Mitsubishi Electric A800 Plus Series Parts list manual

Roll to Roll Function
800-R2R
INVERTER A800 Plus INSTRUCTION MANUAL (ROLL TO ROLL FUNCTION MANUAL)
D
ROLL TO ROLL FUNCTION MANUAL
FR-A820-00046(0.4K)-04750(90K)-R2R
FR-A840-00023(0.4K)-06830(280K)-R2R
FR-A842-07700(315K)-12120(500K)-R2R
The FR-A800-R2R inverter has dedicated functions for roll to roll applications, in addition to the functions of the
standard type FR-A800 inverter.
This Roll to Roll Function Manual explains the functions dedicated to the FR-A800-R2R inverter. For the
functions not found in this Function Manual, refer to the Instruction Manual of the FR-A800 inverter.
In addition to this Roll to Roll Function Manual, please read the Instruction Manual of the FR-A800 inverter
carefully. Do not use this product until you have a full knowledge of the equipment, safety information and
instructions.
Please forward this Function Manual to the end user.
INVERTER
IB(NA)-0600622ENG-D(1808) MEE Printed in Japan Specifications subject to change without notice.
HEAD OFFICE: TOKYO BUILDING 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN

CONTENTS 1
1 INTRODUCTION 5
1.1 FR-A800-R2R overview 5
1.2 SND rating 7
1.2.1 Multiple rating setting........................................................................................................................................7
2 PARAMETER LIST 10
2.1 Parameter list (by parameter number) 10
2.2 Parameter list (by function group) 31
3 DANCER FEEDBACK SPEED CONTROL 41
3.1 Dedicated function list 41
3.2 System configuration example 42
3.3 Control block diagram 42
3.3.1 Analog input signals and pulse train input signals ..........................................................................................43
3.4 Parameter setting procedure for dancer feedback speed control 44
3.4.1 Parameter setting procedure ..........................................................................................................................44
3.4.2 Offline auto tuning...........................................................................................................................................49
3.4.3 Speed control gain adjustment .......................................................................................................................53
3.4.4 PID gain adjustment .......................................................................................................................................57
3.5 Dancer feedback speed control details 58
3.5.1 Dancer feedback speed control function selection .........................................................................................58
3.5.2 Winding/unwinding shaft selection..................................................................................................................59
3.5.3 Line speed command input.............................................................................................................................60
3.5.4 Compensation for line speed command input ................................................................................................66
3.5.5 Acceleration/deceleration time setting for line speed command.....................................................................69
3.5.6 Dancer roll setting...........................................................................................................................................71
3.5.7 Dancer roll position detection .........................................................................................................................73
3.5.8 PID offset displacement..................................................................................................................................73
3.5.9 Dancer roll malposition detection....................................................................................................................74
3.5.10 Tension PI gain tuning....................................................................................................................................76
3.5.11 PID control gain setting...................................................................................................................................84
3.5.12 Integral control action setting..........................................................................................................................85
3.5.13 Differential control action setting.....................................................................................................................86
3.5.14 PID control gain selection...............................................................................................................................86
3.5.15 Reel change function......................................................................................................................................90
3.5.16 Analog output signal function for dancer tension setting ................................................................................92
4 TENSION SENSOR FEEDBACK SPEED
CONTROL 97
4.1 Dedicated function list 97
CONTENTS

2CONTENTS
4.2 System configuration example 98
4.3 Control block diagram 98
4.4 Parameter setting procedure for tension sensor feedback speed control 99
4.4.1 Parameter setting procedure.......................................................................................................................... 99
4.4.2 PID gain adjustment ..................................................................................................................................... 104
4.5 Tension sensor feedback speed control details 105
4.5.1 Tension feedback setting ............................................................................................................................. 106
4.5.2 Tension feedback detection ......................................................................................................................... 107
4.5.3 PID offset displacement ............................................................................................................................... 108
4.5.4 Tension feedback malposition detection ...................................................................................................... 108
5 TENSION SENSORLESS TORQUE CONTROL 110
5.1 Dedicated function list 110
5.2 System configuration example 110
5.3 Control block diagram 111
5.3.1 Block diagram of tension sensorless torque control function ....................................................................... 111
5.4 Parameter setting procedure for tension sensorless torque control 112
5.4.1 Parameter setting procedure........................................................................................................................ 112
5.5 Tension sensorless torque control details 117
5.5.1 Tension sensorless torque control setting method....................................................................................... 117
5.5.2 Input method of tension command ............................................................................................................... 118
5.5.3 Torque generation direction setting.............................................................................................................. 121
5.5.4 Taper function .............................................................................................................................................. 124
5.5.5 Inertia compensation function ...................................................................................................................... 130
5.5.6 Mechanical loss compensation function....................................................................................................... 135
5.5.7 Stall mode function....................................................................................................................................... 137
6 TENSION SENSOR FEEDBACK TORQUE
CONTROL 139
6.1 Dedicated function list 139
6.2 System configuration example 139
6.3 Control block diagram 140
6.3.1 Block diagram of tension sensor feedback torque control function .............................................................. 140
6.4 Parameter setting procedure for tension sensorless torque control 141
6.4.1 Parameter setting procedure........................................................................................................................ 141
6.5 Tension sensor feedback torque control details 147
6.5.1 Tension sensor feedback torque control function selection ......................................................................... 148
6.5.2 Winding/unwinding shaft selection ............................................................................................................... 149
6.5.3 Tension feedback setting ............................................................................................................................. 149
6.5.4 Tension feedback malposition detection ...................................................................................................... 150

CONTENTS 3
6.5.5 Tension feedback detection..........................................................................................................................151
6.5.6 PID control gain setting.................................................................................................................................151
6.5.7 Integral control action setting........................................................................................................................151
6.5.8 Differential control action setting...................................................................................................................151
6.5.9 PID control gain selection.............................................................................................................................152
7 SPEED CONTROL OF INTERMEDIATE SHAFTS
153
7.1 System configuration example 153
7.2 Parameter setting procedure for speed control of intermediate shafts 154
7.2.1 Parameter setting procedure ........................................................................................................................154
7.2.2 Offline auto tuning.........................................................................................................................................157
7.2.3 Speed control gain adjustment .....................................................................................................................157
8 WINDING DIAMETER COMPENSATION
FUNCTION 158
8.1 Winding diameter calculation and winding diameter compensation function 158
8.2 Winding diameter calculation setting 160
8.2.1 Block diagram...............................................................................................................................................160
8.2.2 Basic setting for winding diameter calculation ..............................................................................................161
8.2.3 Winding diameter calculation using actual line speed (actual line speed method).......................................163
8.2.4 Winding diameter calculation using material thickness (thickness method) .................................................166
8.2.5 Line speed at winding diameter calculated value activation .........................................................................167
8.2.6 Averaging process for winding diameter calculation.....................................................................................168
8.2.7 Minimum/maximum winding diameter ..........................................................................................................169
8.2.8 Winding diameter compensation speed filter................................................................................................170
8.2.9 Target winding diameter achieved................................................................................................................171
8.2.10 Winding diameter calculation at a start.........................................................................................................171
8.2.11 Initial winding diameter calculation at a start (Tension sensor feedback speed control / tension sensorless
torque control / tension sensor feedback torque control)..............................................................................175
8.2.12 Winding diameter / winding length storage...................................................................................................176
8.2.13 Speed control proportional gain selection according to the winding diameter calculation result ..................179
9 ROLL TO ROLL FUNCTION RELATED
PARAMETERS 181
9.1 Monitoring of dedicated functions 181
9.1.1 Monitoring of roll to roll dedicated functions .................................................................................................181
9.1.2 Monitor reference..........................................................................................................................................186
9.2 Roll to roll dedicated I/O signal 188
9.2.1 Input signal ...................................................................................................................................................188
9.2.2 Output signal.................................................................................................................................................191
9.3 Two-way operation function 192

4CONTENTS
9.4 Operation command source and speed command source (Pr.338, Pr.339) 193
9.5 Encoder input option selection 194
10 APPENDIX 195
10.1 Differences in the functions from the standard inverter 195
10.2 Compatible options 197
10.3 Common specifications 198
10.4 Application examples 199
10.4.1 Dancer feedback speed control with roll diameter compensation for printers.............................................. 199
10.4.2 Dancer feedback speed control with roll diameter compensation for wire drawing machines ..................... 204
10.4.3 Tension sensorless torque control with roll diameter compensation for printers.......................................... 208
10.4.4 Tension sensor feedback torque control with roll diameter compensation for fabric inspection machines .. 212
10.5 Parameters (functions) and instruction codes under different control methods 217
10.6 Index 238