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Avtron ADDvantage-32 Manual

Advanced control module (acm)
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ADDvantage-32
November 12,1993
I
Cleveland, Ohio
Rev. Aug. 2, 2010

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Summary of Contents for Avtron ADDvantage-32

  • Page 1 ADDvantage-32 ADVANCED CONTROL MODULE (ACM) November 12,1993 Cleveland, Ohio Rev. Aug. 2, 2010...
  • Page 28 ADDvantage-32 Advanced Control Module (ACM) TABLE 1-1. ADDvantage-32 SPECIFICATIONS--Cont. DESCRIPTION SPECIFICATION Chassis Ambient Temperature - Enclosed (See outline 0 to 40 C (32 to 104 drawing for minimum enclosure size.) - Open Chassis 0 to 50 C (32 to 122...
  • Page 61 Control Block Description ADDvantage-32 SECTION IV CONTROL BLOCK DESCRIPTION Table of Contents Page 2 AND.......................4-1 2 OR ........................4-3 4 ANALOG SELECT ..................4-4 5 AND.......................4-6 5 SUMMER ......................4-7 8 BIT INVERT ....................4-9 ABSOLUTE VALUE (ABS)................4-10 ANALOG INVERT ..................4-11 ANALOG SELECT ..................4-12 4.10...
  • Page 62 Control Block Description ADDvantage-32 Table of Contents (Cont.) Page 4.37 HI/LOW COMPARATOR ................4-53 4.38 IIT ........................4-55 4.39 LATCH ......................4-57 4.40 LEAD/LAG..................... 4-59 4.41 LEAST WIN ....................4-61 4.42 LOWPASS FILTER ..................4-62 4.43 MOST WIN ....................4-63 4.44...
  • Page 63 SECTION IV CONTROL BLOCK DESCRIPTION The ADDvantage-32 application software control scheme is based on control blocks. A control block is a software procedure which takes the inputs to the block, performs its function, and outputs the results. The following control blocks are not used in all software applications. They are a combination of all available control blocks.
  • Page 64 Control Block Description ADDvantage-32 Outputs OUT: Implementation OUT is set to one if both INPA and INPB are equal to one. OUT is set to a zero bit if either INPA or INPB is equal to zero.
  • Page 65 Control Block Description ADDvantage-32 2 OR This block implements a 2 input digital OR gate. FIGURE 4-2. 2 OR BLOCK Inputs INPA: INPB: Outputs OUT: Implementation OUT is set to one if either INPA or INPB is equal to one, else OUT = 0.
  • Page 66 Control Block Description ADDvantage-32 4 ANALOG SELECT This block is used to select one of four possible analog signal paths. It can be used to control the application of multiple reference signals to a single input point. FIGURE 4-3. 4 ANALOG SELECT BLOCK...
  • Page 67 Control Block Description ADDvantage-32 Implementation One of the input signals will be directed to the block output by the following combinations of control bits. CNTL1 CNTL2 INPA INPC INPB INPD...
  • Page 68 Control Block Description ADDvantage-32 5 AND This block implements a 5 input digital AND gate. INPA INPB INPC INPD INPE 5 INPUT LOGICAL AND 5ANDD101 FIGURE 4-4. 5 AND BLOCK Inputs INPA: INPB: INPC: INPD: INPE: Outputs OUT: Implementation OUT = 1 if INPA, INPB, INPC, INPD, and INPE are equal to one.
  • Page 69 Control Block Description ADDvantage-32 5 SUMMER The 5 Summer block selectively sums up to five analog input signals. The selection of which inputs are to be summed is set using a series of digital bits. BIT1 BIT2 BIT3 BIT4 BIT5...
  • Page 70 Control Block Description ADDvantage-32 Implementation OUT = (INPA × BIT1) + (INPB × BIT2) + (INPC × BIT3) + (INPD × BIT4) + (INPE × BIT5) If all 5 bits are low, then OUT = 0.
  • Page 71 Control Block Description ADDvantage-32 8 BIT INVERT The 8 BIT INVERT block takes the INP bit and the next seven and inverts them. INP+1 OUT+1 INP+7 OUT+7 8BITINVD101 FIGURE 4-6. 8 BIT INVERT BLOCK Inputs INP: Digital Outputs OUT: Digital Implementation If INP is high (1), then OUT will be low (0).
  • Page 72 Control Block Description ADDvantage-32 ABSOLUTE VALUE (ABS) The Absolute Value block selectively takes the absolute value of an analog variable. The state of EN BIT determines if the OUT value equals INP or the absolute value of the INP value.
  • Page 73 Control Block Description ADDvantage-32 ANALOG INVERT The Invert block is used to invert the value of an analog signal. FIGURE 4-8. ANALOG INVERT BLOCK Inputs INP: Analog Outputs OUT: Analog Implementation If EN is low, then OUT = INP. If EN is high, then OUT = -INP.
  • Page 74 Control Block Description ADDvantage-32 ANALOG SELECT This block is used to select one of two different analog signal paths; for example, switching from field current reference to field economy reference. INPA INPB ANALOG SELECT ANLOGSELLAN FIGURE 4-9. ANALOG SELECT BLOCK...
  • Page 75 Control Block Description ADDvantage-32 4.10 ANALOG SWITCH This block is used to switch in references to control the passage of an analog value or signal between control blocks. FIGURE 4-10. ANALOG SWITCH BLOCK Inputs INP: Analog Outputs OUT: Analog Implementation If the EN bit is high, then OUT is equal to INP.
  • Page 76 Control Block Description ADDvantage-32 4.11 ASM AUTO SHEET MARKER This block sets an output bit high when the number of sheets cut equals an operator- entered setpoint (MARK STPT). The output bit also goes high when the number of sheets cut equals integer multiples of the setpoint. Therefore, every nth sheet sets the output bit high.
  • Page 77 Control Block Description ADDvantage-32 Outputs AUTO MARK: Implementation If NUMBER SHTS = MARK STPT, then AUTO MARK goes high. If NUMBER SHTS = MARK STPT + MARK HOLD, then AUTO MARK goes low and n = n + 1. If MARK RESET bit is high, then n = 1.
  • Page 78 Control Block Description ADDvantage-32 4.12 BALANCE The Balance block switches from one control scheme to another without changing the current operating reference. FDBK OUTPUT TIME BALANCE URE 4-12. BALANCE BLOCK Inputs REF: Analog FDBK: Analog BAL: RET: Outputs OUT: Analog...
  • Page 79 Non-retentive Block On powerup of the ADDvantage-32, "err"=0. Retentive Block On powerup of the ADDvantage-32, DIF will be initialized under the following conditions: If RET = 0, DIF = 0. If RET = 1, DIF is set to its last value. DIF must also be configured to a retentive point (Y***:RET SETPT*) to be updated automatically on powerup.
  • Page 80 Control Block Description ADDvantage-32 4.13 BIT CONVERT The Bit Convert block converts 4 input bits into decimal numbers. The output changes only when the ENABLE bit is high. This block can also be used as the X_IN value of a Table block enabling 16 separate setpoints.
  • Page 81 Control Block Description ADDvantage-32 TABLE 4-13. Bit Convert Block OUT Values INPA INPB INPC INPD 4-19...
  • Page 82 Control Block Description ADDvantage-32 4.14 BIT INVERT A Bit Invert block is used to provide an output bit which is always the opposite state of the blocks input bit. BITINVRT BIT INVERT FIGURE 4-14. BIT INVERT BLOCK Inputs INP: Outputs...
  • Page 83 Control Block Description ADDvantage-32 4.15 BIT SELECT This block is used to select one of two different bit signal paths. FIGURE 4-15. BIT SELECT BLOCK Inputs INPA: INPB: SEL A: Outputs OUT: Analog Implementation If SEL A bit is high (set at 1), OUT is equal to INPA.
  • Page 84 Control Block Description ADDvantage-32 4.16 BUMPLESS SWITCH This block is used to provide a smooth "BUMPLESS" transition when switching control, reference, or feedback between two analog signals. REF2 RAT1 RAT2 REF1 BUMPSWLAN FIGURE 4-16. BUMPLESS SWITCH BLOCK Inputs REF1: Analog...
  • Page 85 Control Block Description ADDvantage-32 Outputs OUT: Analog DN1: DN2: Implementation The RAT1 input is the rate in units/second that the transfer takes place when switching from REF2 to REF1. RAT2 is the rate used when switching from REF1 to REF2. If the rate input = 0, the transfer is performed without ramping.
  • Page 86 Control Block Description ADDvantage-32 4.17 CDS COUNTS DURING STOP This block calculates the number of pulses that will be counted during a controlled stop. It is used in turret applications to determine when the drive run should be removed so that the turret will stop at the appropriate index position.
  • Page 87 Control Block Description ADDvantage-32 Implementation ⋅ ⋅ STOPPING ⋅ STOPPING ⋅ Where: CDS REF = REFERENCE IN RPM STOPPING RT = RATE IN RPM/SEC CDS ADJ = 2 × 60 SEC/MIN GEAR RATIO = NO UNITS PPR = PULSES/REV 4-25...
  • Page 88 Control Block Description ADDvantage-32 4.18 CLAMPING A Clamping block is used to restrict an analog signal to a value between user selectable high (MAXL) and low (MINL) limits. MAXL MINL CLAMPINGLAN FIGURE 4-18. CLAMPING BLOCK Inputs INP: Analog MAXL: Analog...
  • Page 89 Control Block Description ADDvantage-32 Implementation If INP > MAXL, then OUT = MAXL MAX = high, MIN = low If INP < MINL, then OUT = MINL MIN = high, MAX = low If MINL < INP < MAXL, then...
  • Page 90 Control Block Description ADDvantage-32 4.19 COM LOSS The Com Loss block is used as a communication watchdog. WDIN COM_LOSSLAN FIGURE 4-19. COM LOSS Inputs TIM: WDIN: Outputs WDOUT: TRIP: 4-28...
  • Page 91 Control Block Description ADDvantage-32 4.20 COM WD FIGURE 4-20. COM WD BLOCK Inputs WD IP: TOUT: Analog Outputs WDOUT TRIP Implementation When the EN input of the WD COM block is a logic level high (One Bit), the block monitors the WDIN input and will set the TRIP output if the input fails to toggle (transition from low to high or transition from high to low) within the time period (seconds) defined by the TOUT input.
  • Page 92 Control Block Description ADDvantage-32 4.21 COMPARATOR Use this block to set an output bit when the input is greater than a setpoint. The HYS input sets up hysteresis to debounce the output bit. COMPARTRLAN FIGURE 4-21. COMPARATOR BLOCK Inputs INP+:...
  • Page 93 Control Block Description ADDvantage-32 4.22 COPY The Copy block takes the analog value at the input and copies the value to the output. COPY BLOCK COPYD101 FIGURE 4-22. COPY BLOCK Inputs INP: Analog Outputs OUT: Analog Implementation OUT = INP...
  • Page 94 Control Block Description ADDvantage-32 4.23 CURRENT LIMIT This block provides the user with a feature for selecting an automatic taper back of the drive current limits by two events or using fixed current limits. The first event, if enabled by P***:BYPASS I2R = ZERO BIT (DEFAULT), prevents the drive from faulting on a MOTOR (II) T fault.
  • Page 95 Control Block Description ADDvantage-32 Regardless of the POS I LIMIT or NEG I LIMIT values for the motor current limits, actual armature current cannot exceed 200% of the drive D.C. MAX CONT nameplate current. Inputs POS I: Analog 0 - 300...
  • Page 96 Control Block Description ADDvantage-32 Tapered Current Limits If tapered current limits are desired, the BY I2R input must be low by configuring P***:BYPASS I2R = ZERO BIT. The current limit block constantly monitors the I2R Trip input (A***:IIR INTEGR) to detect when the motor armature current rises above 110%.
  • Page 97 Control Block Description ADDvantage-32 FIGURE 4-23. CURRENT LIMIT BLOCK DIAGRAM 4-35...
  • Page 98 Control Block Description ADDvantage-32 4.24 DEADBAND A Deadband block is used to reset an analog signal to zero when it is less than a user selected value. +DBAND -DBAND FIGURE 4-24. DEADBAND BLOCK Inputs REF: Analog DBAND: Analog Outputs OUT:...
  • Page 99 Control Block Description ADDvantage-32 4.25 DEMUX Inputs BIT1: BIT2: INP: Outputs OUT0 OUT1 OUT2 OUT3 Implementation The output bits are set as follows: If BIT1 = 0 and BIT2 = 0 and INP = 1 then OUT0 = 1, else OUT0 = 0...
  • Page 100 Control Block Description ADDvantage-32 4.26 DENSITY This block is used to calculate the approximate density of a winding or unwinding reel of product. It calculates the density of a roll over specific diameter ranges. The range needs to be large enough to make the calculation accurately, taking into account error in the diameter measurements.
  • Page 101 Control Block Description ADDvantage-32 Implementation When RES is high or on power up, the outputs = 0. When not RES, the following occurs: The outputs do not change until the number of winder revolutions equals WRAPS. (1 winder revolution = PPR amount of change in the CNT value) When this occurs, the following calculations are done.
  • Page 102 Control Block Description ADDvantage-32 4.27 DERIVATIVE GAIN (D/DT) The D/DT block performs a derivative gain function. It can be used for inertia compensation. GAIN TIME DGAINDDT FIGURE 4-27. DERIVATIVE GAIN BLOCK Inputs INP: Analog GAIN: Analog Analog Outputs OUT: Analog Implementation INP goes through a third order low pass filter with time constant LP in seconds.
  • Page 103 Control Block Description ADDvantage-32 4.28 DIFF TRIP This block is a combination differential comparator and timer. It is used to detect alarm or fault conditions. FIGURE 4-28. DIFF TRIP BLOCK Inputs INPA: Analog INPB: Analog TICS: Analog LMT: Analog Outputs...
  • Page 104 Control Block Description ADDvantage-32 When it counts up to the TICS input amount, the TRP output will go high. It will stay high as long as the absolute value of OUT is greater than LMT. As soon as the limit condition goes false, the timer is reset to zero and the TRP output goes low.
  • Page 105 Control Block Description ADDvantage-32 4.29 DIGITAL IN The Digital Input block enables the eight digital inputs (USER 7 through USER 14) from the optional FAX-32 board to be mapped to eight consecutive digital data table board addresses. FIGURE 4-29. DIGITAL IN BLOCK...
  • Page 106 Control Block Description ADDvantage-32 Inputs Reference FAX-32 digital inputs on J2 of board. Outputs START: Implementation The digital input for USER 7 through USER 14 will equal ONE/ON when the input’s corresponding FAX-32 J2 terminal is switched to +24 VDC.
  • Page 107 Control Block Description ADDvantage-32 4.30 DIGITAL OR This block implements a 4 input digital OR. INPA INPB INPC INPD DIGITOR 4 INPUT LOGICAL OR FIGURE 4-30. DIGITAL OR BLOCK Inputs INPA: INPB: INPC: INPD: Outputs OUT: Implementation OUT is set to one if either INPA, INPB, INPC, or INPD is equal to one; otherwise OUT equals zero.
  • Page 108 Control Block Description ADDvantage-32 4.31 DIVIDE The Divide block is used to divide two numbers. The block checks for divide by zero to avoid a fault. INPB=0 INPA INPB INPB=0 DIVIDELAN DIVIDE FIGURE 4-31. DIVIDE BLOCK Inputs INPA: Analog INPB:...
  • Page 109 Control Block Description ADDvantage-32 4.32 DROOP The Droop block modifies the speed reference to keep the drive armature current within a particular range. This is useful for controlling a nipped roll where it is in contact with another speed controlled section, or anywhere a "SOFT" speed regulator is required.
  • Page 110 Control Block Description ADDvantage-32 4.33 EIP TOUT FIGURE 4-33. EIP TOUT BLOCK Inputs NONE: Outputs EIP GENL TO EIP IMPL TO Implementation The EIP TOUT block resides in the ESBX module firmware, versions 682767v16 and later. The outputs of this block are written from the ESBX module directly to the drive application software, digital parameters D321:EIP GENL TO and D322:EIP IMPL TO.
  • Page 111 Control Block Description ADDvantage-32 message is scheduled to occur. This bit will transition from low to high, if the implicit communication becomes inactive for a time period greater than the R.P.I. time the implicit message was scheduled to occur. The bit will reset to a logic level low when Implicit messaging resumes.
  • Page 112 Control Block Description ADDvantage-32 4.34 ERROR This block is used to generate an error signal such as speed error or current error. INPA (A - B) INPB ERRORD101 FIGURE 4-34. ERROR BLOCK Inputs INPA: Analog INPB: Analog Outputs OUT: Analog...
  • Page 113 Control Block Description ADDvantage-32 4.35 FREQUENCY OUT The Frequency Out block is used to output a value to the frequency output located on the optional FAX-32 board. For accuracy of the frequency output, the frequency cannot go below 200 Hz. The full range of the frequency output is from 200 to 20,200 Hz. To use the frequency as bidirectional reference, set the offset so 10,100 Hz equals zero;...
  • Page 114 Control Block Description ADDvantage-32 4.36 GAIN The Gain block is used to scale and offset an analog signal. FIGURE 4-36. GAIN BLOCK Inputs INP: Analog GAIN: Analog OFF: Analog Outputs OUT: Analog Implementation OUT = INP × GAIN + OFF...
  • Page 115 Control Block Description ADDvantage-32 4.37 HI/LOW COMPARATOR This block sets the appropriate output bits when the input goes out of limits. Corrective action can be taken at this point. Overspeed and AT ZERO SPEED detection are implemented using a HI/LOW Comparator. The user can enable overspeed protection by configuring Y***:USR FAULT 2 = OVER SPEED.
  • Page 116 Control Block Description ADDvantage-32 Implementation If INP increases so: INP - (STPT × HYS/100) > _ (STPT × HI/100), HI bit goes high. If INP decreases so: INP + (STPT × HYS/100) < (STPT × HI/100), HI bit goes low.
  • Page 117 Control Block Description ADDvantage-32 4.38 Inputs Analog STPT Analog Analog Analog Analog IRES Outputs Analog Implementation The IIT block is used to determine the current overload for a motor. It can be used when more than one motor is used with the drive.
  • Page 118 Control Block Description ADDvantage-32 IRES -0.1 STPT FIGURE 4-38. IIT BLOCK 4-56...
  • Page 119 Control Block Description ADDvantage-32 4.39 LATCH LTCH1 LTCH2 HLD1 HLD2 OUT (LEVEL) OUT (EDGE) LATCHD101 FIGURE 4-39. LATCH BLOCK Inputs LTCH1: LTCH2: HLD1: HLD2: EDGE: Outputs OUT: Implementation If EDGE is low, then: If either latch (LTCH1 or LTCH2) is high and either hold (HLD1 or HLD2) is high, then OUT goes high and stays high, even if both latches later go low, as long as hold stays high.
  • Page 120 Control Block Description ADDvantage-32 If EDGE is high, then: If either latch (LTCH1 or LTCH2) transitions to high, the OUT goes high and stays high, even if both latches later go low. Upon transition of the latch bit high, it does not matter what the state of the hold (HLD1 or HLD2) is in determining the state of the OUT bit, as it does in "If Edge is...
  • Page 121 Control Block Description ADDvantage-32 4.40 LEAD/LAG LEAD COMPENSATION is added to a control loop to improve rise time and the damping. The disadvantage of LEAD COMPENSATION is that it adds instability to the system by increasing high frequency closed loop gain.
  • Page 122 Control Block Description ADDvantage-32 Implementation The LEAD/LAG block is implemented to simulate the following equation. H(s) = LAG/LEAD × (s + LEAD) / (s + LAG) Setting the LEAD value equal to LAG gives the block a unity gain. 4-60...
  • Page 123 Control Block Description ADDvantage-32 4.41 LEAST WIN The block is used to select the lowest value of the inputs for a setpoint reference. Inputs INPA: Analog INPB: Analog INPC: Analog Outputs OUT: Analog Implementation OUT will equal the lowest input value.
  • Page 124 Control Block Description ADDvantage-32 4.42 LOWPASS FILTER Use to filter out high frequency noise from analog signals, such as tension feedback. FREQ TIME C (SECONDS) LOWPASS BODE PLOT FIGURE 4-42. LOWPASS FILTER BLOCK Inputs INP: Analog Analog Outputs OUT: Analog Implementation The lowpass filter takes the INP, filters it for high frequency, then outputs it to OUT.
  • Page 125 Control Block Description ADDvantage-32 4.43 MOST WIN The block is used to select the highest value of the inputs for a setpoint reference. Inputs INPA: Analog INPB: Analog INPC: Analog Outputs OUT: Analog Implementation OUT will equal the highest input value.
  • Page 126 Control Block Description ADDvantage-32 4.44 MOV8 This block is used to move eight variables to another location, when enabled. FIGURE 4-44. MOV8 BLOCK Inputs IN1: Analog IN2: Analog IN3: Analog IN4: Analog IN5: Analog IN6: Analog IN7: Analog IN8: Analog...
  • Page 127 Control Block Description ADDvantage-32 Outputs OUT1: Analog Implementation If EN is low, the output does not change. When EN is high, OUT1 = Next location = Next location = Next location = Next location = Next location = Next location =...
  • Page 128 Control Block Description ADDvantage-32 4.45 MULTIPLY This block is used to multiply two analog signals. For example, draw input × speed reference signal. INPA (A X B MULTIPLY MULTIPLY FIGURE 4-45. MULTIPLY BLOCK Inputs INPA: Analog INPB: Analog Outputs OUT:...
  • Page 129 Control Block Description ADDvantage-32 4.46 NOTCH FILTER The Notch Filter block is a band reject filter designed to damp out machine resonance. In many cases this resonance is speed independent and occurs at approximately 5-7 Hz. fc = NOTCHFLLAN FIGURE 4-46. NOTCH FILTER BLOCK...
  • Page 130 Control Block Description ADDvantage-32 The WD parameter sets the width of the notch and is a unitless quantity ranging from 0.1 to 5.0, where 0.1 is the narrowest and 5.0 is the widest. For example, WD = 2 will reach approximately 90% of the input at 2 Hz from the frequency point.
  • Page 131 Control Block Description ADDvantage-32 4.47 OFF TIMER The block is used to delay actions after the input bit goes low. TICS OFFTIM FIGURE 4-47. OFF TIMER BLOCK Inputs TICS: Analog REF: Outputs OUT: Implementation If REF is high, then OUT is high.
  • Page 132 Control Block Description ADDvantage-32 4.48 ON TIMER Inputs TICS: Analog REF: Outputs OUT: Implementation If REF is low, then OUT is low. When REF goes high, the block waits for TICS amount of block executions before OUT goes high. If during the waiting REF goes back low, the counter is reset.
  • Page 133 Control Block Description ADDvantage-32 4.49 ONE SHOT The block is used to initiate an action only once. FIGURE 4-49. ONE SHOT BLOCK Inputs INP: Outputs OUT: Implementation If INP is low, then OUT is low. When INP goes high, OUT will go high for only one execution time.
  • Page 134 Control Block Description ADDvantage-32 4.50 PEAK DETECT Inputs Analog Outputs Analog Implementation As long as the RES and HLD bits are low OUT = the greater of Old OUT or INP (Greatest wins) if POS = 1 OUT = the least of Old OUT or INP (Greatest wins) if POS = 0 If the HLD bit is high, then OUT is held and INP is ignored.
  • Page 135 Control Block Description ADDvantage-32 4.51 PERCENT DIFFERENCE The Percent Difference block indicates that the percent difference between the reference and feedback is greater than the setpoint. It can be used to detect a web loss condition on a center driven winder application.
  • Page 136 Control Block Description ADDvantage-32 4.52 PERCENT MULTIPLY (Per Mult) The Percent Multiply block converts percentages entered using the keypad into actual values to be used in other blocks. For example, convert percent current limit into actual current limit. (A x B)
  • Page 137 Control Block Description ADDvantage-32 4.53 PROPORTIONAL AND INTEGRAL CONTROL (PI) The PI block performs a proportional and integral gain function on an error signal. It has inputs for maximum and minimum limits which prevent the loop from overcompensating. MAXL ERR>0...
  • Page 138 Control Block Description ADDvantage-32 Outputs Data Type Description OUT: Analog Output Signal IERR: Analog Integral Error Value MAX: Indication Output is Clamped at High Value MIN: Indication Output is Clamped at Low Value Implementation If HOLD = LOW and PRE = LOW, then:...
  • Page 139 Control Block Description ADDvantage-32 If HOLD = HIGH and PRE = LOW, then: The Integral Error component is held at its present value until the HOLD input goes low. The integrator hold input is used to hold the output value during major process disturbances.
  • Page 140 Control Block Description ADDvantage-32 4.54 PROPORTIONAL AND INTEGRAL CONTROL WITH CASCADED HOLD BITS (PI2) The PI2 block performs a proportional and integral gain function on an error signal. It has inputs for maximum and minimum limits which prevent the loop from overcompensating as well as separate bits to hold the integrator in either the positive or negative direction only.
  • Page 141 Control Block Description ADDvantage-32 Outputs Data Type Description OUT: Analog Output Signal IERR: Analog Integral Error Value MAX: Indication Output is Clamped at High Value MIN: Indication Output is Clamped at Low Value CMX: Indication Output is Clamped at High Value or is Being Held in the Positive Direction.
  • Page 142 Control Block Description ADDvantage-32 If OUT > MAXL or H-UP = 1: The CMX bit = 1 (HIGH). If OUT < MINL or H-DN = 1: The CMN bit = 1 (HIGH). If H-UP = HIGH and PRE = LOW, then: The Integral Error component cannot increase in the positive direction until the H-UP input goes low.
  • Page 143 Control Block Description ADDvantage-32 4.55 QUAD LTCH Inputs BIT1: BIT2: BIT3: BIT4: Outputs OUT1 OUT2 OUT3 OUT4 Implementation On a low to high transition of the EN input, the following outputs are sampled. If BIT1 = 1 then OUT1 = 1 else OUT1 = 0...
  • Page 144 Control Block Description ADDvantage-32 4.56 RAMP The Ramp block provides a variable rate linear ramp with user programmable smoothing. The purpose of this block is to provide a smooth reference from changing setpoint values. FIGURE 4-56. RAMP BLOCK Inputs REF:...
  • Page 145 Control Block Description ADDvantage-32 Outputs OUT: Analog RMP: Implementation If ZERO bit is low, OUT = 0. When ZERO bit goes high, OUT ramps to REF by the UP or DWN ramp rates. (Highest bit priority.) If the RES bit is high, OUT = REF. (Second in priority.) If the HLD bit is low, OUT is held at its present value.
  • Page 146 Control Block Description ADDvantage-32 4.57 RATE CHANGE This block is used to restrict the rate of change of an analog signal to a user programmable maximum rate limit. RATE TIME INPUT RATECHG OUTPUT FIGURE 4-57. RATE CHANGE BLOCK Inputs INP:...
  • Page 147 Control Block Description ADDvantage-32 4.58 RATIO The Ratio Block calculates the diameter of a center driven winder. It can be used for a winder or an unwinder. The initial diameter is a preset input value to obtain the correct diameter starting speed.
  • Page 148 On powerup of the ADDvantage-32, UNOUT = IDIAM BIOUT = IDIAM Retentive Block On powerup of the ADDvantage-32, BIOUT and UNOUT will be initialized under the following conditions: If RET = 0, then UNOUT = IDIAM and BIOUT = IDIAM If RET = 1, UNOUT and BIOUT are set to their last value.
  • Page 149 Control Block Description ADDvantage-32 4.59 RECIPE Inputs RECA: Analog RECB: Analog RECC: Analog ENA: ENB: ENC: Outputs OUT: Analog FLT: Implementation RECA, RECB, RECC points to the first address of 10 consecutive calibration locations. OUT points to the first address of 10 consecutive analog locations.
  • Page 150 Control Block Description ADDvantage-32 RECA RECB RECC RECIPE FIGURE 4-59. RECIPE BLOCK 4-88...
  • Page 151 4.60 RESOLVER 1 The RESOLVER 1 block is only used in conjunction with the Avtron optional Resolver board. The Resolver board mounts on the first SBX site on the Maxi system board. It provides 16 digital inputs and two digital outputs. This block provides the software interface to the board.
  • Page 152 Control Block Description ADDvantage-32 Implementation DO 1 and DO 2 bits control the two digital outputs on the resolver board. When they are equal to one, the corresponding output is high. CNT 1 and CNT 2 decide how many of the input bits are used in a BCD conversion for a...
  • Page 153 Control Block Description ADDvantage-32 4.61 RMP2 The RMP2 block provides a variable rate linear ramp with user programmable smoothing. The purpose of this block is to provide a smooth reference from changing setpoint values. The difference between the RAMP block and RMP2 is the RND input. RAMP uses a low-pass filter for rounding, causing a "J"...
  • Page 154 Control Block Description ADDvantage-32 FIGURE 4-61A RAMP CHANGE BLOCK Inputs Analog DWN: Analog REF: Analog Outputs RP OUT: Analog RMP: Implementation The following holds true while the HLD, ZERO bits are set high and the RES bit is low (explained in detail in ADDITIONAL CONTROL I/O).
  • Page 155 Control Block Description ADDvantage-32 If REF is increasing faster than UP, the RMP bit is set high and RP OUT ramps at the UP value (time period t to t of Figure 4-61). If REF decreases faster than DWN, the RMP...
  • Page 156 Control Block Description ADDvantage-32 FIGURE 4-61B The maximum rate of change allowed by the RMP2 ROC filter block depends upon time. This time is measured from the beginning of a ramp input to the present time instant. The maximum rate of change of the output of this filter is time dependent of the form: Rate = S * T Equation 4-61.1...
  • Page 157 Control Block Description ADDvantage-32 Exact Time ROC Filter (Slope) at OUT 1 Sec. 5 FPM/SEC 2 Sec. 10 FPM/SEC 3 Sec. 15 FPM/SEC 4 Sec. 20 FPM/SEC 5 Sec. 20 FPM/SEC Notice that since the input to the filter is 20.0 FPM/SEC, the rate from 4 to 5 Sec. of the output does not increase past 20 FPM/SEC.
  • Page 158 Control Block Description ADDvantage-32 ADDITIONAL CONTROL I/O Inputs ZERO Outputs If ZERO bit is low, OUT = 0. When ZERO bit goes high, OUT ramps to REF by the UP or DWN ramp rates in addition to the RND input.
  • Page 159 Control Block Description ADDvantage-32 FIGURE 4-61D 4-97...
  • Page 160 Control Block Description ADDvantage-32 FIGURE 4-61E 4-98...
  • Page 161 Control Block Description ADDvantage-32 4.62 RRAMP3 The RRAMP3 block provides a variable rate linear ramp with user programmable smoothing. The purpose of this block is to provide a smooth reference from changing setpoint values. The difference between the RRAMP3 block and RMP2 is the additional RAMP inputs.
  • Page 162 Control Block Description ADDvantage-32 The RRAMP3 block can be divided internally into three components to aid in the understanding of its operation. These components are a Ramp Change Block, a Rate of Change Limit Block and Additional Control I/O as can be seen in Figure 4-62A.
  • Page 163 Control Block Description ADDvantage-32 Outputs RP OUT: Analog RMP: Implementation The following holds true while the HLD, ZERO bits are set high and the RES bit is low (explained in detail in ADDITIONAL CONTROL I/O). If REF is increasing (positive) faster than AF, the RMP bit is set high and RP OUT ramps...
  • Page 164 Control Block Description ADDvantage-32 4.63 SBXDIA The SBXDIA block calculates the diameter by relating a reference pulse generator with a once-per-revolution pickup. This block requires the GSBX board connected to the Maxi system board. The board provides the following: Reference pulse generator input...
  • Page 165 Control Block Description ADDvantage-32 Inputs (Continued) Digital Digital Digital Digital Outputs DIA1 Analog DIA2 Analog Digital Implementation If the RES1 is high, then DIA1 = IDIAM1. If HLD1 is high, the output is frozen at its last value. RES1 has a higher priority.
  • Page 166 Control Block Description ADDvantage-32 4.64 SBXDIA4 The SBXDIA4 block calculates the diameter by relating a reference pulse generator with a once-per-revolution pickup. This block requires the GSBX board connected to the Maxi system board. The board provides the following: Reference pulse generator input...
  • Page 167 Control Block Description ADDvantage-32 Inputs (Cont.) RES1 Digital RES2 Digital RES3 Digital RES4 Digital HLD1 Digital HLD2 Digital HLD3 Digital HLD4 Digital Digital Digital Digital Digital Outputs DIA1 Analog Digital Implementation This block uses the GSBX board to generate four diameter readings. It does this by calculating the distance the material has traveled based on one revolution of the roll.
  • Page 168 Control Block Description ADDvantage-32 DO1 through DO4 are the programmable digital outputs available on the board. These outputs must be isolated. DI1 is the first location where the eight digital inputs are stored. The next seven locations store the next seven inputs.
  • Page 169 WEBS WEBS LNGTH LNGTH SDSSHT1D101 FIGURE 4-65. SDS SHEETS DURING STOP BLOCK Inputs REF: Analog RAT: Analog ADJ: Analog WEBS: Analog LNGTH: Analog Digital * This function is not part of the ADDvantage-32 but is part of relay logic. 4-107...
  • Page 170 Control Block Description ADDvantage-32 Outputs SDS: Analog Implementation If EN is high: × WEBS × × LNGTH Where: RAT = line speed in units per second ÷ LENGTH UNITS LINE SPEED UNITS Else: SDS = 0 60 = 60 seconds/1 minute to adjust stopping rate in seconds and line speed in minutes.
  • Page 171 Control Block Description ADDvantage-32 4.66 SETPOINT The Setpoint block enables the use of the INC and DEC inputs to modify a setpoint. The rates for the INC/DEC are adjustable along with the limits. The limits can be defined as min/max difference or ratio draw. This block is used in the beginning of the speed loop and tension loop.
  • Page 172 Control Block Description ADDvantage-32 Outputs OUT: Analog DIF: Analog MAX: MIN: Implementation When the INC bit is high, the OUT value starts to ramp up at INCR rate. INCR is a rate entered in process units per second. The ramp continues until the INCR bit goes low or the OUT value reaches a limit.
  • Page 173 Control Block Description ADDvantage-32 On a low to high transition of the RES bit, OUT resets to the REF value. DIF is equal to the change of the setpoint. If ABS = 1, then DIF = OUT - REF (within the limits)
  • Page 174 Control Block Description ADDvantage-32 4.67 SNAPAVG Inputs INP: Analog TICS: Analog RES: HLD: RET: Outputs OUT: Analog TTL: Analog CNT: Analog Implementation The SNAPAVG block is used to get an average of a value with a specific time frame. The block has two internal count values to enable the block to function on short windows or longer windows.
  • Page 175 Control Block Description ADDvantage-32 FIGURE 4-67. SNAPAVG BLOCK 4-113...
  • Page 176 Control Block Description ADDvantage-32 4.68 SPLICER The Splicer block calculates two analog pulse count values, one for the pressure roll and one for the knife. Each value equals the amount of pulses to be received from the oncoming roll pulse generator before enabling the pressure roll and knife firing outputs.
  • Page 177 Control Block Description ADDvantage-32 Implementation K = (PPR)(GR) π PPS = K (RPS) ANGLE = (RPS)(PR T)(360º) TMP = (GL A) - ANGLE If TMP <0.1, TMP = TMP + 360º Else, TMP = TMP + (CL A) ⎛ ⎞...
  • Page 178 Control Block Description ADDvantage-32 4.69 SUMMING JUNCTION, SELECTABLE 3 INPUT This block adds input signals such as speed reference and tension trim. It selects which inputs to add using the bit select lines. BIT1 BIT2 BIT3 INPA INPB A+B+C INPC SUMMING3 FIGURE 4-69.
  • Page 179 Control Block Description ADDvantage-32 4.70 TABLE The Table block is used to modify an analog variable "INP" by a factor which is proportional to a second analog variable "X IN". An example of such an application would be to taper a tension setpoint based on roll diameter.
  • Page 180 Control Block Description ADDvantage-32 Implementation The Table block is used to perform a non-linear look up operation y = f(X_IN), and output a value using the following formula: OUT = f(X_IN) × GAIN × INP. Where: Y is calculated as a function of X IN by using the selected TABLE values.
  • Page 181 Control Block Description ADDvantage-32 4.71 TACH SELECT AND TACH SELECT-W The blocks TACH SELECT and TACH SELECT-W are almost identical and behave as described below. The difference between the two blocks is described in the SPECIAL NOTE. TACH 1 FAIL...
  • Page 182 Control Block Description ADDvantage-32 This block selects the type of speed feedback to be used by the speed loop. Either CEMF or speed feedback may be employed. When tach feedback is selected, tach loss detection can be used by configuring Y***:USR FAULT 1 = TACH LOSS.
  • Page 183 Control Block Description ADDvantage-32 If SPDVOL = low, OUT = CEMF × GAIN. If SPDVOL = high and 1 OR 2 = high, and no tach loss is detected, OUT = TACH1 × GAIN. If SPDVOL = high and 1 OR 2 = low, and no tach loss is detected, OUT = TACH2 ×...
  • Page 184 "run away" and damage machinery or injure personnel. For this reason, any time V RED = low and SPDVOL = high, Avtron HIGHLY RECOMMENDS configuring one of the USR FAULTS (described in Section III) to the TL output of the TACH SELECT block.
  • Page 185 Control Block Description ADDvantage-32 4.72 TIMER The Timer block is used to delay setting a bit until an appropriate count has occurred. It can be used to buffer faults for FIFO logging or to shut the drive down if in maximum tension for a period of time.
  • Page 186 On powerup of the ADDvantage-32, VAL = 0 Retentive Block On powerup of the ADDvantage-32, VAL will be initialized under the following conditions: If RET = 0, then VAL = 0 If RET = 1, VAL is set to its last value prior to power loss. VAL must be configured to a retentive point Y***:RET SETPT* to be updated automatically on powerup.
  • Page 187 Control Block Description ADDvantage-32 4.73 TYPE 2 DIA This block calculates the roll diameter of a center driven winder or unwinder section by using operator entered material thickness value and counting the number of spindle revolutions. This diameter calculation block can be used instead of the RATIO block. It is as accurate as the value of THCK that is entered.
  • Page 188 Control Block Description ADDvantage-32 Implementation If RES is high, then the output DIA = IDIAM. If DIA is calculated to go beyond the MAX diameter or MIN diameter limits, then DIA will be clamped at the limit. When the RES bit is set low, the DIA is calculated by the following: If UP/DWN is high, then: DIA = (LNTH/GAIN ×...
  • Page 189 Control Block Description ADDvantage-32 4.74 TYPE 3 DIA This block calculates the roll diameter of a winder by counting the footage of the surface roll section. The accuracy of this block is comparable to the value of THICK + DIA.
  • Page 190 On powerup of the ADDvantage-32, DIA = IDIAM Retentive Block On powerup of the ADDvantage-32, DIA will be initialized under the following conditions: If RET = 0, then DIA = IDIAM If RET = 1, DIA is set to its last value prior to power loss. DIA must be configured to a retentive point Y***:RET SETPT* to be updated automatically on powerup.
  • Page 191 Control Block Description ADDvantage-32 4.75 UNITY SCALE The Unity Scale block rescales the minimum and maximum limits of a given value to 0- MIN-INP MIN- UNITYSCL FIGURE 4-75. UNITY SCALE BLOCK Inputs INP: Analog MIN: Analog MAX: Analog Outputs OUT:...
  • Page 192 Control Block Description ADDvantage-32 4.76 UV PROTECT The block can be used to try to prevent a shoot through condition on a low AC voltage. It does this by disabling the regenerating bridge current limit in a low voltage condition.
  • Page 193 Control Block Description ADDvantage-32 If CEMF is Positive POSO = POSI NEGO = 0.1% If CEMF is Negative POSO = -0.1% NEGO = NEGI In the application, execute the block between the current limit setpoints and the current loop limit to protect the drive.
  • Page 194 Control Block Description ADDvantage-32 4.77 WINDER WK/D This block calculates the inertia of a winder/unwinder. The inertia of the material which is essentially a hollow cylinder is equal to WK2 = const × width × ((dia ) - (core dia Therefore, total inertia of a roll of material is the result of the previous equation plus the fixed inertia.
  • Page 195 Control Block Description ADDvantage-32 The torque required to accelerate a roll is equal to the WK of the body times the change in RPM. Change × Torque (For a Fixed Diameter) Time Change × Torque (For a Variable Diameter) Time...
  • Page 196 Control Block Description ADDvantage-32 4.78 WINDOW COMPARE The Window Compare takes an input and checks to see if it is between a high and low setpoint. The block offers options for absolute value of the input and a complementary output bit.
  • Page 197 Control Block Description ADDvantage-32 Implementation If ABS is Low (0), then IN = 1 if (LOW <= INP <= HI) Else IN = 0. If ABS is High (1), then IN = 1 if (|LOW| <= |INP| <= |HI|) Else IN = 0.
  • Page 271 ADDvantage-32, refer to Avtron Engineering Report 14363-001 for the RS-485 serial link or the Avtron ADDvantage-32 LAN Specification. These reports can be obtained upon request. DATA TABLES Information in the ADDvantage-32 is accessed using tables (Files). Each table contains a specific group of parameters or information associated with those parameters.
  • Page 272 ADDvantage-32 Advanced Control Module (ACM) W A R N I N G Particular locations have been writing information ADDvantage-32. These locations are A***:LOCATION X for analog values and D***:LOC BIT X for digital values. It is highly recommended that all information...
  • Page 273 ADDvantage-32 Advanced Control Module (ACM) TABLE 9-1. DATA FILES Structure File Bytes/ Data Data Number Table Name Element Type Mode (PAR) ANALOG IO (A000-A***) ADT LABELS (A000-A***) ADT UNITS (A000-A***) DEFAULT ADT UNITS (A000-A***) CAL TABLE UNITS (T000-T127) CAL TABLE DEFAULT...
  • Page 274 ADDvantage-32 Advanced Control Module (ACM) Structure File Bytes/ Data Data Number Table Name Element Type Mode (PAR) ANALYZER CAL HIGH LIM ANALYZER CAL LOW LIMITS ANALYZER CAL DEFAULTS ANALYZER CAL ANALYZER CONFIG PROMPT (Z002-Z006) (Z102-Z106) (Z202-Z206) (Z302-Z306) ANALYZER CONFIG LEGALS...
  • Page 275 ADDvantage-32 Advanced Control Module (ACM) 9.3.2 FILE 10 - ADT LABELS Contains all of the predefined label definitions for each analog input listed in File 9. Typical values could be: First element - FIL_SPEED__ (spaces are shown as __ )
  • Page 276 ADDvantage-32 Advanced Control Module (ACM) organized as one floating point value grouped in sub-files of 32 elements each. For example: Sub-File 0 Value element element 31 Sub-File 1 Value element 32 element 63 9.3.7 FILE 15 - CAL TABLE LOLIM This file contains the one predefined low limit value for all calibration entries.
  • Page 277 ADDvantage-32 Advanced Control Module (ACM) Reading the first element returns the following data: ..5AH 45H 52H 4FH 20H 41H 4EH 42H 4CH 4FH 47H ..9.3.11 FILE 19 - CONTROL CAL HI LIMS This file contains all of the predefined high limit values for each control calibration value.
  • Page 278 ADDvantage-32 Advanced Control Module (ACM) be loaded with the contents of File 21 at initial power up, and if the drive is defaulted. 9.3.20 FILE 28 - DIG IO This file defines the digital data table. Each bit in the structure represents real time digital data.
  • Page 279 ADDvantage-32 Advanced Control Module (ACM) 9.3.22 FILE 30 - DRIVE CAL LABELS This file contains all predefined label definitions for the drive calibration. One element is used to produce one label. For example: First element - I/O_V-REF Next element - MOTOR_IARM 9.3.23...
  • Page 280 ADDvantage-32 Advanced Control Module (ACM) The upper four bits define the type assigned, while the lower 12 bits define the index into the file elements defined by the type. For example, if the type bits were 03, then the index value would be the offset into the drive calibration table.
  • Page 281 ADDvantage-32 Advanced Control Module (ACM) CHECKSUM AREA ELEMENT NUMBER Drive Calibration Control Calibration Drive Configuration Control Configuration Calibration Analyzer Calibration Analyzer Configuration 9.3.33 FILE 41 - CAL VERSION This file consists of one integer element containing the version number of the calibration data.
  • Page 282 ADDvantage-32 Advanced Control Module (ACM) NOTE While scrolling through ADDvantage-32 keypad in the ANALYZER SETUP menu, parameters Z000:RESET 1 and Z001:OUTPUT 1 appear. Z000, Z001, Z100, Z101, Z200, etc., are not included elements in this file. The RESET and OUTPUT functions are only available when executed on the keypad.
  • Page 283 ADDvantage-32 Advanced Control Module (ACM) 9.3.40 FILE 48 - ANALYZER CAL This file contains the actual calibration values used for each of the four channels in File 44 to process the collected analyzer data. The default values initially used for each channel identical.
  • Page 284 ADDvantage-32 Advanced Control Module (ACM) integer values for each of the four channels, for a total of 76 elements. Channel 1: VARIABLE First element - ENABLE_REC1 Next element - INP1_A/D Last element Channels 2 through 4 are identical in form.
  • Page 285 ADDvantage-32 Advanced Control Module (ACM) 9.3.46 FILE 60 - FAULT TABLE This file contains the drive fault FIFO and is organized as 16 short integer elements. Each element may contain one fault value detected by the drive. RETURN FAULTS Each table element is defined as follows:...
  • Page 286 ADDvantage-32 Advanced Control Module (ACM) 9.3.47 FILE 61 THROUGH 62 KEYBOARD/DISPLAY MODE TABLES KEYBOARD/ DISPLAY MODE NOTE When writing to file 61 using the Allen-Bradley Client Server Protocol (AB-CIP), the data packet received by the ADDvantage32 will be regarded as an AutoScan Write, with the expected data structure as given within Table 9.3.47-1 below.
  • Page 287 ADDvantage-32 Advanced Control Module (ACM) • The Analog Setpoint Data Starting Address refers directly to the analog data table address where the Analog Setpoint values will be consecutively written. The Analog Setpoint Data Starting Address is interpreted as a 32-bit integer, with Word 1 being the least significant, Word 2 as most significant.
  • Page 288 ADDvantage-32 Advanced Control Module (ACM) RSLogix 5™ MSG configuration for AutoScan Write: Figure 9.3.47 - 1 9-18...
  • Page 289 ADDvantage-32 Advanced Control Module (ACM) NOTE Reading File 61 using the Allen-Bradley Client Server Protocol (AB-CIP), will be regarded as an AutoScan Read by the ADDvantage32, with the return data packet structured as given in ™ Table 9.3.47-2 below. A sample RSLogix 5...
  • Page 290 ADDvantage-32 Advanced Control Module (ACM) • The Digital Feedback data starts at the beginning of the digital data table (D000:), in 16-bit integral blocks who’s length is determined by the requested length of the AutoScan Read message. For example, if an AutoScan Read...

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