy and Electric Systems
A wide range of power and electrical products from generators to large-scale displays.
Electronic Devices
A wide portfolio of cutting-edge semiconductor devices for systems and products.
Home Appliance
Dependable consumer products like air conditioners and home entertain-
ment systems.
Information and Communication Systems
Commercial and consumer-centric equipment, products and systems.
Industrial Automation Systems
Maximizing productivity and efficiency with cutting-edge automation technology.
Through Mitsubishi Electric’s vision, “Changes for the Better“ are possible for a brighter future.

Features
Standard specifications
Outline dimensions
Roll to roll function related parameters
Warranty
Support
6
22
27
29
34
35
Contents
2
3
1
2
3
4
5
6
Global Player
GLOBAL IMPACT OF
MITSUBISHI ELECTRIC
We bring together the best minds to
create the best technologies. At
Mitsubishi Electric, we understand
that technology is the driving force of
change in our lives. By bringing
greater comfort to daily life, maximiz-
ing the efficiency of businesses and
keeping things running across
society, we integrate technology and
innovation to bring changes for the
better.
Mitsubishi Electric is involved in many areas including the following
Energy and Electric Systems
A wide range of power and electrical products from generators to large-scale displays.
Electronic Devices
A wide portfolio of cutting-edge semiconductor devices for systems and products.
Home Appliance
Dependable consumer products like air conditioners and home entertain-
ment systems.
Information and Communication Systems
Commercial and consumer-centric equipment, products and systems.
Industrial Automation Systems
Maximizing productivity and efficiency with cutting-edge automation technology.
Through Mitsubishi Electric’s vision, “Changes for the Better“ are possible for a brighter future.

for Roll to Roll
4
5
SPECIALTY
Pursuing optimum functions
to meet our customers' needs
A new lineup of dedicated inverters for specialized fields are born!
The optimum functions for each dedicated field are added to the already
high performance and high functionality FR-A800 series inverter.

for Roll to Roll
4
5
SPECIALTY
Pursuing optimum functions
to meet our customers' needs
A new lineup of dedicated inverters for specialized fields are born!
The optimum functions for each dedicated field are added to the already
high performance and high functionality FR-A800 series inverter.

6
7
1
1
Roll to Roll
In roll to roll applications, control is necessary for machining of elongated products such as paper, film, and
thread. Processing types include printing, slitting, coating, and twisting. High productivity can be achieved by
stable tension control.
The FR-A800-R2R inverter can be used in a wide variety of systems with various dedicated functions.
Intermediate shaft Winding/unwinding shaft
The line speed is controlled by driving
the intermediate shafts such as a
reference shaft with a constant
winding diameter or the feeding shaft.
Tension control (speed control /
torque control) is enabled by input-
ting the dancer roll position or the
feedback from the tension sensor.
Stable control can be achieved
by winding diameter calculation,
even with a large difference be-
tween the maximum and mini-
mum diameters.
System simplification
Stable winding/unwinding can be achieved by the
inverter alone.
Wide range of applications
The FR-A800-R2R inverter enables the use in various
system applications such as winding/unwinding in the
wire drawing machines and printers.
Easy startup and adjustment
Parameters can be used for mechanical adjustment
according to applications.
Features
Features
Features
Features
Roll to roll
dedicated model with
functions optimum for
winding/unwinding

6
7
1
1
Roll to Roll
In roll to roll applications, control is necessary for machining of elongated products such as paper, film, and
thread. Processing types include printing, slitting, coating, and twisting. High productivity can be achieved by
stable tension control.
The FR-A800-R2R inverter can be used in a wide variety of systems with various dedicated functions.
Intermediate shaft Winding/unwinding shaft
The line speed is controlled by driving
the intermediate shafts such as a
reference shaft with a constant
winding diameter or the feeding shaft.
Tension control (speed control /
torque control) is enabled by input-
ting the dancer roll position or the
feedback from the tension sensor.
Stable control can be achieved
by winding diameter calculation,
even with a large difference be-
tween the maximum and mini-
mum diameters.
System simplification
Stable winding/unwinding can be achieved by the
inverter alone.
Wide range of applications
The FR-A800-R2R inverter enables the use in various
system applications such as winding/unwinding in the
wire drawing machines and printers.
Easy startup and adjustment
Parameters can be used for mechanical adjustment
according to applications.
Features
Features
Features
Features
Roll to roll
dedicated model with
functions optimum for
winding/unwinding

The present winding diameter for
the winding/unwinding shaft is
calculated from the actual line
speed or the actual motor speed.
8
9
Winding diameter calculation
System simplification
The FR-A800-R2R inverter has various dedicated functions such as winding diameter calculation, providing
stable winding/unwinding control independently.
By adjusting the speed control
proportional gain according to the
winding diameter, the response
level can be kept constant.
Speed control proportional
gain compensation
The line speed command and actual line
speed required for calculating the winding
diameter can be input through the analog
input terminal or plug-in option.
Line speed command
input selection / actual
line speed input selection
When material rupture (break) occurs and
the sensor feedback value (dancer/tension
feedback) is held at the upper/lower limit
for a certain period of time, the break
detection signal is output.
Dancer roll malposition detection
By automatically adjusting the tension
PI gain for PID control, time required for
adjustment is significantly cut down.
Anyone can start the system easily.
Tension PI gain tuning
Example of dancer feedback control (winding)
Variable
tension
Constant
tension
Dancer roll
position
Break detection
time
Break
detection
signal
Start
signal
Winding diameter calculation function selection
The present value of winding diam-
eter and winding/unwinding length
can be stored.
The winding diameter and winding
length values are stored in the in-
verter even during power-OFF.
Winding diameter /
winding length storage
D = V
π × n × Z
PID control is performed using feedback
of the detected dancer roll position or
feedback from the tension sensor. Stable
control can be achieved in combination
with the winding diameter calculation.
•Actual line speed calculation method
The winding diameter is calculated
from the line speed and the main
speed (actual motor speed).
•Thickness calculation method
The material thickness is added up to
find the overall winding diameter.
D = Initial diameter ± 2 × d × N × Z
D: Diameter
n: Motor speed
d: Material thickness
V: Line speed
N: Number of rotations
Z: Reduction ratio
Initial winding diameter calculation
When the winding diameter changes after the material change or others, the present winding diameter is calculated in the following two ways.
The winding diameter calculation method can be selected in order to improve the
tension control performance.
•The present winding diameter is calculated based
on the dancer roll movement at a start from the
lower limit position to the target position.
•The present winding diameter is calculated from
the line speed and the actual motor speed. (The
system must be started at low speed.)
Dancer roll
target position
Dancer roll
position
Line speed
Start signal
Initial winding
diameter
calculation
Winding
diameter
measurement
Line speed at
winding diameter
calculation
activation
Winding
diameter
Start signal
Actual line
speed
The tension applied to the material is main-
tained constant by raising a commanded
torque to compensate mechanical loss
caused by factors such as friction on the
dancer roll or winding/unwinding shaft.
Mechanical loss
compensation function
During acceleration/deceleration, the ten-
sion applied to the material is maintained
constant by adjusting the variable tension
on the winding and unwinding sides.
Inertia compensation function
By adjusting the tension on the work-
piece, it is possible to avoid imperfec-
tions such as wrinkles or deformation
caused by the increase in diameter.
Taper function
The cushion time is set for the tension command to avoid sudden change in tension.
Tension command cushion time
Commanded
torque
Acceleration
Deceleration
Line speed
Tension
Winding
diameter
Taper ratio
Maximum
winding
diameter
Minimum
winding
diameter Diameter at taper start
Dancer feedback speed control
Tension sensor feedback speed control
The output torque of a motor is
controlled so that the tension applied
to a material is constant by calculat-
ing the winding diameter of a roll.
Tension sensorless torque control
Tension sensor feedback torque control
Vibrated dancer roll
Stabilized
dancer roll
V
d
D
Zn
N
1
1
Features
Features
Features
Features
Stabilized

The present winding diameter for
the winding/unwinding shaft is
calculated from the actual line
speed or the actual motor speed.
8
9
Winding diameter calculation
System simplification
The FR-A800-R2R inverter has various dedicated functions such as winding diameter calculation, providing
stable winding/unwinding control independently.
By adjusting the speed control
proportional gain according to the
winding diameter, the response
level can be kept constant.
Speed control proportional
gain compensation
The line speed command and actual line
speed required for calculating the winding
diameter can be input through the analog
input terminal or plug-in option.
Line speed command
input selection / actual
line speed input selection
When material rupture (break) occurs and
the sensor feedback value (dancer/tension
feedback) is held at the upper/lower limit
for a certain period of time, the break
detection signal is output.
Dancer roll malposition detection
By automatically adjusting the tension
PI gain for PID control, time required for
adjustment is significantly cut down.
Anyone can start the system easily.
Tension PI gain tuning
Example of dancer feedback control (winding)
Variable
tension
Constant
tension
Dancer roll
position
Break detection
time
Break
detection
signal
Start
signal
Winding diameter calculation function selection
The present value of winding diam-
eter and winding/unwinding length
can be stored.
The winding diameter and winding
length values are stored in the in-
verter even during power-OFF.
Winding diameter /
winding length storage
D = V
π × n × Z
PID control is performed using feedback
of the detected dancer roll position or
feedback from the tension sensor. Stable
control can be achieved in combination
with the winding diameter calculation.
•Actual line speed calculation method
The winding diameter is calculated
from the line speed and the main
speed (actual motor speed).
•Thickness calculation method
The material thickness is added up to
find the overall winding diameter.
D = Initial diameter ± 2 × d × N × Z
D: Diameter
n: Motor speed
d: Material thickness
V: Line speed
N: Number of rotations
Z: Reduction ratio
Initial winding diameter calculation
When the winding diameter changes after the material change or others, the present winding diameter is calculated in the following two ways.
The winding diameter calculation method can be selected in order to improve the
tension control performance.
•The present winding diameter is calculated based
on the dancer roll movement at a start from the
lower limit position to the target position.
•The present winding diameter is calculated from
the line speed and the actual motor speed. (The
system must be started at low speed.)
Dancer roll
target position
Dancer roll
position
Line speed
Start signal
Initial winding
diameter
calculation
Winding
diameter
measurement
Line speed at
winding diameter
calculation
activation
Winding
diameter
Start signal
Actual line
speed
The tension applied to the material is main-
tained constant by raising a commanded
torque to compensate mechanical loss
caused by factors such as friction on the
dancer roll or winding/unwinding shaft.
Mechanical loss
compensation function
During acceleration/deceleration, the ten-
sion applied to the material is maintained
constant by adjusting the variable tension
on the winding and unwinding sides.
Inertia compensation function
By adjusting the tension on the work-
piece, it is possible to avoid imperfec-
tions such as wrinkles or deformation
caused by the increase in diameter.
Taper function
The cushion time is set for the tension command to avoid sudden change in tension.
Tension command cushion time
Commanded
torque
Acceleration
Deceleration
Line speed
Tension
Winding
diameter
Taper ratio
Maximum
winding
diameter
Minimum
winding
diameter Diameter at taper start
Dancer feedback speed control
Tension sensor feedback speed control
The output torque of a motor is
controlled so that the tension applied
to a material is constant by calculat-
ing the winding diameter of a roll.
Tension sensorless torque control
Tension sensor feedback torque control
Vibrated dancer roll
Stabilized
dancer roll
V
d
D
Zn
N
1
1
Features
Features
Features
Features
Stabilized

10
11
During dancer feedback speed control, speed is controlled for keeping a constant tension on the workpiece
(winding/unwinding shaft) by using the dancer roll position and line speed data.
Further stable speed control is possible by performing PID control and winding diameter calculation in the inverter.
Tension sensor feedback speed control is a control function to keep the tension constant using feedback from the tension
sensor, instead of the dancer roll position.
Example of dancer feedback speed control
Speed detector
Actual line speed
Motor speed
Dancer roll position
Line speed command
Dancer roll
Relevant functions
By adjusting the speed control proportional
gain according to the winding diameter, the
response level can be kept constant.
By automatically adjusting the tension
PI gain, time required for adjustment is
significantly cut down. Anyone can
start the system easily.
The present winding diameter is calcu-
lated based on the dancer roll move-
ment at a start from the lower limit
position to the target position.
The circumferential speed of the winding
shaft is kept constant by calculating the
winding diameter of the winding shaft. Hunt-
ing can be reduced in dancer roll control.
The unwinding shaft rotation speed is
controlled to keep the dancer roll
position constant. The wire tension is
kept constant.
Some systems require peripheral devices such as regenerative options.
Wire drawing machine
Dancer feedback
speed control
The control function is useful for winding in the wire drawing machine. High-
speed winding is offered for high-inertia loads.
The FR-A800-R2R inverter offers four types of control functions which enable the use in various system applications such
as winding/unwinding in the wire drawing machines and printers.
Dancer roll
position
PID control
set point
Actual line
speed
Line speed
command
Functions integrated into the inverter
PID calculation
Winding diameter
calculation
Speed control
Acceleration/
deceleration
1
1
Wire drawing section Reference shaft Winding shaft
Actual line speed Motor speed Dancer roll position Line speed command
The wire drawing section pulls the wire at a constant speed to
make the wire thinner. For the winding shaft, the inverter pro-
vides dancer feedback speed control to keep the dancer roll
position, achieving constant tension winding.
In addition, using the winding diameter calculation function,
the circumferential speed of the winding reel is kept constant.
Wide range of applications
Features
Features
Features
Features
Dancer feedback
speed control
Winding diameter
calculation function
Speed control proportional
gain compensation
Initial winding
diameter calculation
Tension PI gain tuning
Dancer feedback
speed control
Tension sensor
feedback speed control
Tension sensorless
torque control
Tension sensor feedback
torque control
Inverter FR-A800-R2R
(with the FR-A8AP*1 installed)
Inverter FR-A800-R2R
(with the FR-A8AP*
1
and FR-A8AZ*
2
installed)
Encoder-equipped motor SF-PR-SC
Dancer roll
Speed detector
The products in the parentheses
are plug-in options.
*1 Used for vector control.
*2 Used for the line speed output.