Simatic Converting Toolbox en

SIMATIC Converting Toolbox
SIMATIC
Application August 2014
Applications & Tools

Answers for industry.
Siemens Industry Online Support
This article is taken from the Siemens Industry Online Support. The following link
takes you directly to the download page of this document:
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Caution
The functions and solutions described in this article confine themselves to the
realization of the automation task predominantly. Please take into account
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context of Industrial Security when connecting your equipment to other parts of the
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under the Item-ID 50203404.
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Siemens AG 2014 All rights reserved
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s Application Description 1
Technology overview 2
Integration 3
Functional Description 4
SIMATIC
SIMATIC Converting Toolbox Application example as
5
demonstration system
Winder and line tension control
Related literature 6
Contact 7
History 8
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Warranty and liability
Warranty and liability

Note The Application Examples are not binding and do not claim to be complete
regarding the circuits shown, equipping and any eventuality. The Application
Examples do not represent customer-specific solutions. They are only intended
to provide support for typical applications. You are responsible for ensuring that
the described products are used correctly. These application examples do not
relieve you of the responsibility to use safe practices in application, installation,
operation and maintenance. When using these Application Examples, you
recognize that we cannot be made liable for any damage/claims beyond the
liability clause described. We reserve the right to make changes to these
Application Examples at any time without prior notice.
If there are any deviations between the recommendations provided in these
application examples and other Siemens publications – e.g. Catalogs – the
contents of the other documents have priority.
We do not accept any liability for the information contained in this document.
Any claims against us – based on whatever legal reason – resulting from the use of
the examples, information, programs, engineering and performance data etc.,
described in this Application Example shall be excluded. Such an exclusion shall
not apply in the case of mandatory liability, e.g. under the German Product Liability
Act (“Produkthaftungsgesetz”), in case of intent, gross negligence, or injury of life,
body or health, guarantee for the quality of a product, fraudulent concealment of a
deficiency or breach of a condition which goes to the root of the contract
(“wesentliche Vertragspflichten”). The damages for a breach of a substantial
contractual obligation are, however, limited to the foreseeable damage, typical for
the type of contract, except in the event of intent or gross negligence or injury to
life, body or health. The above provisions do not imply a change of the burden of
proof to your detriment.
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Any form of duplication or distribution of these Application Examples or excerpts

hereof is prohibited without the expressed consent of Siemens Industry Sector.

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About this Document
About this Document

Targeted Readers
The SIMATIC Converting Toolbox is intended for programmers who would like to
develop and implement programs for converting machines based on the SIMATIC
controller family and SINAMICS drives.
Basic know-how about SIMATIC, S7-SCL and SINAMICS is required to
successfully use the toolbox.
The knowledge of terminology and operating principles for converting, tension
control, winding and control theory is necessary.
Main Contents
The documentation gives a detailed overview about each implemented function or
function block which are ready to apply.
The toolbox contains functions and function blocks from ranging from simple handy
functions to sophisticated solution for tension control and winding.
Limitations
The documentation does not discuss the properties of different S7 platform nor
does it discuss how SINAMICS drives are operated.
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Table of contents
Table of contents
Warranty and liability ............................................................................................... 4
About this Document ............................................................................................... 5
1 Application Description ................................................................................. 8
1.1 Area of Application ............................................................................ 8
1.1.1 Segment, Machine, Unit Description .................................................. 8
1.1.2 Scope of Application .......................................................................... 8
1.2 Objectives ......................................................................................... 8
1.2.1 Task .................................................................................................. 8
1.2.2 Advantages ....................................................................................... 8
1.3 Automation and Drive Overview ......................................................... 9
1.3.1 System Requirements ....................................................................... 9
1.3.2 Scope of Supply ................................................................................ 9
2 Technology overview ................................................................................... 10
2.1 Tension control principles ................................................................ 10
2.2 Winder related functions .................................................................. 17
3 Integration..................................................................................................... 20
3.1 Integration into a User Program ....................................................... 20
4 Functional Description ................................................................................. 22

4.1 Tools ............................................................................................... 22
4.1.1 ReadCycleTime – Determining the cycle time .................................. 22
4.1.2 Linear – linear interpolation .............................................................. 22
4.1.3 TableChar – Non linear characteristic .............................................. 23
4.1.4 RFG – Ramp-function generator ...................................................... 26
4.1.5 RFGJ – Ramp-function generator with rounding-off .......................... 31
4.1.6 CalcStopDistance ............................................................................ 36
4.2 Logic function blocks ....................................................................... 37
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4.2.1 F_TRIG ........................................................................................... 37

4.2.2 R_TRIG ........................................................................................... 38
4.2.3 TRIG ............................................................................................... 39
4.3 Conversion function blocks .............................................................. 40
4.3.1 BytesIntoWord ................................................................................. 40
4.3.2 BitsIntoByte ..................................................................................... 41
4.3.3 BitsIntoWord .................................................................................... 42
4.3.4 WordIntoBytes ................................................................................. 43
4.3.5 ByteIntoBits ..................................................................................... 43
4.3.6 WordIntoBits .................................................................................... 44
4.4 Scaling function blocks .................................................................... 46
4.4.1 ScalingDWDRL................................................................................ 46
4.4.2 ScalingRLDWD................................................................................ 47
4.4.3 ScalingWDRL .................................................................................. 47
4.4.4 ScalingRLWD .................................................................................. 48
4.4.5 Scaling ............................................................................................ 49
4.5 Closed-loop function blocks ............................................................. 50
4.5.1 PT1 – PT1 filter................................................................................ 50
4.5.2 ReadAnalogInput ............................................................................. 52
4.5.3 Differentiator .................................................................................... 53
4.5.4 Integrator ......................................................................................... 54
4.5.5 DT1 – DT1-filter ............................................................................... 57
4.5.6 Limiter – Limiter with feedback signal ............................................... 59
4.5.7 LevelControl – Limit value monitor ................................................... 61
4.5.8 DeadBand – Dead-band filter........................................................... 63

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Table of contents
4.5.9 DeadZone – Dead-zone filter ........................................................... 64

4.5.10 AverageValue – Average-value filter ............................................... 66
4.5.11 PID – PID-controller ......................................................................... 68
4.5.12 TPID – PID-controller with setpoint channel ..................................... 74
4.6 Drive related function blocks ............................................................ 80
4.6.1 DriveControl .................................................................................... 80
4.6.2 SetpointChannel .............................................................................. 88
4.6.3 FrictionMeasurement – Friction characteristic measurement ............ 92
4.7 Sectional Drive ................................................................................ 95
4.7.1 SectionalConfigSetup ...................................................................... 95
4.7.2 TorquePrecontrol ............................................................................. 97
4.7.3 SectionalDrive ............................................................................... 102
4.8 Winder function blocks................................................................... 109
4.8.1 DiamCalcDivision .......................................................................... 109
4.8.2 DiamCalcIntegral ........................................................................... 112
4.8.3 DiamCalcAddition .......................................................................... 116
4.8.4 WITorquePrecontrol....................................................................... 119
4.8.5 RestLengthCalc ............................................................................. 124
4.8.6 RestDiameterCalc ......................................................................... 126
4.8.7 Taper............................................................................................. 127
4.8.8 WinderConfigSetup........................................................................ 131
4.8.9 Winder........................................................................................... 135
4.9 Overview of Structures................................................................... 143
4.9.1 SectionalConfigType...................................................................... 143
4.9.2 WinderConfigType ......................................................................... 144

5 Application example as demonstration system ........................................ 147
5.1 Installing the hardware and software .............................................. 147
5.1.1 Regarding your safety.................................................................... 147
5.1.2 Hardware structure and mounting/installation ................................. 149
5.1.3 Installing the standard SIEMENS software ..................................... 149
5.1.4 Downloading the user program and the drive parametrization
into the devices.............................................................................. 150
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5.2 Using the application example ....................................................... 152

5.2.1 Brief instructions to demonstrate .................................................... 152
5.2.2 Detailed operating instructions ....................................................... 156
6 Related literature ........................................................................................ 162
6.1 Bibliography................................................................................... 162
6.2 Internet link specifications .............................................................. 162
7 Contact........................................................................................................ 163
8 History ........................................................................................................ 163

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1 Application Description
1.1 Area of Application
1.1 Area of Application
1.1.1 Segment, Machine, Unit Description
The "Converting Toolbox" is intended to provide SIMATIC users with help when
engineering and programming converting machinery. The Converting Toolbox
provides standards that can be adapted depending on the particular machine and
application. These standards cover the typical basic functions of a converting
machine. The functions available are open source. The appropriate interfaces are
provided to make adaptations depending on the specific machine and application.
These interfaces are described in detail in the following documentation. Changes
to these standard functions should only be made in exceptional cases.
1.1.2 Scope of Application
The SIMATIC Converting Toolbox can be used for the widest range of applications,
e.g.:
Foil & film machines
Printing machines
Coating machines
Paper-finishing machines
Wire-drawing machines
Textile machines
Post-printing machines
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1.2 Objectives
1.2.1 Task
The SIMATIC Converting Toolbox is intended to offer a comprehensive solution for

the converting industry to quickly implement typical machine functions.
The Toolbox consist of simple building blocks which can be helpful for any machnie
and also includes complete solutions to fulfill the demanding requirements of
winders, tension controlled sections and material transport.
1.2.2 Advantages
The SIMATIC Converting Toolbox is an open source solution, which contrary to

black-box solutions, allows the user to modify or expand its functionality if
necessary. With the use of the Toolbox programming and commissioning can be
speeded up as the tasks will be shifted from programming to parameterization.
The Toolbox is documented and updated on a regular basis.
The Toolbox is available free of charge.

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1.3 Automation and Drive Overview
1.3 Automation and Drive Overview

1.3.1 System Requirements
The SIMATIC Converting Toolbox is intended to be used with SIMATIC S7-300,

S7-400 and S7-1200 series PLCs.
As the Toolbox is available as a SCL source file an additional license is required in
order to use the SCL editor.
The package is intended to be used with SINAMICS S120, S150 and G120 series
drives.
1.3.2 Scope of Supply
The SIMATIC Converting Toolbox consists of the following components:

SCL source file of the implemented functions, function blocks and user defined
types.
A configuration Script to be used with the drive commissioning tool STARTER
or SCOUT to set up the communication interface with the respective drives.
Documentation of the implemented functions, function blocks and user defined
types.
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2 Technology overview
2.1 Tension control principles
Generally the mechanical system in which tension or dancer position control is
necessary consists of the material web which needs to be controlled, of a motor
which drives the web and of an equipment which is used to set or measure the web
tension.
Typical machines with tension control are for example coating lines, rewinders,
slitters, narrow web machines usually running with materials like paper, laminates,
wire, foil and film (plastic or metal), textiles or cables.
The task of the controlled motor is to:

transport the material with the defined machine velocity
hold or control the setpoint tension in order to avoid tension drops or increases
the motor is typically connected via a gearbox to a roll which is used to transmit
tension and velocity to the material web. It must be ensured that the roll
surface and the roll surface contact area can transmit the desired tension
effectively to avoid slippage and tension drop. Additional mechanical elements
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may be required (nips, s-rolls, etc.). The roll diameter is typically constant.
In case of simple concepts the tension is only set and not controlled. This
means that the speed setpoint of the motor is preset and the tension is defined
by the friction between the material and the roll surface.
If a more sophisticated tension control is required then the system must be
amended to include a tension measuring cell or a dancer system. Closed-loop
tension control and dancer control require a controller – in this document
referenced as the technology controller or TPID. The technology controller is
realized as a PID controller which includes setpoint conditioning and jerk-free
switch-on functionality.
Dancer system
A dancer control system is a position based measuring system, which is used to
set the material tension. In conjunction with a dancer the motor controls the
position instead of the tension. Typically the system is designed so that the dancer
normally sits in the cenres position during production. The position of the dancer is
controlled by the drive, with the change of the speed setpoint.

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+
sact
P -
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In the simplest design the dancer is tensioned using a spring, and therefore the
tension varies as the dancer roll moves. More complex systems can consist of
pressure controlled cylinders in order to maintain a constant tension even if the
dancer roll is deflected.
Load cell
With tension measuring the material tension is directly measured for example using
a load cell. The measured value is interpreted by the technology controllers
algorithm and is used to adjust the speed or torque setpoint of the drive.
Inertia compensation and torque pre-control

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When the material web is being accelerated and decelerated an additive torque
can be switched to the drive in order to respond dynamically (quickly) to velocity
changes.
The inertia compensation method avoids tension dips or tension increases due to
velocity change. This pre-control is required, especially for indirect tension control
but also for tension control with a load cell.
Apart from the acceleration torque the torque pre-control has two other
components:
Tension torque, a function of the set tension, gear ratio and actual diameter
Friction torque from the friction characteristic
Draw Control
Using this method the web tension is set via the web segments velocity ratio,
meaning that the velocity of the transport rolls at the segment beginning is slower
than at the segment end. The velocity difference causes material tension, which in
turn defines the web tension. The resulting tension depends on the material type,
the friction between the material and the transport roll (slip) and the transport
system itself.
v OUT - v IN
T2 T1 C
v IN

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This method is used for simple tension control, especially when an additional
measuring system is not available or is to be avoided, but it does not offer high
level tension accuracy. This method cannot be used with axial winders.
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Tension control with dancer roll

In the case of dancer control, in comparison to tension control with a load cell, it is
not the tension that is controlled but the dancer position. The web tension is set by
the dancer system itself. The actual dancer position is measured using an encoder
or potentiometer. Position control is based on the difference between the setpoint
and the actual position. The controller output is used as additional velocity setpoint
in order to maintain the setpoint position.

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Indirect tension control

With this method the web tension is set on the basis of the process parameters.
There is no measuring system necessary as there is no feedback used to control
the tension. To set the web tension the tension setpoint is converted into a torque
setpoint which is based on the roll diameter and the gear ratio. The motor is driven

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using this torque setpoint. Friction and acceleration compensation are absolutely
necessary to achieve accurate web tension control.
When using this control method is must be ensured that the gear ratio of the
system is kept as low as possible. This includes good motor selection and the
selection of a highly efficient gearbox with low friction losses.
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Tension control with a load cell and torque limiting

Compared with indirect tension control the mechanical system is expanded using a
web tension measuring device, which is used to give feedback to the

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superimposed tension controller. The controller output is interpreted as an

additional torque setpoint for the controlled axis. Tension control is used if the
accuracy of the indirect tension control is not sufficient, for example if the losses in
the transmission system are not known or there are disturbances in the system
which need to be eliminated.
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Tension control with a load cell and velocity correction

Compared with indirect tension control the mechanical system is expanded using a
web tension measuring device which is used to give feedback to the superimposed
tension controller. The controller output is interpreted as an additional speed
setpoint for the controlled axis. Tension control is used if the accuracy of the
indirect tension control is not sufficient, for example if the losses in the transmission
system are not known or there are disturbances in the system which need to be
eliminated.
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2.2 Winder related functions
V-constant control
In this mode the winder will be controlled by the line set velocity without override. The tension
will be build up by a nip – the winder build up a holding torque to hold its set velocity.
For the diameter calculation the line actual velocity is necessary. This value will be detected by
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a tachometer. If a line axis with nip is available the set velocity of this axis can be used also to
control the winder in this mode.
The interconnection of the line actual velocity is done with the input variable
<lineActualVelocity> of the winder function block.

In general a winder solution comprises of a winder drive, a material web and
possibly sensors. The function of a winder is to unwind or rewind a material web
with a defined tension. When winding the diameter changes. Depending on
whether it involves an unwinder or rewinder, the material is unwound or wound.
The motion control system calculates the actual diameter using several system
variables and controls the motor speed so that the tension of the material web is
kept constant. To do this, the actual velocity of the material web and the speed of
the winder shaft must be known. If the system must fulfill higher demands
regarding the performance and tension accuracy, then an appropriate range of
sensors must be added to the winder solution.
Surface (contact) winder

With a surface winder the roll is driven by one or several rolls that are in contact
with the roll being wound. The drive speed and power depend on the diameter of

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the roll being wound. From a mechanical design perspective this winding technique
is more complicated than that of a center winder.
The surface (contact )winder is used if there are no special requirements placed on
the surface quality of the material being wound.
Center (axial) winder

With a center (axial) winder the roll is driven by a central shaft. The diameter range
is an important factor when designing this winder type. The reason for this is that
for constant web velocity and constant tension, the speed is inversely proportional
to the diameter. This means that the maximum required drive speed is defined by
the minimum roll diameter – whereby the maximum required torque is defined by
the maximum diameter.

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The center winder is more complicated and, from a control perspective more
difficult to handle than the surface winder; however it is still the more widely
established of the two winder types.
Diameter calculation
The following different methods can be used to calculate the diameter of the roll
being wound:
Using the ratio between the velocity of the material web and the winder speed
By adding the material thickness
Using an external sensor
Using the ratio between the material length and the number of revolutions of
the winder (integration)

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Tension taper
A tension taper characteristic is required if the tension, with which the material is to
be wound, is to be decreased as the diameter of the roll being wound increases. 5
different methods are available to calculate the tension taper characteristic:
No characteristic
Linear characteristic – the tension is reduced linearly as a function of the actual
diameter
Hyperbolic characteristic type 1 – the tension decreases according to a
hyperbolic function/characteristic
Hyperbolic characteristic type 2 – the tension decreases according to a
hyperbolic function/characteristic
Interpolated characteristic using a table of points
Controller adaptation
The gain of the technology controller can be adapted as a function of the diameter.
This permits higher controller gain at larger diameters.
The speed controller gain in the drive can be adapted as a function of the moment
of inertia or the actual diameter of the roll being wound. This is necessary so that a
full roll can also be rapidly accelerated or decelerated
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3 Integration
3.1 Integration into a User Program
3 Integration
Importing the source code
The SCL source file of the SIMATIC Converting Toolbox (S7LConLib.scl) can be
imported into the user project using the Step7 manager.
Step Screenshot
Open Sources in the project

tree
After a right click select Insert

New Object > External
Source…
Select the S7LConLib.scl

source file and import it

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SCL editor settings

All blocks in the SIMATIC Converting Toolbox have symbolic names and therefore
an appropriate symbol table needs to be generated. To do this set up the SCL
editor to create block numbers automatically during compilation.
Step Screenshot
Go to options and select

Customize… or push Ctrl +
Alt + E
On the first tab click and
activate the Create
block numbers
automatically option.
After compilation the
symbol table can be
adjusted if necessary.

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3 Integration
Compile the source code

The imported SCL source code is ready to be compiled. After compilation the
blocks are ready to be used in the user program. The SCL source can either be
compiled in the Step7 manager or in the SCL editor itself.
Step Screenshot
Select the source in the Step7

manager, open the option
menü by a right click and
select compile or push Ctrl + B
The SCL editor will be opened

and the source will be compiled.
As an alternative you can also

compile the source code in the

SCL editor using the buttons or by
pushing Ctrl + B.
In the SCL editor selective
compilation is also possible.
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4 Functional Description
4.1 Tools
4.1 Tools
4.1.1 ReadCycleTime – Determining the cycle time
Determine the cycle time of the calling OB.

The function can be called in any task. ID: 1001
Schematic LAD Representation

Input and Output Parameters

Name Type Data type M/O Initial value Description
RET_VAL OUT REAL - - [ ms ] The actual cycle time of the task in REAL
format.
If the function outputs a 0.0, the block is not
called in a cyclic task (OB30-OB38).
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Functionality
The function determines the cycle time of the calling OB by using the system
function SFC6 (RD_SINFO). The cycle time of the OB is the return value in REAL
format.
If the return value is 0.0 the function is not called in a cyclic task.
4.1.2 Linear – linear interpolation
Linear interpolation between two breakpoints

The function can be called in any task. ID : 0001.

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4.1 Tools
Input and output parameters

x IN REAL M 0.0 Input value
X1 IN REAL M 0.0 First breakpoint, x value
Y1 IN REAL M 0.0 First breakpoint, y value
X2 IN REAL M 0.0 Second breakpoint, x-value

Y2 IN REAL M 0.0 Second breakpoint, y value
RET_VAL OUT REAL - - Output value
Functionality
Using the breakpoints entered, this function determines the matching Y coordinate
of the coordinate present at input x. The interpolated Y coordinate is provided as a
return value of the function. The input point x is limited by the coordinates X1 and
X2. If the coordinates X1 and X2 are equal, 0.0 is displayed as return value and no
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interpolation is performed.
X X1
RET _ VAL * Y 2 Y1 Y1
X 2 X1
Graphical representation
4.1.3 TableChar – Non linear characteristic
Interpolation from breakpoint table

The function block can be called in any cyclic task. ID: 0106

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4.1 Tools

enable IN BOOL M - TRUE: Function block activation

FALSE: function block deactivation
x IN REAL M - Input value
dbPointer IN ANY M - Pointer to breakpoint table data block with

REAL elements:
Offset: 0 REAL x1 value
Offset: 4 REAL y1 value

.. .. .. ..
error OUT BOOL - FALSE FALSE: No error

TRUE: An error has occurred, refer to
error identification
errorID OUT DWORD - 16#0000_0000 Error identification, refer to error messages

errorID 16#0000_8000: Warning
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errorID 16#0000_8000: Error
y OUT REAL - 0.0 Output value
busy OUT BOOL - FALSE TRUE: Function block active

FALSE: Function block inactive
Functionality
The function blocks adapts the output value y corresponding to the input value x
based on a breakpoint table of variable size. Between the breakpoints the values
are interpolated linearly.
The purpose of the function block is to e.g.:
Linearize characteristic curves
Simulation of non-linear transfer elements
The minimum number of breakpoint elements is two. The x values of the curve
must increase monotonically, the y values have no limitation. The total number
of breakpoints is defined by the size of the data reference. The data type of the
addressed data area must be REAL. Is x is less than the x value of the first
coordinate, the output y value will maintain the level of the y value of the first
coordinate. The same applies if x is larger than the last x coordinate of the
table.

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4.1 Tools
Warning messages
Warnings are indicated by the status of the outputs error and errorID: error =
FALSE and errorID <> 16#0000_0000.
ErrorID Description
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16#0000_0000 No warning
16#0106_4005 The table of entered values is not monotonically (steadily)

increasing -> no matching value found
16#0106_4008 The table of entered values is not monotonically (steadily)

increasing -> 2 values are identical
Error messages
Error messages are indicated by the status of the outputs error and errorID: error =
TRUE and errorID <> 16#0000_0000.
ErrorID Description
16#0000_0000 No error
16#0106_8003 Less than two pairs of values in the breakpoint table or uneven
number of points.
16#0106_8005 Invalid configuration data:

Pointer is not addressing a data block
16#0106_84A1 Data block number bigger than allowed or zero (SFC 24 /

TEST_DB)

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4.1 Tools
ErrorID Description
16#0106_84B1 Data block not existent (SFC 24 / TEST_DB)
16#0106_84B2 Data block unlinked (SFC24 / TEST_DB)
4.1.4 RFG – Ramp-function generator
Ramp function generator with motor potentiometer and follow-up operation –

without rounding
The function block has to be called in a cyclic interrupt, e.g. OB35. ID: 1106

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x IN REAL M 0.0 Input quantity
nominalValue IN REAL M 1.0 Normalization value
upperLimit IN REAL M 0.0 Upper limit value
lowerLimit IN REAL M 0.0 Lower limit value
setValue IN REAL O 0.0 Setting value
rampUpTime IN REAL M 0.0 [ ms ] Ramp-up time

[ cycle time – MAX_RAMP_TIME_MS]
rampDownTime IN REAL M 0.0 [ ms ] Ramp-down time

[ cycle time – MAX_RAMP_TIME_MS]
set IN BOOL O FALSE FALSE: Normal ramp calculation

TRUE: Output is set to setValue

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4.1 Tools
followup IN BOOL M FALSE TRUE: Normal ramp calculation
increase IN BOOL O FALSE FALSE: Normal ramp calculation

TRUE: Increase output with change
rate
decrease IN BOOL O FALSE FALSE: Normal ramp calculation

TRUE: Decrease output with change
rate
error OUT BOOL FALSE FALSE: No error

errorID OUT DWORD 16#0000_0 Error identification, refer to error

000 messages
y OUT REAL 0.0 Output value
ya OUT REAL 0.0 [ - / cycle ] Acceleration value
SetpointReached OUT BOOL FALSE FALSE: Setpoint calculation active

TRUE: Setpoint (input x) reached
upperLimit OUT BOOL FALSE FALSE: Upper limit value not reached
Reached TRUE: Upper limit value reached
lowerLimit OUT BOOL FALSE FALSE: Lower limit value not reached
Reached TRUE: Lower limit value reached
Functionality
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The function block includes an integrator with two integration time constants that
can be set independently of each another. Output y changes according to the
following algorithm:
Fehler! Es ist nicht möglich, durch die Bearbeitung von Feldfunktionen
Objekte zu erstellen.
The change rate ya is calculated separately for the up ramp and down ramp. An up
ramp is when the output value y moves away from zero. A down ramp is when the
output value y approaches zero.
For the change rate when ramping-up the following applies:
cycleTime
YA * no min alValue für Y 0
rampupTime
cycleTime
rampupTime

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4.1 Tools
For the change rate when ramping-down the following applies:

cycleTime
rampdownTime
cycleTime
rampDownTime
The changeover between ramp-up time and ramp-down time is realized when the
direction changes or at the zero crossover of the transfer function. Depending on
the logical states of the control inputs set, follow-up, increase and decrease, the
operating mode is specified by the control logic. The output quantity can be limited
using inputs upperLimit and lowerLimit. When the set limits are reached the binary
outputs, upperLimitReached or lowerLimitReached, are set to TRUE. Binary output
setpointReached is TRUE if y=x.
Ramp-up time and ramp-down times

The ramp-up time rampupTime is the time in which the absolute value of the output
quantity increases by nominalValue.
The ramp-down rampdownTime is the time in which the absolute value of the
output quantity decreases by nominalValue.
The ramp-up time and ramp-down time can be selected to be different. The lower
cycleTime/rampupTime or cycleTime/rampDownTime and the lower the amplitude

change at y from one sampling instant to the next.
Priority of control inputs

For the control inputs, the following priority sequence applies:
set before followup before increase and decrease
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set = 1 Setting value setValue is loaded into the integrator, non-integrating
followup = 1 Output y integrating to setpoint x, tracking
Increase = 1 Output y integrating torques upperLimit, tracking
decrease = 1 Output y integrating torques lowerLimit, tracking
Operating modes and control of the ramp-function generator

The combination of commands at the control inputs and the possible operating
modes can be taken from the truth tables.
Standard ramp-function generator operation involves lowerLimit 0 upperLimit
and lowerLimit < yn < upperLimit. However, other settings are also possible:
For the setting with lowerLimit upperLimit, the following applies: Limit upperLimit
is dominant with respect to limit lowerLimit.
If output y reaches one of the set limits lowerLimit or upperLimit, during the control
sequence, the integrator value is held. Output value y is then kept constant until
the integrator value leaves the limit due to a change of the input quantities.
If the integrator is at the limit and the limit value is changed the integrator behaves
differently depending on the direction in which the limit value was changed.
If the absolute value of a limit value is increased, and if the control logic specifies
that the ramp-function generator should run in the same direction, then the
integrator integrates from the previously defined value according to the selected
ramp-up time until the output once again reaches the limit value.

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4.1 Tools
If the absolute value of a limit value is reduced, the integrator integrates from the
previously held value – according to the selected ramp-down time – until the output
once again reaches the limit value.
The integrator operates internally with increased accuracy so that even for small
setpoint-actual value differences it still integrates. However, it should be carefully
noted that the sampling time is sufficiently low compared to the ramp-up or ramp-
down time.
rampupTime and rampdownTime are internally limited:
rampupTime cycleTime, rampdownTime cycleTime
set Follow Inc Dec Yan yn Mode Comment

up
0 0 0 0 0 yn-1 Stop y is constant
1 1 1 1 Step setValuen Sets output to setValue is any

setValue value, fixed or
variable
0 1 1 1 cycleTime / yn-1+yan Normal rampupTime for

rampupTime; operation [x > y y 0]
cycleTime / x [x < y y 0]
ramp rampdownTime for
downTime [x > y y < 0]
[x < y y > 0]
0 0 1 0 cycleTime / yn-1+yan Approach the rampupTime,

rampup Time upper limit rampdownTime as
(cycleTime / value before, dependent
rampdown upperLimit on the starting
Time) (initial) position
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0 0 0 1 cycleTime / yn-1+yan Approach the rampupTime,

rampdown lower limit rampdownTime as
Time value before, dependent
(cycleTime / lowerLimit on the starting
rampup (initial) position
Time)

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4.1 Tools
Timing diagram - Motor potentiometer

Timing diagram - Normal operation

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4.1 Tools
Error Messages
ErrorID Description
16#0000_0000 No error
16#1106_8001 The function block is not called in a cyclic interrupt, e.g. OB35.
4.1.5 RFGJ – Ramp-function generator with rounding-off
Ramp-function generator with ramp-up, ramp-down times and rounding-off


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Input parameters
Name Type Data M/O Initial value Description
type
run IN BOOL M FALSE FALSE: Function block de-activated

TRUE: Function block activated
enable IN BOOL M FALSE FALSE: No calculation

TRUE: Function block enabled
mode IN BOOL O TRUE FALSE: Fast stop ramp

(fastRampDownTime)
TRUE: Normal sequence
(rampDownTime)
enable IN BOOL O TRUE FALSE: Without rounding-off

Rounding TRUE: With rounding-off

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4.1 Tools

type
hold IN BOOL O FALSE FALSE: Normal sequence

TRUE: Ramping will be held with respect
to jerk limiting change rate will be
decreased to zero. Input x is ineffective.
zeroRounding IN BOOL O FALSE TRUE: Rounding at zero crossing

FALSE: No rounding at zero crossing
x IN REAL M 0.0 Setpoint value
nominalValue IN REAL O 1000.0 Max. setpoint and reference value

Internally processed as absolute value
rampupTime IN REAL O 1.0 [ s ] Ramp-up time

cycleTime < rampupTime <
MAX_RAMP_TIME_S (1000.0)
rampdownTime IN REAL O 1.0 [ s ] Ramp-down time

cycleTime < rampupTime <
FastRampdown IN REAL O 0.1 [ s ] Fast ramp-down time

Time cycleTime < rampupTime <

roundingTime IN REAL O 0.5 [ s ] Rounding-off time

cycleTime < rampupTime
busy OUT BOOL - FALSE FALSE: Function block disabled


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000 errorID 16#0000_8000: warning
errorID 16#0000_8000: error
Setpoint OUT BOOL - FALSE FALSE: Setpoint not reached

Reached TRUE: Setpoint reached
setpointZero OUT BOOL - FALSE FALSE: Calculated setpoint is not zero

TRUE: Calculated setpoint is zero
accelerating OUT BOOL - FALSE FALSE: Absolute output value not

increasing
TRUE: Absolute output value increasing
decelerating OUT BOOL - FALSE FALSE: Absolute output value not

decreasing
TRUE: Absolute output value decreasing
ya OUT REAL - 0.0 [ / sec ] Actual change rate

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4.1 Tools
Functionality
The function block is active with the input run set to TRUE and the calculation can
be started or stopped with input enable. Depending on the parameterization of the
inputs a ramp function is calculated. Various options can be set by selecting the
inputs. If mode is at False, the ramp is braked using a special entered deceleration
time (fastRampdownTime) and without jerk limiting. This means that the ramp can
be effectively decelerated for an Emergency Stop – this is also possible while
accelerating. If mode is at True, then the drive is braked normally with the entered
deceleration time (rampdownTime). The acceleration is always calculated with the
entered acceleration time (rampupTime) independent of mode.
In order to reach the setpoint (x), the appropriate interval values are output (at y)
and the actual change rate is output (at ya). If input enableRounding is set to
TRUE, the ramp is calculated with jerk limiting. The rounding-off is determined by
the rounding-off time (roundingTime). The zero crossing (when the input x changes
direction) can be parameterized with or without rounding. As soon as the output
value is zero this is displayed using the setpointZero output. When accelerating the
output acceleration is set, when decelerating theoutput deceleration is set and for a
constant value setpointReached is set. If the block is in the enable mode, then
output busy is set to TRUE. If the hold input is set to TRUE, the ramp-function
generator is stopped (held) and the actual acceleration is ramped-down to zero. As
long as hold is TRUE, setpoint x is ignored and output ya is set to zero.
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4.1 Tools
Normal operation with rounding

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With and without zero rounding

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4.1 Tools
Operation with fast stop mode

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Error messages
TRUE and errorID <> 16#0000_0000.Error = TRUE
ErrorID Description
16#0000_0000 No error

nominalValue = 0.0

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4.1 Tools
4.1.6 CalcStopDistance
Calculation of the braking distance and the associated time to ramp down to zero
with the given ramp parameters from the given speed and acceleration.


velocity IN REAL M 0.0 [ LU / min ] Actual velocity
acceleration IN REAL M 0.0 [ LU / s²] Actual acceleration
maxVelocity IN REAL M 1000.0 [LU / min ] Reference velocity for

acceleration.
The absolute value is used internally.
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rampupTime IN REAL M 1.0 [ s ] Ramp-up time

rampdownTime IN REAL M 1.0 [ s ] Ramp-down time

roundingTime IN REAL O 0.0 [ s ] Rounding time

error OUT BOOL - - FALSE: No error

TRUE: An error has occurred, refer to error
identification
errorID OUT BOOL - - Error identification, refer to error messages:

stopDistance OUT REAL - - [ LU ] Stopping distance
stopTime OUT REAL - - [ s ] Stopping time
Functionality
The function calculates the braking time and braking distance taking the actual
motion vector of a drive (velocity, acceleration) as well as the specification of

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4.2 Logic function blocks
dynamics (maxVelocity, rampUpTime, rampdownTime, roundingTime) into

account.
The length unit of the calculation corresponds to the unit used as input for the
lineSpeed input. The units of the inputs must be consistent.
With roundingTime = 0.0 the rounding (jerk limiting, smoothing) is deactivated.
Error messages
ErrorID Description
16#0000_0000 No Error

maxVelocity = 0.0
(rampupTime = 0.0 AND roundingTime <> 0.0)
rampdownTime = 0.0
Initial acceleration too high.

4.2.1 F_TRIG
Falling edge detection

The function can be called in any cyclic task. ID: 0102
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CLK IN BOOL M - Input signal
Q OUT BOOL - - FALSE: No falling edge detected

TRUE: Falling edge detected
Functionality
The function block outputs a true signal if a falling edge is detected on the input
signal (CLK). The duration of the output signal is one cycle.

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Timing diagram
4.2.2 R_TRIG
Rising edge detection


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Q OUT BOOL - - FALSE: No rising edge detected

TRUE: Rising edge detected
Functionality
The function block outputs a true signal if a rising edge is detected on the input
signal (CLK). The duration of the output signal is one cycle.

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Timing Diagram
4.2.3 TRIG
Edge detection

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QF OUT BOOL - - FALSE: No falling edge detected

TRUE: Falling edge detected
QR OUT BOOL - - FALSE: No rising edge detected

TRUE: Rising edge detected
Functionality
The function block evaluates the input signal (CLK) for rising and falling edges. The
result of a falling edge is signaled on the QF output, the rising edge on the QR
output.

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4.3 Conversion function blocks
Timing Diagram

4.3.1 BytesIntoWord
Assembling a word out of 2 bytes

The function block can be called in any task. ID: 000B
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byte0 IN BYTE M - Least significant byte/low byte
byte1 IN BYTE M - Most significant byte/high byte
RET_VAL OUT BOOL - - Result

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Functionality
The function assembles a word out of two bytes by specifying high byte and low
byte.
4.3.2 BitsIntoByte
Assembling a byte out of 8 bits

The function can be called in any task. ID: 000C

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bit0 IN BOOL M - Least significant bit 0/LSB
bit1 IN BOOL M - Bit 1
bit7 IN BOOL M - Most significant bit 7/MSB
RET_VAL OUT BYTE - - Result
Functionality
The function assembles a byte out of 8 bits.

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4.3.3 BitsIntoWord
Assembling a word out of 16 bits

The function can be called in any task. ID: 000D

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bit0 IN BOOL M - Least significant bit 0/LSB

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bit15 IN BOOL M - Most significant bit 15/MSB
RET_VAL OUT WORD - - Result
Functionality
The function assembles a word out of 16 bits.
4.3.4 WordIntoBytes
Generates 2 bytes out of a word value

The function can be called in any task. ID: 000E

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IN IN WORD M - Input value
BYTE0 OUT BYTE - - Byte 0, least significant byte
BYTE1 OUT BYTE - - Byte 1, most significant byte
Functionality
The function block generates two bytes out of a word.
4.3.5 ByteIntoBits
Generates 8 bits out of a byte value

The function can be called in any task. ID: 000F

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In IN BYTE M - Input value
bit0 OUT BOOL - - Bit 0, least significant bit
bit1 OUT BOOL - - Bit 1

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bit7 OUT BOOL - - Bit 7, most significant bit
Functionality
The function block generates eight bits out of a byte.
4.3.6 WordIntoBits
Generates 16 bits out of a word value


V1.2.0, Item-ID: 58565043 44


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In IN BYTE M - Input value
bit0 OUT BOOL - - Bit 0, least significant bit

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4.4 Scaling function blocks
bit15 OUT BOOL - - Bit 15, most significant bit
Functionality
The function block generates sixteen bits out of a word.

4.4.1 ScalingDWDRL
Conversion and scaling of DWORD values into REAL values


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x IN DWORD M - Input value in DWORD format
maxValue IN REAL M - Maximum value
base IN REAL O 1073741824.0 Normalization value

(RET_VAL = 0 if base = 0)
RET_VAL OUT REAL - - Output value in REAL format

[ -2*maxValue - 2*maxValue]
Functionality
The function converts a DWORD input (x) using a normalization value (base) and
the maximum reference value (maxValue) into a REAL value. The output value is
limited to -2*maxValue and 2*maxValue.
x
RET _ VAL * max Value
base

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4.4.2 ScalingRLDWD
Conversion and scaling of REAL values into DWORD values


x IN REAL M - Input value in REAL format

[ -2*maxValue - 2*maxValue]

(RET_VAL = 0 if maxValue = 0)
RET_VAL OUT WORD - - Output value as WORD

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Functionality
The function converts a REAL value (x) into a DWORD using a normalization value
(base) and the maximum reference value (maxValue). The input value x is limited
to the values
-2*maxValue and 2*maxValue
x
RET _ VAL * base
maxValue
4.4.3 ScalingWDRL
Conversion and scaling of WORD values into REAL values


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x IN WORD M - Input value in WORD format

Functionality
This function converts a WORD value (x) into a REAL value using a normalization
value (base) and the maximum reference value (maxValue). The output value is
limited between the values -2*maxValue and 2*maxValue.
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x
base
4.4.4 ScalingRLWD
Conversion and scaling of REAL values into WORD values


V1.2.0, Item-ID: 58565043 48


RET_VAL OUT WORD - - Output value in WORD format
Functionality
This function converts a REAL value (x) into a WORD value using a normalization
value (base) and the maximum reference value (maxValue). The input value x is
limited between the values -2*maxValue and 2*maxValue.
x
RET _ VAL * base
max Value
4.4.5 Scaling
Scaling of a value in REAL format

The function can be called in any task. ID: 000A

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base IN REAL M - Normalization value


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4.5 Closed-loop function blocks
Functionality
This function scales an input value (x) using a normalization value (base) and the
maximum reference value (maxValue).
x
base

4.5.1 PT1 – PT1 filter
Calculation of a PT1 – low-pass filter



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type
set IN BOOL O FALSE FALSE: Operation as PT1-filter

TRUE: The setValue is output
setValue IN REAL O 0.0 Set value, activated with set = TRUE
smoothingTime IN REAL M 100.0 [ ms ] Smoothing time

TRUE: An error has occurred, refer
to error identification
errorID OUT DWORD - 16#0000_0000 Error identification, refer to error

messages:
Functionality
The input value x is filtered using the time constant smoothingTime and output at
the output y. To precisely calculate the internal steps the sampling time in which
the block is processed is determined internally. Additionally it is possible to

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permanently set the output to the value of the input (setValue) by setting the input
(set).
In order to generate a hold, output y should be connected to the input setValue.
This means that when setting set to TRUE, the output value is maintained until set
is again set to FALSE. If the time constant is set to zero the filter is de-activated
and the output value is equal to the input value.
63% of the input value is reached at the output after one period of the time
constant.
95% of the input value is reached at the output after three periods of the time
constant.
For an appropriately high smoothingTime/cycleTime (smoothingTime/cycleTime >
10) the transfer function corresponds to the following characteristic:
t / smoothingTime
Y (t) X *(1 e ) with t n * cycleTime
The discrete values are calculated using the following algorithm:
cycleTime
Yn Yn 1 * X n Yn 1
smoothingT ime
Timing diagram
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Error messages
ErrorID Description
16#0000_0000 No error

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4.5.2 ReadAnalogInput
Analog input evaluation with PT1 filter



type
set IN BOOL O FALSE FALSE: Normal operation

TRUE: Set output of the function block to setValue
x IN WORD M - Input value in WORD format

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maxValue IN REAL M - Maximum value for output limitation
base IN REAL O 16384.0 Base value for WORD/REAL conversion
setValue IN REAL O 0.0 Value to be set with set = TRUE
smoothingTime IN REAL O 100.0 [ ms ] Smoothing time constant of the internal PT1

filter.
With smoothingTime = 0.0 the filter is inactive.

identification
errorId OUT DWORD - 16#0000_0 Error identification, refer to error messages:

000 errorID 16#0000_8000: Warning
Functionality
This function converts an analog input signal in WORD format (x) into a REAL
value using a normalization value (base) and the maximum reference value

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(maxValue). The output value is limited between the values -2*maxValue and
2*maxValue.
x
ana log_ value * max Value
base
Optionally the analog value can be filtered using a settable PT1-filter and a filter
time smoothingTime. If the input parameter smoothingTime = 0, the filter is
disabled. The internal limit for the filter time is 5000 ms.
The functionality is a combination of the ScalingWDRL function and the PT1
function block.
Error Messages
ErrorID Description
16#0000_0000 No error

base = 0.0
4.5.3 Differentiator
Numerical differentiator
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diffTime IN REAL M 0.0 [ ms ] Differentiating time constant

identification

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Functionality
The output value y changes as a function of the rate of change of input value x,
multiplied by the differential time constant diffTime.
The input diffTime is internally limited: cycleTime diffTime 1000
Discrete values are calculated using the following algorithm:
diffTime
Yn Xn Xn 1 *
cycleTime
Error messages
ErrorID Description
16#0000_0000 No error
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4.5.4 Integrator
Numerical integrator

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type
set IN BOOL O FALSE FALSE: Normal integrator function

TRUE: Output is setValue
setValue IN REAL O 0.0 SetValue for setting function with set =

TRUE
upperLimit IN REAL M 1.0 Upper integration limit
lowerLimit IN REAL M 0.0 Lower integration limit
integralTime IN REAL M 5.0 [ ms ] Integration time Ti


messages

errorID 16#0000_8000:Error
upperLimitReached OUT BOOL - FALSE FALSE: Upper limit not reached

TRUE: Upper limit reached
lowerLimitReached OUT BOOL - FALSE FALSE: Lower limit not reached

TRUE: Lower limit reached
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Functionality
The function block integrates the input value x with integration time integralTime.
The result is output at y. The integrator is limited by the upper limit upperLimit and
the lower limit lowerLimit. If the integrator reaches one of the limits, then this is
connected to the output. When the particular limit at the output is reached this is
indicated using upperLimitReached and lowerLimitReached.
Using the setting function, which is activated with set =True, the output can be set
to a pre-defined value (setValue). If set is reset, then starting from the setting
value, the integrator continues to integrate in the direction specified using input
value x.
The input integralTime is internally limited: cycleTime integralTime 10000
The discrete values are calculated using the following algorithm:
cycleTime
Yn Yn 1 * Xn
integralTi me

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Truth table for lowerLimit < upperLimit

Set Condition y upper lower Mode
Limit Limit
Reached Reached
0 lowerLimit < yn 0 0 Integrating

yn-1 + x * cycleTime /
integralTime
< upperLimit
0 yn-1 + x * cycleTime / upper 1 0 Integrator at the

integralTime upperLimit Limit upper limit
0 yn-1 + x * cycleTime / lower 0 1 Integrator at the

integralTime lowerLimit Limit lower limit
1 lowerLimit < setValue < set 0 0 Setting

upperLimit Valuen
1 setValue upperLimit upper 1 0 Integrator at the

Limit upper limit
1 setValue lowerLimit lower 0 1 Integrator at the

Limit lower limit
Truth table for lowerLimit > upperLimit

Set Condition Y upper lower Mode
Limit Limit
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Reached Reached
any lowerLimit < Yn 0 0 Integrator limited

yn-1+x * cycleTime / integralTime by upper Limit
< upperLimit

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Timing diagram
Error messages
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ErrorID Description
16#0000_0000 No error
4.5.5 DT1 – DT1-filter
DT1-filte

V1.2.0, Item-ID: 58565043 57

type
set IN BOOL O FALSE FALSE: Operation as DT1-filter

TRUE: setValue is set as output value
setValue IN REAL O 0.0 Setting value
smoothingTime IN REAL M 0.0 [ ms ] Smoothing time constant
diffTime IN REAL M 0.0 [ ms ] Differentiating time constant


messages
errorID 16#0000_8000: warning

ypt OUT REAL - 0.0 Output value of the smoothing element
Functionality
Input value x is dynamically delayed with the smoothing time constant
smoothingTime entered via a differentiating element. The output value isat output
ypt. The output value y of the complete DT1 element is proportional to the change
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rate of ypt multiplied with differential time constant diffTime. The input diffTime is
internally limited: cycleTime diffTime 1000
The input smoothingTime defines the gradient of the down ramp of the output
value. This specifies the time after which the transfer function – after smoothing
and differentiation – has dropped to 37% of x-diffTime/ smoothingTime. For a
sufficiently high smoothingTime/cycleTime (smoothingTime /cycleTime > 10), the
transfer function corresponds to a characteristic of:
diffTime t/smoothingTime
Y(t) x* *e where t n * cycleTime
smoothingT ime
The input smoothingTime is internally limited: cycleTime smoothingTime 5000
The discrete values are calculated using the algorithm:
diffTime
Y 1n * ( xn YPTn 1 )
smoothingTime
cycleTime
YPTn YPTn 1 * ( xn YPTn 1 )
smoothingTime
The higher smoothingTime/cycleTime, the lower the amplitude change at y and at
ypt from one sampling instant to the next.
The higher the diffTime/cycleTime, the higher the amplitude change at y from one
sampling instant to the next.

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Setting function
When the setting function is active, setting value setValue is transferred to output y;
the output of the smoothing element is obtained as follows:
smoothingTime
YPTn Xn * setValuen for diffTime 0
diffTime
In this case, the internal limits for smoothingTime and diffTime apply. For diffTime
= 0, the output values remain unchanged as long as set = TRUE.
Error messages
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ErrorID Description
16#0000_0000 No error
4.5.6 Limiter – Limiter with feedback signal
Limit-value filter

V1.2.0, Item-ID: 58565043 59

upperLimit IN REAL M 0.0 Upper limit value
lowerLimit IN REAL M 0.0 Lower limit value
RET_VAL OUT REAL - 0.0 Output value
upperLimitReached OUT BOOL - TRUE FALSE: Upper limit not reached

TRUE: Upper limit reached
lowerLimitReached OUT BOOL - TRUE FALSE: Lower limit not reached

TRUE: Lower limit reached
Functionality
The function block transfers the input value x tothe output value RET_VAL. The
input value is limited dependent on the input parameters upperLimit and lowerLimit.
If the input quantity reaches upper limit upperLimit, output upperLimitReached is

set to TRUE.
If the input quantity reaches lower limit value lowerLimit, output lowerLimitReached
is set to TRUE.
If the lower limit value is greater or equal to the upper limit value, output y is set to
the upper limit value upperLimit.
Timing diagram
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V1.2.0, Item-ID: 58565043 60
Error messages
If upperLimitReached and lowerLimitReached are both at TRUE, the lower limit
lowerLimit is greater than upper limit upperLimit.
4.5.7 LevelControl – Limit value monitor
Limit value monitor



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run IN BOOL M FALSE TRUE: Enable function block

FALSE: Disable function block
alarmHigh IN REAL O 100.0 Alarm, upper limit value
warningHigh IN REAL O 80.0 Warning, upper limit value
warningLow IN REAL O -80.0 Warning, lower limit value
alarmLow IN REAL O -100.0 Alarm, lower limit value
hyst IN REAL O 0.0 Hysteresis

This value is taken into account as an
absolute value.
delayTime IN TIME O T#3s [ s ] Output delay time

delayTime = 0, signal delay is disabled
busy OUT BOOL - FALSE TRUE: Function block is disabled
FALSE: Function block is enabled
alarmUpper OUT BOOL - FALSE TRUE: Upper alarm limit value exceeded
Limit FALSE: Upper alarm limit value not
exceeded

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warningUpper OUT BOOL - FALSE TRUE: Upper warn limit value exceeded
Limit FALSE: Upper warn limit value not
exceeded
warningLower OUT BOOL - FALSE TRUE: Lower warn limit value exceeded
Limit FALSE: Lower warn limit value not
exceeded
AlarmLower OUT BOOL - FALSE TRUE: Lower alarm limit value exceeded
Limit FALSE: Lower alarm limit value not
exceeded
Functionality
This function block monitors an input value (x) to identify whether it violates
(exceeds, falls below) parameterized limit values as long as it is active with run =
TRUE. If the block is enabled this can be identified using the busy output. When
the warningHigh value is exceeded, output warningUpperLimit is set after the
delayTime. The same applies when the alarmHigh value is exceeded with the
associated output alarmUpperLimit. If the input value drops below the limit value
warningHigh or alarmHigh minus the hysteresis value (hyst), the particular output is
reset. The same applies for the lower limit monitoring with the limits warningLow
and alarmLow as well as the associated outputs warningLowerLimit and
alarmLowerLimit. However, in this case, the hysteresis (hyst) is added to the limit
value. Warnings are not reset as a result of an alarm.
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Timing Diagram
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4.5.8 DeadBand – Dead-band filter
Dead-band filter

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bandBorder IN REAL M 0.0 Limit value for dead band
Functionality
If the input value (x) is located in the dead band range (-bandBorder < x <
+bandBorder), the output value is set to zero. However, if it is at or below (–
bandBorder) the output will be x – bandBorder. If the input value is at or above
+bandBorder, x + bandBorder is set as output value. The dead band – symmetrical
around the zero point – can be set using the bandBorder parameter.
x + bandBorder for x -bandBorder

0 for -bandBorder < x < +bandBorder
x - bandBorder for x +bandBorder
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4.5.9 DeadZone – Dead-zone filter
Dead-zone filter

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zoneBorder IN REAL M 0.0 Limit value for dead zone
Functionality
If the input value (x) lies in the range of the dead zone (-zoneBorder < x < +
zoneBorder), the output value is set to zero. If the input value lies at / below (–
zoneBorder) or at / above +zoneBorder, input x is the output value. The dead zone
– symmetrical around the zero point – can be set using the value zoneBorder.
x for x -zoneBorder
0 for -zoneBorder < x < +zoneBorder
x for x +zoneBorder
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V1.2.0, Item-ID: 58565043 65
4.5.10 AverageValue – Average-value filter
Average-value filter
The function block must be called in a cyclic task. ID: 0105


type
enable IN BOOL M FALSE FALSE: Function block is deactivated

TRUE: Function block is activated
sizeOfArray IN INT M 255 Size of the array
dbNumber INT M - Number of the data block that will be

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created for storage of the input values
busy OUT BOOL - FALSE FALSE: Function block is deactivated


TRUE: An error has occurred, refer
to error identification

messages
averageValue OUT REAL - 0.0 Averaged output value
maxValueReached OUT BOOL - FALSE FALSE: Array not yet filled with
values
TRUE: Maximum number of values
in the array (sizeOfArray)
Functionality
The function block calculates the moving average value (averageValue) of the
input values that are entered. Each time the block is called the value (x) currently

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present is saved in a data block that is created (dbNumber). The data block is
deleted upon deactivation of the function block.
The function block is activated via the input enable and calculates values from that
instant. The output maxValueReached is set if the number of values in the data
block reaches the defined number sizeOfArray.
Error messages
ErrorID Description
16#0000_0000 No error

Assigned data block too small
dbNumer invalid (data block not assigned to this function block)
16#0105_8291 Maximum nesting level reached (SFC22 / CREATE_DB)
16#0105_8292 The data block cannot be created because (SFC22 / CREATE_DB):

The “compress user memory” function is currently active
The number of data blocks in the CPU has reached the maximum
possible number
The H CPU is running coupling or update functions
WinAC software CPU has detected an error in the operating system
of the computer where WinAC is installed
The previous delete action is not yet completed
16#0105_82A2 Error in the length of the data block (SFC22 / CREATE_DB)

The length is 0
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The length was specified as an odd number

The length is greater than permitted by the CPU
16#0105_82B1 There is no data block number free (SFC22 / CREATE_DB)
16#0105_82B2 There is not enough free memory available (SFC22 / CREATE_DB)
16#0105_82B3 There is not enough continuous memory space available (SFC22 /

CREATE_DB), compress memory.
16#0105_8391 Maximum nesting level reached (SFC23 / DEL_DB)
16#0105_8392 The data block cannot be deleted (SFC23 / DEL_DB), because:

The compress user memory function is active
The data block to be deleted is in copying process
The H CPU is running coupling or update functions
WinAC software CPU has detected an error in the operating system
of the computer where WinAC is installed
16#0105_83A1 Error in the input parameter DB_NUMBER: the actual parameter

selected
Is 0.
Is greater than the maximum permitted DB number for the CPU used.
16#0105_83B1 The DB with the specified number does not exist on the CPU.

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ErrorID Description
16#0105_83B2 The DB with the specified number created using the keyword
UNLINKED.
16#0105_83B3 The data block is on a flash card (SFC23 / DEL_DB)
16#0105_83B4 The DB cannot be deleted (SFC23 / DEL_DB), possible reasons:

It belongs to an F-program
It is an instance data block of a block for S7 communication (S7-400)
It is a technology data block
16#0105_83C1 The data block cannot be deleted at this time because of a temporary
resource bottleneck (SFC23 / DEL_DB).
16#0105_84A1 Data block number bigger than allowed or zero (SFC 24 / TEST_DB)

4.5.11 PID – PID-controller
PID controller with actual value smoothing and optional D component in the actual
value branch
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V1.2.0, Item-ID: 58565043 68


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type
enable IN BOOL M FALSE FALSE: Function block is deactivated

reset IN BOOL O FALSE FALSE: Normal operation

TRUE: Function block restart
setpointValue IN REAL M 0.0 Setpoint value
actualValue IN REAL M 0.0 Actual value
preControl IN REAL O 0.0 Pre-control value
propGain IN REAL M 2.0 Controller gain
integTime IN REAL O 999.0 [ ms ] Integration time constant

With value = 0.0 the integral channel is
deactivated.
derivTime IN REAL O 0.0 [ ms ] Derivative time constant

With value = 0.0 the differential channel is
deactivated.
filterTime IN REAL O 10.0 [ ms ] Actual value filter time

With values 0.0 the smoothing is
deactivated.

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type
upperLimit IN REAL O 100.0 Upper limit value of the control output

upperLimit > lowerLimit
lowerLimit IN REAL O 0.0 Lower limit value of the control output.
intSetValue IN REAL O 0.0 Integrator set value
holdIntChannel IN BOOL O FALSE FALSE: Normal operation

TRUE: Hold integral action
setIntChannel IN BOOL O FALSE FALSE: Normal operation

TRUE: Set integrator
controlMode IN BOOL O FALSE FALSE: D component in controller deviation

TRUE: D component active in actual value
branch
deadBand IN REAL O 0.0 Width of the deadband filter, deactivated with

0.0
actualValue IN REAL O 1.0 Scaling factor of the actual value quantity

Factor
actualValue IN REAL O 0.0 Offset of the actual value quantity

Offset
outValueFactor IN REAL O 1.0 Scaling factor of the output value
outValueOffset IN REAL O 0.0 Offset of the output value
busy OUT BOOL - FALSE FALSE: Function block deactivated


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identification

000 errorID 16#0000_8000: warning
upperLimit OUT BOOL - FALSE FALSE: No output limitation

Reached TRUE: Controller output has reached the
upper limit, the integrator is limited
lowerLimit OUT BOOL - FALSE FALSE: No output limitation

Reached TRUE: Controller output has reached the
lower limit, the integrator is limited
deviationValue OUT REAL - 0.0 Controller deviation after the deadband filter
pOutValue OUT REAL - 0.0 P component output, unlimited
iOutValue OUT REAL - 0.0 I component output, unlimited
dOutValue OUT REAL - 0.0 D component output, unlimited (if not in the
actual value branch)
outValue OUT REAL - 0.0 Controller output, limited and scaled

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Functionality
The function block is used to implement a universal PID controller that can be
switched to P controller or I controller modes. The D component can either be
calculated in the actual value branch or in the system deviation.
The integrator can be set using the inputs intSetValue (setting value) and
setIntChannel. In addition, the instantaneous value of the integrator can be held
using holdIntChannel (P controller). Internally the I component is limited, based on
the controller output limits (“anti-windup”). The integrator is set to zero at switch-on.
All of the block parameters can be changed in operation.
The scaled and smoothed actual value (actualValue) is subtracted from the
setpoint (setpointValue) according to the following equation:
t
deviationValue (actualValue actualValueFactor ) actualValueOffset 1 e T setpo int Value
The result is the system deviation deviationValue (after the deadband) and is then
multiplied with the proportional coefficient propGain. The result is transferred to the
integrator – and optionally to the D component. The settable integral time
integTime as well as the time constant of the D component derivTime (optional)
define the controller behavior.
Component Calculation
P component pOutValue n propGain deviationV alue n

I component pOutValue n pOutValue n 1 cycleTime
iOutValue n iOutValue n 1
2 int egTime
The integrator includes "anti-windup" functionality, i.e. if the controller
output is limited, the integrator cannot continue to integrate in the same
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direction.
The inputs setIntChannel and holdIntchannel can be used to set the
integrator (intSetValue) – or manually hold it. The integrator is set to zero
using reset or with a rising edge for enable
D component derivTime
dOutValue n pOutValue n pOutValue n 1
(if activated) cycleTime
The controller output is first scaled and is then limited.

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Timing diagram
Case 1, 6 – Blocked is switched-in with enable = TRUE. Output busy = TRUE,

outValue is activated.
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Case 2, 7 – An error has been detected, error = TRUE, busy = FALSE,

outValue = 0.0 – up to reset = TRUE or restart.
Case 3 – Block reset – as long as reset = TRUE. Error = FALSE.
Case 4 – Block has been reset and reset = FALSE, output busy = TRUE,
outValue is activated.
Case 5 – Block is deactivated with enable = FALSE while busy = TRUE. Busy
changes to FALSE, outValue = 0.0.
Case 8 – Block is deactivated with enable = FALSE while error = TRUE. Error
changes to FALSE.

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Block diagram
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V1.2.0, Item-ID: 58565043 73
Error messages
ErrorID Description
16#0000_0000 No error

upperlimit < lowerlimit
4.5.12 TPID – PID-controller with setpoint channel
Technology controller based on a PID controller for use as a tension or dancer roll
position controller in closed-loop winder or material web control.

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V1.2.0, Item-ID: 58565043 74

Name Type Data M/O Initial Description
type value
enable IN BOOL M FALSE FALSE: Falling edge, the controller output

limitation will be ramped to zero and the
controller will be deactivated
TRUE: Rising edge, RFG will be started and
PID controller activated (if openLoop = FALSE)
openLoopCtrl IN BOOL O FALSE FALSE: PID controller is active

TRUE: PID controller and limiting are
deactivated. Only setpoint generator is enabled.
setpointValue IN REAL M 0.0 Controller setpoint value
actualValue IN REAL O 0.0 Actual value
preControl IN REAL O 0.0 Pre-control value
adaptionValue IN REAL O 0.0 Abscissa value of Kp-adaption
holdIntChannel IN BOOL O FALSE FALSE: Normal operation

TRUE: Hold integral action
setIntChannel IN BOOL O FALSE FALSE: Normal operation

TRUE: Set integrator
x1 IN REAL O 0.0 First breakpoint of Kp-adaption characteristic, x1
Kp1 IN REAL O 1.0 First breakpoint of Kp-adaption characteristic,

Kp1
x2 IN REAL O 0.0 Second breakpoint of Kp-adaption characteristic,

x2
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Kp2 IN REAL O 1.0 Second breakpoint of Kp-adaption characteristic,

Kp2
limRampTime IN REAL O 1000.0 Ramp time for controller output
setNominalValue IN REAL O 100.0 Normalisation value for setpoint RFG
setRampTime IN REAL O 1000.0 Ramp time for setpoint RFG
integTime IN REAL O 2000.0 [ ms ] Integration time constant

With value = 0.0 the integral channel is
deactivated.
derivTime IN REAL O 0.0 [ ms ] Derivative time constant

With value = 0.0 the derivative channel is
deactivated.
filterTime IN REAL O 10.0 [ ms ] Actual value filter time

With values 0.0 the smoothing is deactivated.
intSetValue IN REAL O 0.0 Integrator set value
controlMode IN BOOL O FALSE FALSE: D component in controller deviation

TRUE: D component active in actual value
branch
deadBand IN REAL O 0.0 Width of the deadband filter, deactivated with 0.0
outValueFactor IN REAL O 1.0 Scaling factor of the output value

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type value
upperLimit IN REAL O 20.0 Upper limit value of the control output

upperLimit > lowerLimit
lowerLimit IN REAL O -20.0 Lower limit value of the control output.
busy OUT BOOL - FALSE FALSE: Function block deactivated


identification
errorID OUT DWO - 16#0000 Error identification, refer to error messages

RD _0000 errorID 16#0000_8000: warning
upperLimit OUT BOOL - FALSE FALSE: No output limitation

Reached TRUE: Controller output has reached the upper
limit, the integrator is limited
lowerLimit OUT BOOL - FALSE FALSE: No output limitation

Reached TRUE: Controller output has reached the lower
limit, the integrator is held
RFGLimReached OUT BOOL - FALSE FALSE: Controller output limited

TRUE: Controller output limitation deactivated
RFGSetpoint OUT BOOL - FALSE FALSE: RFG output <> setpoint value
Reached TRUE: RFG output reached setpoint value
RFGSetpoint OUT REAL - 0.0 Setpoint after RFG

Value
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outValue OUT REAL - 0.0 Controller output
effectiveKp OUT REAL - 0.0 Effective gain after adaption
Functionality
The block is enabled using the enable input; as a consequence, the setpoint ramp-
function generator and the limiting ramp-function generator are started with their
respective ramp-up times and the PID controller is activated. In addition with the
rising edge the setpoint ramp-function generator is set to the value that is present
at the input (actualValue). This guarantees jerk-free and smooth transition into the
controlled mode.
When the edge at the enable input falls, the limiting ramp-function generator is
ramped back to zero and therefore the controller output is limited. This results in
bumpless controller shutdown. As soon as the outValue output is zero and enable
= FALSE, the block is deactivated and the output busy is set to FALSE. The
setpoint is internally ramped to the actual value during the switch-off phase.
If input openLoopCtrl = TRUE, then the block operates in the open-loop control
mode. As a consequence, the setpoint channel remains active and the controller or
the output limits remain inactive. The output busy stays TRUE as long as the
setpoint ramp output is not zero. The input actualValue is 0.0.

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Setpoint ramping
The setpoint ramp-function generator is used to avoid setpoint steps in the setpoint
channel. The setpoint ramp-function generator is configured using the parameters
setRampTime and setNominalValue, whereby setNominalValue defines the
reference value for the ramp-up or ramp-down time. The function is always active,
if enable = TRUE. If openLoopCtrl = FALSE, enable = FALSE and busy = TRUE
(switch-off phase), then the setpoint is internally set to the actual value.
The ramp times are internally limited to the cycle time.
Controller functionality
The controller setpoint is provided via the input setValue, the actual value via the
actValue input. The setpoint channel includes a settable setpoint ramp-function
generator, via which the setpoint is routed; the effective setpoint can be monitored
at output RFGSetpointValue. The control algorithm used corresponds to that
described in function block PID.
Kp adaptation
A linear adaptation is carried out as Kp adaptation. The interpolation line is defined
by the value tuple (x1, kp1) and (x2, kp2).
1st case: (adaptionValue < x1) or (x1 = x2):

effectiveKp = Kp1
2nd case: x1 adaptionValue x2:
( adaptionValue x1)( kp 2 kp1)

effectiveK p kp1
( x 2 x1)
3rd case: adaptionValue > x2:

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effectiveKp = kp2
The value kp1 is used as effective Kp if the Kp adaptation is deactivated.

V1.2.0, Item-ID: 58565043 77
Timing diagram
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V1.2.0, Item-ID: 58565043 78
Block Diagram
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V1.2.0, Item-ID: 58565043 79
4.6 Drive related function blocks
Error Messages
ErrorID Description
16#0000_0000 No error

setNominalValue 0.0

4.6.1 DriveControl
The function block is used as an interface between the PLC program and a drive
from the SINAMICS drive family. The function block enables the full control of the
respective drive.
The function can be called in any task but it is highly recommended that the
function is called in a cyclic interrupt task such as OB35, especially if the drive is
part of a higher-level control loop, such as a tension controller. ID: 3101

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V1.2.0, Item-ID: 58565043 80

type value
enable IN BOOL M FALSE FALSE: Function block disabled

TRUE: Rising edge enables
communication and saves the parameters
enableTorqueLimits IN BOOL O FALSE FALSE: No torque limiting, limits are set

to 200% of the reference torque.
TRUE: Enable torque limiting by entered
input values.
onOff1 IN BOOL M FALSE FALSE: Drive disabled

TRUE: Enable drive
noOff2 IN BOOL M FALSE FALSE: Coast stop request

TRUE: No coast stop request
noOff3 IN BOOL M FALSE FALSE: Fast stop request

TRUE: No fast stop request
speedSetpointEnabl IN BOOL M FALSE FALSE: Speed setpoint disabled

e TRUE: Speed setpoint enabled
enableFixedEndstop IN BOOL O FALSE FALSE: Travel to fixed end stop disabled

TRUE: Enable travel to fixed end stop
(no error message if torque limits reached)
ackFaults IN BOOL O FALSE FALSE: No fault acknowledgement

TRUE: Rising edge, acknowledge faults
openBrake IN BOOL O FALSE If motor is equipped with holding brake:

FALSE: Brake controlled by brake control
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TRUE: Release brake
infeedOperation IN BOOL M FALSE FALSE: Infeed disabled

TRUE: Infeed enabled, DC bus is ready
speedSetpoint IN REAL M 0.0 [ rpm ] Speed setpoint
additiveTorque IN REAL O 0.0 [ Nm ] Torque pre-control, additive torque
upperTorqueLimit IN REAL O 0.0 [ Nm ] Upper torque limit
lowerTorqueLimit IN REAL O 0.0 [ Nm ] Lower torque limit
kpAdaption IN REAL O 100.0 [ % ] Speed controller gain adaption value.

At 100% the effective Kp = p1460 in the
drive.
referenceSpeed IN REAL M 100.0 [ rpm ] Normalization speed for S120

drives, this parameter equals p2000 in the
drive
Value is saved upon rising edge of enable.
referenceTorque IN REAL M 1.0 [ Nm ] Normalization torque for S120

drives, this parameter equals p2003 in the
drive
logAddr IN INT M - Logical IO address of the drive


V1.2.0, Item-ID: 58565043 81

type value
busy OUT BOOL - FALSE FALSE: Block disabled, no

communication active
TRUE: Block active, valid configuration,

TRUE: Error occurred, refer to error
identification
errorID OUT DWORD - 16#000 Error identification, refer to error

0_0000 messages
readyToPowerUp OUT BOOL - FALSE FALSE: Missing enables

TRUE: Drive is ready
readyForMotion OUT BOOL - FALSE FALSE: Missing enables

TRUE: Drive enabled for motion
fault OUT BOOL - FALSE FALSE: No drive fault

TRUE: Drive fault present
faultCode OUT DINT - 0 Drive fault code, refer to drive manual for
more information (r2131 from the drive)
speedActual OUT REAL - 0.0 [ rpm ] Speed actual value (r63 from the
drive)
torqueActual OUT REAL - 0.0 [ Nm ] Torque actual value (r80 from the
drive)
torqueActualFtlbs OUT REAL - 0.0 [ ft / lbs ] Torque actual value

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torqueActualPercent OUT REAL - 0.0 [ % ] Torque actual value in percent of

nominal torque
Functionality
This function block is utilized to interface and control the drive from the PLC
program. The Drive Control function block is designed to interface to the Sinamics
family of drives but can also be easily adapted to other drives if the telegram
structure is adhered to. Through this function block the programmer is able to
enable, disable, open brake (if available), adjust speed, adjust torque, adjust the
Kp and adjust torque pre-control if required. The programmer also has access to
standard status bits and values.
If torque limiting is active, the function block monitors the actual speed of the drive
to avoid uncontrolled acceleration in the opposite direction to the specified setpoint.
This can happen if the upper torque limit is negative or the lower torque limit is
positive while drive is operating at the torque limit. If the drive accelerates beyond
50 rpm in the opposite direction the drive will be stopped with setpoint zero and the
torque limits will be opened.

V1.2.0, Item-ID: 58565043 82
Control interface
This function block interfaces with the drive via PROFIBus or PROFINet. The
communication between the drive and the PLC is based on a 10 word in and 10
word out telegram. The function block communicates via SFC14 (DPRD_DAT) and
SFC15 (DPWR_DAT) called from within the function block. The user can enter the
logical address of the drive as an input labeled “logAddr” to the function block. It is
necessary to make the drive’s input and output logical addresses identical.
Telegram structure
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The communication telegram is structured to address the requirements of the most

demanding converting applications. Additionally spare words are incorporated for
customer specific needs.
The interface must be consistent on the PLC and the drive side. For this reason a
configuration script is part of the SIMATIC Converting Toolbox for SINAMICS S120
SERVO controlled drives to create the communication interface.
For detailed descriptions of the control and status signals at the drive level, review
the list and function manuals for the drive.
Control Telegram
Element Offset Data Description Interconnected to
(bytes) type
cw1 0 WORD Control word 1 See Control Word 1
speedSetpoint 2 DINT Main speed setpoint p1155

1073741824 = 100% of the reference
speed (p2000)
cw2 6 WORD Control word 2 See Control Word 2
upperTorqueLimit 8 INT Upper torque limit p1522

16384 = 100% of the reference torque
(p2003)

V1.2.0, Item-ID: 58565043 83

(bytes) type
lowerTorqueLimit 10 INT Lower torque limit p1523

(p2003)
additiveTorque 12 INT Additional torque p1511

(p2003)
kpAdaption 14 INT Speed controlled gain adaption p1455

16394 = 100% of the set gain (p1460)
word09 16 WORD not used -
Control Word 1
Element Offset (bits) Data type Description Interconnected to
onOff1 0 BOOL ON / OFF p840

noOff2 1 BOOL No coast stop request p844
noOff3 2 BOOL No fast stop request p848
enable 3 BOOL Enable controller - enable inverter p852
enableRFG 4 BOOL Enable RFG p1140
startRFG 5 BOOL Start RFG p1141
enSpeedSet 6 BOOL Enable speed setpoint p1142

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acknFault 7 BOOL Acknowledge faults p2103
bit08 8 BOOL not used -
controlReq 10 BOOL PLC request control p854
reverseDir 11 BOOL Direction reversal p1113
mopRaise 13 BOOL MOP increase value p1035
mopLower 14 BOOL MOP lower value p1036
Control Word 2
dds0 0 BOOL Drive data set selection 0 p820

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closeBrake 5 BOOL Close brake p858
infeedOn 6 BOOL Infeed module enabled p864
parkAxis 7 BOOL Park drive object p897
travToFixStop 8 BOOL Traverse to fixed stop p1545

openBrake 15 BOOL Open brake p855
Status Telegram
(bytes) type
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sw1 0 WORD Status word 1 See Status Word 1
actualSpeed 2 DINT Actual speed r63

1073741824 = 100% of the reference speed
(p2000)
sw2 6 WORD Status word 2 See Status Word 2
actualTorque 8 INT Actual torque r80

16384 = 100% of the reference torque (p2003)
faultNum 10 INT Actual fault code r2131

V1.2.0, Item-ID: 58565043 85
Status Word 1
rdvTpPwr 0 BOOL Ready to power r899.0
rdyToOp 1 BOOL Ready to operate r899.1
inOperation 2 BOOL In operation r899.2
faultPresent 3 BOOL Fault present r2139.3
noOFF2Act 4 BOOL OFF2 inactive r899.4
noOFF3Act 5 BOOL OFF3 inactive r899.5
powerInhibit 6 BOOL Power ON inhibit active r899.6
alarmPresent 7 BOOL Alarm present r2139.7
spdDevOK 8 BOOL n_act < speed threshold r2197.7

value 3
controlReq 9 BOOL Control requested r899.9
spdValReached 10 BOOL n actual > = compare value r2199.1

speed 2
curTrqPwrOK 11 BOOL I, M, P limit not reached r1407.7
brkSetpEN 12 BOOL Enable set point from brake r899.12

control
mtrTempOK 13 BOOL No motor temperature alarm r2135.14
mrtRotDir 14 BOOL Motor direction of rotation r2197.3
pwrUnitTempOK 15 BOOL No power unit temperature r2135.15

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over load
Status Word 2
dds0 0 BOOL Drive data set 0 r837.0
almClass0 5 BOOL Alarm class bit0 r2139.11
almClass1 6 BOOL Alarm class bit1 r2139.12
axisParked 7 BOOL Drive parked r896.0
fixedEndstop 8 BOOL Traverse to fixed end stop r1406.8

active

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pulsesEnabled 10 BOOL Output pulses enabled r899.11
dataSetChanging 11 BOOL Data set change over is active r835.0
Block diagram
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Warning Messages
FALSE and errorID <> 16#0000_0000.
ErrorID Description
16#0000_0000 No warning
16#3101_4009 Communication error while reading from bus system
16#3101_400A Communication error while writing on bus system

V1.2.0, Item-ID: 58565043 87
Error Messages
ErrorID Description
16#0000_0000 No error

logAddr 0
referenceSpeed 0.0
referenceTorque 0.0
16#3101_8065 Torque Limits may not be plausible any more; a break in the web
could cause this problem. Axis runs in the opposite direction too
fast. Reaction: brake with full torque.
4.6.2 SetpointChannel
The SetpointChannel Function Block is designed to provide the functionality

required to produce a drive speed setpoint for the DriveControl function block.

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V1.2.0, Item-ID: 58565043 88

type
jogPos IN BOOL O FALSE FALSE: No jog operation

TRUE: Start Jog forward at jogVelocity
jogNeg IN BOOL O FALSE FALSE: No jog operation

TRUE: Start Jog reverse at jogVelocity
enableRFG IN BOOL O FALSE FALSE: Velocity setpoint ramp disabled

TRUE: Enable velocity setpoint ramp
holdRFG IN BOOL O FALSE FALSE: No hold operation of the RFG

TRUE: Hold actual velocity with jerk limit
noFastStop IN BOOL O TRUE FALSE: Fast stop with fastStopTime

TRUE: Normal ramp operation
metricUnits IN BOOL O TRUE FALSE: Imperial units

TRUE: Metric units
jogVelocity IN REAL O 0.0 [ LU/min] Jog velocity setpoint

w/o Ramp
velocity1 IN REAL O 0.0 [LU/min ] Velocity setpoint w/ Ramp
velocity4 IN REAL O 0.0 [LU/min] Velocity setpoint w/o Ramp
velocityPID IN REAL O 0.0 [LU/min ] Tension correction velocity w/o

Ramp
draw IN REAL O 1.0 [ % ] Draw ratio [1.00 = 100%]

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roundingTime IN REAL O 0.5 [ s ] Ramp rounding time
rampUpTime IN REAL O 30.0 [ s ] Ramp up time
rampDownTime IN REAL O 30.0 [ s ] Ramp down time
fastStopTime IN REAL O 3.0 [ s ] Fast stop down time
gearRatio IN REAL M 1.0 Gear ratio, motor:load
diameter IN REAL O 0.0 [ m or inch ] Diameter of driven roll

If the input is zero then a standard value is
used which gives 1.0 LU as circumference.
actDriveSpeed IN REAL M 0.0 [ rpm ] Actual speed from drive
maxVelocity IN REAL M 0.0 [LU/min ] Max line velocity for normalization

and limiting

identification
errorId OUT DWORD - 16#0000_0 Error identification, refer to error messages

setVelocity OUT REAL - 0.0 [LU/min] Total velocity setpoint

V1.2.0, Item-ID: 58565043 89

type
actVelocity OUT REAL - 0.0 [LU/min ] Actual velocity
acceleration OUT REAL - 0.0 [ LU/ s2 ] Set line acceleration
setDriveSpeed OUT REAL - 0.0 [ rpm ] Speed setpoint to drive
actShaftSpeed OUT REAL - 0.0 [ rpm ] Actual shaft speed
zeroSpeed OUT BOOL - FALSE FALSE: Shaft speed not zero

TRUE: Actual shaft speed at zero
Functionality
The block must be configured using the correct total gear ratio, diameter of driven
roll and max velocity. This function block consistently checks for plausible
parameters and will display an error with corresponding errorId should invalid data
be entered at the rising edge of enable.
With the enableRFG set to true, the velocity1, velocity2 and velocity3 are summed
together and sent to the input of the RFGJ together with the configuration data and
ramp control functions for holding, rounding, and ramp times entered at this
function block. With a False entered at enableRFG the input is set to zero and the
ramp is kept enabled until the ramped signal is zero. velocity4, Draw (multiplier)
and the tension correction – velocityPID – inputs are always active unless jog is
requested and the ramp output is zero.
RFG operation has priority over jog. The jog commands must be exclusive
commands.
With the enableRFG false, the jogPos set to true and jogNeg is false, the
jogVelocity is set as the velocity setpoint. Additionally, with the enableRFG false,
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the jogNeg set to true and jogPos is false, a negative jogVelocity is set as the
velocity setpoint.
The jog velocity, summed velocity setpoints 1-4 times the draw factor are limited to
+/- max velocity value. The tension velocity is added after this limit to allow tension
or any other superimposed control even at 100% velocity.
The function block will calculate the correct drive speed setpoint based upon the
diameter (in meterr or in inches) and gear ratio.
velocitySet
driveSpeedSet * gearRatio
(diameter * PI )
The function block will calculate the correct Shaft actual speed based upon the
actual motor speed and gear ratio.
driveSpeedAct
shaftSpeedAct
gearRatio
The function block will check for zero speed if the absolute actual speed is less
then 0.1 rpm.

V1.2.0, Item-ID: 58565043 90
Measure Metric unit Imperial unit
speed revolutions per minute (rpm)
velocity meters per minute (m/min) ft per minute (ft/min)
acceleration meters per second squared (m/s ) 2

ft per second squared (ft /s2)
diameter meters (m) inch (in)
LU m ft
(length unit)
Block diagram
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Error Messages
ErrorID Description
16#0000_0000 No error

maxVelocity 0.0
gearRatio = 0.0
The configuration data are checked for plausibility at the enable
rising edge.

V1.2.0, Item-ID: 58565043 91
4.6.3 FrictionMeasurement – Friction characteristic measurement
The function block is used to record the friction characteristic of the drive. The
characteristic can subsequently be used as a component in the torque pre-control.


type
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execute IN BOOL M FALSE FALSE: Friction measurement disabled

TRUE: Rising edge starts the friction
measurement
abort IN BOOL O FALSE FALSE: Normal sequence

TRUE: Rising edge interrupts the sequence
and stops the axis
warmupTime IN TIME O - [ T# ] System warm-up time at maximum

speed for reaching operating conditions
rampTime IN REAL M - [ ms ] Ramping time for speed setpoint

ramping
actualTorque IN REAL M - [ Nm or ft/lbs ] Torque feedback from the drive
valueNumber IN INT M 100 Number of measurement points per speed

step [limited internally to 50 – 500]
maxSpeed IN REAL O 0.0 [ rpm ] Max. speed reference.

If specified, the data block will be pre-
assigned with the x (speed) values evenly
distributed.
If the input is zero, values for measurement
are taken directly from the data block, the
highest x value will be used as maximum
speed reference.

V1.2.0, Item-ID: 58565043 92

type
dbPointer IN ANY M - Pointer to breakpoint table of the friction

characteristic, x: speed, y: torque
.. .. .. ..
Length defined by size of the data area, min.
length 16 bytes for two breakpoints.
All speed (x) values must be positive.
done OUT BOOL - FALSE FALSE: Measurement of friction characteristic

not active
TRUE: Measurement completed, friction
characteristic generated
aborted OUT BOOL - FALSE FALSE: Measurement was not interrupted

TRUE: Measurement was prematurely
interrupted
busy OUT BOOL - FALSE FALSE: Function block inactive

TRUE: Function block active

identification

speedSetpoint OUT REAL - 0.0 [ rpm ] Speed setpoint for drive control
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Functionality
The function block measures the friction characteristic (speed/torque breakpoints)
of a specific mechanical system. Speed setpoints are taken and torque values are
saved in the specified data area referenced by dbPointer. The data structure
contains breakpoints of the characteristic (x value: speed, y value: torque), while
the speed setpoint value has to be specified before starting the function block.
The user has to possibility to let the function block pre-assign the speed values into
the data block. For this the input parameter maxSpeed must be unequal to zero.
The speed values will be distributed evenly according to the length of the data
block. The first entry will always be zero speed with zero torque.
The function block is started using the input enable. Once started, the output
speedSetpoint outputs the drive’s speed based on the values in the breakpoint
table. If the input warmupTime > 0.0, the drive moves for this defined period of time
at the maximum speed before starting the measurement of the corresponding
torque values.
The actual torque value of the drive must be connected to the actualTorque input
of the function block. The torque values are averaged with a defined number of
samplings specified by input valueNumber. The ramp times for changing the speed
setpoint are specified using the input ramptime. If the sequence is active, done =
FALSE and busy = TRUE. If finished, done = TRUE and busy = FALSE.

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If an error occurs during the sequence, this is displayed at the error output and the
associated errorID. If the abort signal abort is set to TRUE the measurement is
interrupted and the setpoint ramped to zero.
Timing diagram
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Error Messages
ErrorID Description
16#0000_0000 No error
entries in the table.

Pointer is addressing a write protected data block
16#3103_84A1 Data block number larger than allowed or zero (SFC 24 /

TEST_DB)
16#3103_84B1 Data block does not exist (SFC 24 / TEST_DB)

V1.2.0, Item-ID: 58565043 94
4.7 Sectional Drive
4.7 Sectional Drive

4.7.1 SectionalConfigSetup
This function block is used to enter individual configuration data into a sectional
drive configuration data structure used by the sectional drive function block.
The function block can be called in any task. ID: 6001

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4.7 Sectional Drive

type value
metricUnits IN BOOL O TRUE FALSE: Imperial

TRUE: Metric
jogVelocity IN REAL O 10.0 [ LU/min ] Jog velocity setpoint (no ramp)
speedMatchRamp IN REAL O 0.5 [ s ] Ramp time for acceleration to line speed

Time
diameter IN REAL O 1.0 [ m or inch ] Diameter value
kpAdaptionValue IN REAL O 0.0 TPID - Kp-Adaption signal
holdIntChannel IN BOOL O TRUE FALSE: TPID – Normal integrator operation

TRUE: TPID - Hold (freeze) integrator
setIntChannel IN BOOL O FALSE FALSE: TPID - Normal integrator operation

TRUE: TPID - Set integrator channel to
intSetValue
x1 IN REAL O 0.0 TPID - Abscissa-1 for KP-adaption(1)

kp1 IN REAL O 1.0 TPID - KP-adaption point(1)
limRampTime IN REAL O 1000.0 [ ms ] TPID - Ramp-up time for PID controller

output limiting
setNominalValue IN REAL O 100.0 TPID - Normalisation value for setpoint RFG

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setRampTime IN REAL O 1000.0 [ ms ] TPID - Ramp up time for setpoint RFG
integTime IN REAL O 2000.0 [ ms ] TPID - Integration time constant
derivTime IN REAL O 0.0 [ ms ] TPID - Differentiation time constant
filterTime IN REAL O 10.0 [ ms ] TPID - Actual value filter time constant
intSetValue IN REAL O 0.0 TPID - Integrator set value
derivControlMode IN BOOL O FALSE FALSE: TPID – D-Action acts on system

deviation
TRUE: TPID - D-Action acts in the actual value
deadBand IN REAL O 0.0 TPID - Deadband parameter
outValueFactor IN REAL O 1.0 TPID - Output scaling factor
upperLimit IN REAL O 20.0 TPID - Controller output upper limit
lowerLimit IN REAL O -20.0 TPID - Controller output lower limit
overrideVelocity IN REAL O 10.0 [ LU/min ] Speed controller bias (override,

overcontrol) for torque controlled modes
TensionAdjustme IN REAL O 1.0 1.0 = 100%

nt Tension torque adjustment factor

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4.7 Sectional Drive

type value
tensionReference IN REAL O 0.0 [ N or lbf ] Reference value for tension setpoint. If

set to zero the setpoint is interpreted as absolute
value instead of a percentage.
JFixed IN REAL O 0.0 [ kgm2 or lbft / s2 ] Fixed moment of inertia, motor

side
JMandrel IN REAL O 0.0 [ kgm2 or lbft/s2 ] Fixed moment of inertia, load

side
JMotor IN REAL O 0.0 [ kgm2 or lbft/s2 ] Motor inertia
frictionAdjustment IN REAL O 0.0 1.0 = 100%

Adjustment factor of the friction characteristic
output. With 0.0 friction compensation is off.
maxVelocity IN REAL M - [ LU/min ] Max velocity for normalization
gearRatio IN REAL M - Gear Ratio, Motor/Load
referenceSpeed IN REAL M - [ rpm ] Normalization speed of drive (p2000)
referenceTorque IN REAL M - [ Nm ] Normalization torque of drive (p2003)

logAddr IN INT M - Logical address of the drive
SectionalConfig OUT Section - - Sectional drive configuration Data

al
Config
Type
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Functionality
This function creates one output structure of SectionalConfigType from the
configuration parameters. This is done to reduce the number of input variables on
the sectional drive function block but still give the user easy access.
4.7.2 TorquePrecontrol
Torque pre-control calculation.

The function block has to be called in a cyclic task. ID: 6101

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4.7 Sectional Drive


type value
enable IN BOOL M FALSE FALSE: Deactivate Function block

TRUE: Activate function block

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TRUE: Metric
typeOfDrive IN INT M 0 Drive type:

0: Pull
1: Held
driveSpeed IN REAL O 0.0 [ rpm ] Actual drive speed (for the friction
characteristic)
lineAcceleration IN REAL M 0.0 [ LU/s2 ] Actual line acceleration
diameter IN REAL M 0.0 [ m or inch ] Diameter value
tensionSetpoint IN REAL O 0.0 [ N or lbf ] Tension setpoint values
jFix IN REAL O - [ kgm2 or lbft/s2 ] Fixed moment of inertia,

motor side
jMandrel IN REAL O - [ kgm2 or lbft/s2 ] Fixed moment of inertia,

load side
jMot IN REAL O - [ kgm2 or lbft/s2 ] Motor inertia
frictionAdjustment IN REAL O - 1.0 = 100%

Adjustment factor of the friction
characteristic output. With 0.0 friction
compensation is off.

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4.7 Sectional Drive

type value
tensionAdjustment IN REAL O - 1.0 = 100%

Tension torque adjustment factor
dbPointer IN ANY O - Pointer to breakpoint table of the friction

.. .. .. ..
busy OUT BOOL - FALSE FALSE: Function block not activated


identification
errorID OUT DWORD - 16#000 Error identification, refer to error messages

0_0000 errorID 16#0000_8000: warning
totalInertia OUT REAL - 0.0 [ kgm2 or lbft / s2 ] Total inertia of the

mechanical system, reflected to the motor
side
preCtrlMotor OUT REAL - 0.0 [ Nm ] Motor torque from friction and

acceleration
totalTorquePreCtrl OUT REAL - 0.0 [ Nm ] Sum of motor torque

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tensionTorque OUT REAL - 0.0 [ Nm ] Motor torque from tension.
Functionality
The block determines the pre-controlled torque for v/ t
The torque pre-control outputs the following torque setpoints to pre-control the
drive:
A torque setpoint as a function of the acceleration setpoint of the
machine/system ramp-function generator and the inertia
Friction torque setpoint is generated depending on the drive speed using a
characteristic.
Tension torque based on the tension setpoint and the diameter
In order to quickly compensate for disturbances and to implement the closed-loop
control in the first place (for a replacing speed control), the torque to be provided
from the drive must be specified as accurately as possible. Depending on the
control type, this is either realized additively after the speed controller or by
dynamically adjusting the torque limits.
In both cases the appropriate torque must be calculated using its moment of inertia
and transferred to the drive.

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4.7 Sectional Drive
As an alternative to the method integrated in this block, the integrated friction

characteristic of the drive system (SINAMICS) can also be used.
NOTICE The precise setting of the compensation is particularly important for indirect
tension control. This is so that the torque-generating current emulates, as far as
possible, the material tension.
Calculations
The function block FBTorquePrecontrol calculates the following physical quantities:
Quantity Formula
Total moment of inertia JMandrel

TotalInertia JMot JFix
GearRatio 2
Angular acceleration of the lineAcceleration GearRatio
drive 2
diameter
Acceleration torque M accel TotalInert ia

Friction torque M frict f (n)
Tension torque tensionSetpo int tensionAdjustment diameter

M tension
2 gearRatio
This friction torque is internally determined using the function block TableChar. The
user is responsible for providing valid and sensible values in the appropriate data
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fields. If the factor FrictionAdjustment is set to 0.0 TableChar is not called and
therefore a frictional torque is not added.
The pre-control torque of the motor, the sum of all pre-control torques and the
tension torque are calculated depending on the drive type. The total torque is
always the sum of the preCtrlMotor and tensionTorque.
Drive mode Total torque
Pull MpreCtrlMotor = Macc + Mfrict MtensionTorque = MtensionTorque

Held MpreCtrlMotor = Macc + Mfrict MtensionTorque = - MtensionTorque

V1.2.0, Item-ID: 58565043 100
4.7 Sectional Drive
Block diagram
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V1.2.0, Item-ID: 58565043 101
4.7 Sectional Drive
Warning Messages
FALSE and errorID <> 16#0000_0000
ErrorID Description
16#0000_0000 No Warning
16#6101_4005 The table of entered values is not monotonically (steadily) increasing

-> no matching value found

-> 2 values are identical
Error Messages
ErrorID Description
16#0000_0000 No error
number of points.
16#6101_8005 One or more configuration values are invalid.

gearRatio 0.0
Jfix < 0.0
Jmandel < 0.0
Jmot < 0.0
typeOfDrive < 0
typeOfDrive > 1
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The configuration data are checked for plausibility at the rising edge
of enable.
Pointer is not addressing a data block.
16#6101_8006 Invalid diameter value

diamActVal 0.0
16#6101_84A1 Data block number bigger than allowed or zero (SFC 24 / TEST_DB)
4.7.3 SectionalDrive
This function block is used to control a converting line sectional drive from a PLC
program. The function block was designed to handle the requirements of a tension
or ratio adjusted driven section.

V1.2.0, Item-ID: 58565043 102
4.7 Sectional Drive

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Input and Output parameters

type value

communication and saves parameters
onOFF1 IN BOOL M FALSE FALSE: Drive disabled

TRUE: Enable drive
noOFF2 IN BOOL M FALSE FALSE: Coast stop request

noOFF3 IN BOOL M FALSE FALSE: Fast stop request



TRUE: Release brake


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4.7 Sectional Drive

type value
driveKp IN REAL O 100.0 [ % ] Speed controller gain adaption value.

drive.
lineVelocity IN REAL M 0.0 [ LU/min ] Master line velocity
additionalVelocity IN REAL O 0.0 [ LU/min ] Additional velocity (always

enabled)
draw IN REAL M 1.0 [ - ] Percent ratio to master line speed, 1.0 =

100%
typeOfDrive IN INT O 0 Specifies the drive mode:

0: PULL
1: HELD
controlMode IN INT O 0 Specifies the tension control mode:

0: DANCER_SPEED_ADAPT
1: DANCER_SPEED_ADAPT_HD
2: TENSION_SPEED_ADAPT
3: TENSION_SPEED_ADAPT_HD
4: TENSION_TORQUE_ADAPT
5: INDIRECT
6: DRAW_CONTROL

TRUE: Start Jog forward at Jog Sp

TRUE: Start Jog reverse at Jog Sp
frictionDbPointer IN ANY O -
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Pointer to breakpoint table of the friction

.. .. .. ..
Length defined by size of the data area,
min. length 16 bytes for two breakpoints.
CtrlEnable IN BOOL O FALSE FALSE: TPID and tension not enabled

TRUE: TPID enable
CtrlSetpoint IN REAL O 0.0 TPID Setpoint
CtrlActual IN REAL O 0.0 TPID actual value
SectionalConfig IO sectional M - This data type includes all configuration

Config data required for parameterization of the
Tpye SectionalDrive function block
busy OUT BOOL - FALSE FALSE: Block disabled, no communication

active

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4.7 Sectional Drive

type value


_0000 errorID 16#0000_8000: Warning
driveReadyToPowerUp OUT BOOL - FALSE FALSE: Missing enables

driveReadyForMotion OUT BOOL - FALSE FALSE: Missing enables

driveZeroSpeed OUT BOOL - TRUE FALSE: Shaft speed not zero

driveFault OUT BOOL - FALSE FALSE: No drive fault

driveFaultCode OUT DINT - 0 Drive fault code, refer to drive manual for
driveSpeedActual OUT REAL - 0.0 [ rpm ] Speed actual value (r63 from the
drive)
driveTorqueActual OUT REAL - 0.0 [ Nm ] Torque actual value (r80 from the
drive)
driveTorqueActualFtlbs OUT REAL - 0.0 [ ft/lbs ] Torque actual value
driveTorqueActual OUT REAL - 0.0 [ % ] Torque actual value in percent of

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Percent nominal torque
actVelocity OUT REAL - 0.0 [ LU/min ] Actual line velocity
pidOutValue OUT REAL - 0.0 TPID controller output
pidEffectiveKp OUT REAL - 0.0 TPID effective Kp
pidUpperLimitReached OUT BOOL - FALSE TPID at upper limit
pidLowerLimitReached OUT BOOL - FALSE TPID at lower limit
Functionality
This function block utilizes the DriveControl, SetpointChannel, TorquePrecontrol
and TechPID function blocks of the Simatic Converting Toolbox. This function block
checks for valid configuration data and calls the individual function blocks to
minimize application development time.
With the enable set to true a plausibility check is done on the configuration data
and will display an error with corresponding error Id should invalid data be entered.
This input allows control functionality. With the function block enabled the

V1.2.0, Item-ID: 58565043 105
4.7 Sectional Drive
driveControl function block will become active, which in turn will set the busy output
true.
With the enables set true the sectional drive will follow the sum of the lineVelocity
and additionalVelocity multiplied by the draw factor. Sectional drives are typically
made to follow the master without any ramps. The programmer is responsible for
proper interlocks to prevent unwanted behavior.
The configuration data has diameter, gear ratio and max line speed parameters
which are utilized to calculate the correct surface velocity of the driven roll to match
the section to the master line velocity.
The configuration data also has parameters for torque pre-control. Torque pre-
control is necessary for torque based tension control modes and is optional for
speed based tension control modes. Speed based tension control modes with the
_HD (high dynamic) prefix utilize torque pre-control.
With the enable set to true and DrvReadyForMotion and Cntrlenable then the
CntrlSetpoint will be ramped up based on configuration data. The Tension
controller correction value will be added to the total speed setpoint or additional
torque, scaled and sent to the drive using the driveControl function block as
required.
Function block output parameters allow the user to view the calculated surface
velocity of the section (actVelocity), the section’s actual shaft speed
(actshaftSpeed), motor actual speed in RPM (actdriveSpeed), motor torques

(driveTorqueActual, driveTorqueActualFtlbs, driveTorqueActualPercent) and
pertinent PID data.
Tension operating modes

The following overview shows the tension operating modes depending on the
position of the dancer or tension measuring devices location in relation to the web
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axis as well as the orientation of the setting variables (speed, force, torque). The
tension operating mode is selected by the typeOfDrive input of the function block.
The following table shows the different tension operating modes and the direction
of velocity, tension and torque. During commissioning of the application it must be
ensured that the direction convention and signs of the process variables are

V1.2.0, Item-ID: 58565043 106
4.7 Sectional Drive
aligned. It may might be necessary to change the direction of rotation in the drive
system.
Operation Representation Description
mode
PULL V: Machine velocity

F: Tension in material line
n: speed of drive
nO: velocity override for speed
controller overcontrol
Mf: Friction torque

HELD MP: Pre-control torque
MT: Tension torque
Block diagram
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Warning Messages
Warnings are indicated by the status of the outputs error and errorID:
error = FALSE and errorID <> 16#0000_0000

V1.2.0, Item-ID: 58565043 107
4.7 Sectional Drive
ErrorID Description
16#0000_0000 No Warning
16#3101_4009 Communication error while reading from bus system (DriveControl)
16#3101_400A Communication error while writing on bus system (DriveControl)
16#6101_4005 The table of entered values is not monotonically (steadily) increasing ->
no matching value found (Torque Precontrol, friction table)
16#6101_4008 The table of entered values is not monotonically (steadily) increasing -> 2
values are identical (Torque Precontrol, friction table)
Error Messages
ErrorID Description
16#0000_0000 No error
16#3101_8005 Invalid configuration data: (DriveControl)

logAddr 0
referenceSpeed 0.0
referenceTorque 0.0
16#3101_8065 Torque Limits may not be plausible any more; a break in the web could
cause this problem. Axis runs in the opposite direction too fast. Reaction:
brake with full torque. (DriveControl)
(SetpointChannel)
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16#3102_8005 Invalid configuration data: (SetpointChannel)

maxVelocity 0.0
gearRatio = 0.0
The configuration data are checked for plausibility at the rising edge of
enable.
16#1108_8001 The function block is not called in a cyclic interrupt, e.g. OB35. (TPID)
16#1108_8005 Invalid configuration data: (TPID)

setNominalValue 0.0
16#6101_8003 Less than two pairs of values in the breakpoint table or uneven number
of points. (Torque Precontrol, friction table)
16#6101_8005 One or more configuration values are invalid. (Torque Precontrol)

gearRatio 0.0
Jfix < 0.0
Jmandel < 0.0
Jmot < 0.0
typeOfDrive < 0
typeOfDrive > 1
enable.
Pointer is not addressing a data block. (Torque Precontrol, friction table)

V1.2.0, Item-ID: 58565043 108
4.8 Winder function blocks
ErrorID Description
16#6101_8006 Invalid diameter value (Torque Precontrol)

diamActVal 0.0
16#6101_84A1 Data block number larger than allowed or zero (SFC 24 / TEST_DB)
(Torque Pre-control, friction table)
16#6101_84B1 Data block does not exist (SFC 24 / TEST_DB) (Torque Precontrol,
friction table)
16#6101_84B2 Data block unlinked (SFC24 / TEST_DB) (Torque Precontrol, friction

table)
16#7101_8005 Invalid configuration data

controleMode < 0
controlMode > 6
typeOfDrive < 0
typeOfDrive > 1
sectionalConfig.diameter 0.0
sectionalConfig.maxVelocity = 0.0
sectionalConfig.gearRatio = 0.0
sectionalConfig.referenceSpeed = 0.0
sectionalConfig.referenceTorque = 0.0
sectionalConfig.logAddr = 0
enable.
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4.8.1 DiamCalcDivision
This function block is used to calculate the diameter of a winder by dividing the
material velocity by the winding shaft speed.

V1.2.0, Item-ID: 58565043 109


Name Type Data type M/O Initial Description
value

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holdDiameter IN BOOL O FALSE FALSE: Diameter calculation

TRUE: Hold diameter calculation

TRUE: Metric
setDiameter IN BOOL O FALSE FALSE: Diameter calculation

TRUE: Set diameter to diameter set value
diameterSetValue IN REAL O 1.0 [ m or inch ] Diameter set value
lineVelocity IN REAL M 0.0 [ LU/min ] Line velocity
shaftSpeed IN REAL M 0.0 [ rpm ] Actual shaft speed
minDia IN REAL M 0.1 [ m or inch ] Minimum diameter
maxDia IN REAL M 2.0 [ m or inch ] Maximum diameter
minLineVelocity IN REAL O 5.0 [ LU/min ] Minimum line velocity for

calculation
minShaftSpeed IN REAL O 5.0 [ rpm ] Minimum shaft speed for calculation
lineFilterTime IN REAL O 20.0 [ ms ] Filter time of the line velocity
shaftFilterTime IN REAL O 20.0 [ ms ] Filter time of the shaft speed

V1.2.0, Item-ID: 58565043 110

value
diameterFilter IN REAL O 50.0 [ ms ] Filter time for the calculated diameter

Time
diameter IO REAL - - [ m or inch ] Diameter


identification

_0000 errorID 16#0000_8000: warning
atMinDia OUT BOOL - FALSE At minimum diameter
atMaxDia OUT BOOL - FALSE At maximum diameter

Functionality
The function block determines the actual diameter value (diameter) of the roll being
wound (or unwound) using the following input quantities:
Web velocity (lineVelocity) - the web velocity is the setpoint velocity of the
machine and the velocity with which the main drive moves the material web. In
exceptional cases it is possible to use the actual value from a tachometer
measuring the web speed.
Shaft speed of the mandrel (shaftSpeed) – Actual speed of the winder shaft.
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The actual motor speed is converted to the roll shaft (by the gear ratio) and is
used to calculate the diameter.
The calculation is based on the D = v/( *n) formula.
Quantity Metric Imperial
line velocity m/min ft/min
winder shaft speed rpm rpm
diameter meter (m) inch (in)
The holdDiameter input will pause the diameter calculation and hold the resulting
diameter at the current value when set to true.
The setDiameter input writes the diameterSetvalue as the diameter as long as the
actual shaft speed is below minimum shaft speed. The set value is limited by the
minimum and maximum diameter.
With actual line velocity above the line minimum velocity y and the actual shaft
speed above minimum shaft speed and not held, the diameter is calculated. The
result of the division is limited and smoothed.

V1.2.0, Item-ID: 58565043 111
Block diagram
Error Messages
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ErrorID Description
16#0000_0000 No error

minDia 0.0
maxDia 0.0
minDia maxDia
minLineVelocity 0.0
minShaftSpeed 0.0
enable.
4.8.2 DiamCalcIntegral
This function block is used to calculate the diameter of a winder by dividing the
material length change by the number of winding shaft revolutions.

V1.2.0, Item-ID: 58565043 112



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TRUE: Metric

TRUE: Set diameter to diameter set
value
diameterSetValu IN REAL O 1.0 [ m or inch ] Diameter set value

e
linevelocity IN REAL M 0.0 [ LU/min ] Line velocity
minLineVelocity IN REAL O 0.5 [ LU/min ] Minimum line velocity for

calculation
minShaftSpeed IN REAL O 0.5 [ rpm ] Minimum shaft speed for

calculation
lineFilterTime IN REAL O 20.0 [ ms ] Filter time of the line velocity

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shaftFilterTime IN REAL O 20.0 [ ms ] Filter time of the shaft speed
Measuring IN REAL O 2.0 [ rev ] Winder shaft revolutions for

RevolutionCount diameter calculation interval


identification

000 messages

Functionality
The diameter calculator determines the actual diameter value (diameter) of the roll
being wound (or unwound) using the input quantities:
Web velocity (lineVelocity) - the web velocity is the setpoint velocity of the
machine and the velocity with which the main drive moves the material web. In
exceptional cases, it is possible to use the actual value from a tachometer
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which is used to measure the web speed.

Shaft speed of the mandrel (shaftspeed) – Actual speed of the winder shaft.
The actual motor speed is converted to the roll shaft speed (using the gear
ratio) and is used to calculate the diameter.
The integral diameter calculation is also based on the division of the integral of the
web velocity by the integral of the angular velocity. However, v and are
integrated over a number of roll revolutions that can be specified by
measuringRevolutionCount. This is to minimize the disturbing effect of processing
just individual values. The following applies:
Diameter 2 * ( s / )
Quantity Metric Imperial
line velocity m/min ft/min
winder shaft speed rpm rpm
diameter meter (m) inch (in)
angle rad rad
length m ft

V1.2.0, Item-ID: 58565043 114
When set to true the holdDiameter input will pause the diameter calculation and
hold the resulting diameter at the current value.
As long as the actual shaft speed is below the minimum shaft speed the
setDiameter input writes the diametersetvalue as the diameter. The set diameter is
limited.
When the actual line velocity is above minimum and the actual shaft speed is
above and not held, the diameter is calculated. The result is limited and
interpolated.
If the number of revolutions of the winding shaft - specified by parameter
measuringRevolutionCount – is reached, then the integrators are reset. One
integrator will give the length change of the material for the specified number of
winder shaft revolutions. From these two values the (average) diameter can be
calculated.
Additionally ,based on the diameter change, the actual material thickness is
calculated in every measuring interval, e.g. for remaining length calculation.
Thickness = |diameterNew – diameterOld|/measuringRevolutionCount
Block Diagram
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Error Messages
ErrorID Description
16#0000_0000 No error

V1.2.0, Item-ID: 58565043 115
ErrorID Description

minDia 0.0
maxDia 0.0
minDia maxDia
measuringRevolutionCount 0.0
minLineSVelocity 0.0
minShaftSpeed 0.0
enable.
4.8.3 DiamCalcAddition
This function block is used to calculate the diameter of a winder roll being wound
by adding twice the material thickness per winding shaft revolution.

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value




V1.2.0, Item-ID: 58565043 116

value
typeOfWinder IN INT M 0 Winder type:

0: Rewind from above
1: Rewind from below
2: Unwind from above
3: Unwind from below
webThickness IN REAL M 0.001 [ m or inch ] Web thickness
minShaftSpeed IN REAL O 0.5 [ rpm ] Minimum shaft speed for calculation
shaftFilterTime IN REAL O 20.0 [ ms ] Filter time of the shaftSpeedActual


identification

_0000 errorID 16#0000_8000: warning

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Functionality
The diameter calculator determines the actual diameter value (diameter) of the roll
being wound (or unwound) using the input quantities:
Web Thickness - the actual web (material) thickness.
Shaft speed of the mandrel (shaftSpeed) – Actual speed of the winder shaft.
The actual motor speed is converted to the roll shaft speed (using the gear
ratio) and is used to calculate the diameter.
The holdDiameter input will pause the diameter calculation and hold the resulting
diameter at the current value when set to true.
The setDiameter input writes the diametersetvalue as the diameter as long as the
actual shaft speed is below minimum shaft speed. The diameter set value is
limited.
With the actual shaft speed above minimum and not held, the diameter is
calculated by integrating the diameter change rate based on the web thickness and
mandrel speed. The result of the integration is limited and smoothed.

V1.2.0, Item-ID: 58565043 117
NOTICE This calculation method relies very much on the accuracy of the material
thickness and the starting diameter value. Any deviation between the actual
effective material thickness and the set material thickness will lead to an
incorrect diameter, whose error will increase with each revolution. An incorrect
initial value will remain as an offset between the actual and the calculated
diameter.
This calculation mode is mostly useful for metals where air entrapment and
inwound tension does not influence the effective material thickness.
Block diagram
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Error Messages
ErrorID Description
16#0000_0000 No error

minDia 0.0
maxDia 0.0
minDia maxDia
webThickness 0.0
minShaftSpeed 0.0
typeOfWinder < 0
typeOfWinder > 0
enable.

V1.2.0, Item-ID: 58565043 118
4.8.4 WITorquePrecontrol
Torque pre-control calculation for a winder.

The function block has to be called in a cyclic task. ID: 4102

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value
enable IN BOOL M FALSE FALSE: Deactivate Function block

TRUE: Activate function block
torqueOn IN BOOL M FALSE FALSE: Only inertia calculation

TRUE: Activate torque calculation

TRUE: Metric
typeOfWinder IN INT M 0 Winder type:

0: Rewind from above
1: Rewind from below
2: Unwind from above
3: Unwind from below
driveSpeed IN REAL O 0.0 [ rpm ] Actual winder speed (for the friction
characteristic)

V1.2.0, Item-ID: 58565043 119

value
lineAcceleration IN REAL M 0.0 [ m/s2 or ft/s2 ] Actual line acceleration
diamActVal IN REAL M 0.0 [ m or inch ] Diameter actual value
tensionSetpoint IN REAL O 0.0 [ N or lbf ] Tension setpoint values
density IN REAL M - [ kg/m3 or lb/ft3 ] Material density
diamMin IN REAL M - [ m or inch ] Minimum diameter
diamMax IN REAL M - [ m or inch ] Maximum diameter
width IN REAL M - [ m or inch ] Width of the material
fillFactor IN REAL O - 1.0 = 100%

Material fill factor (used in the case of
materials being traversed such as wire)
jFix IN REAL O - [ kgm2 or lbft/s2 ] Fixed moment of inertia,

motor side
jMandrel IN REAL O - [ kgm2 or lbft/s2 ] Fixed moment of inertia,

load side
jMot IN REAL O - [ kgm2 or lbft/s2 ] Motor inertia
frictionAdjustment IN REAL O - 1.0 = 100%

Adjustment factor of the friction
compensation is inactive.
tensionAdjustment IN REAL O - 1.0 = 100%

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dbPointer IN ANY O - Pointer to breakpoint table of the friction

.. .. .. ..
busy OUT BOOL - FALSE FALSE: Function block not activated


identification

0_0000 errorID 16#0000_8000: warning
totalInertia OUT REAL - 0.0 [ kgm2 or lbft/s2 ] Total inertia of the

mechanical system, reflected to the motor
side
mass OUT REAL - 0.0 [ kg or lbft ] Mass of the material

V1.2.0, Item-ID: 58565043 120

value
preCtrlMotor OUT REAL - 0.0 [ Nm ] Motor torque from friction and

acceleration
totalTorquePreCtrl OUT REAL - 0.0 [ Nm ] Sum of motor torque
variableInertia OUT REAL - 0.0 [ kgm2 or lbft/s2 ] Inertia resulting from the
material, reflected to the motor side.
maxInertia OUT REAL - 0.0 [ kgm2 or lbft/s2 ] Maximum inertia (at

maximum diameter).
tensionTorque OUT REAL - 0.0 [ Nm ] Motor torque from tension.
Functionality
The block determines the following:
The variable moment of inertia for Kp adaptation of the speed and tension
controller
The pre-controlled torque for v/ t
The torque pre-control outputs the following torque setpoints to pre-control the
winder drive:
A torque setpoint as a function of the acceleration setpoint of the
machine/system ramp-function generator and the inertia
Friction torque setpoint is generated depending on the shaft speed of the
winder using a characteristic.
Tension torque based on the tension setpoint and the diameter
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In order to quickly compensate for disturbances and to implement the closed-loop

control in the first place (for a replacing speed control), the torque to be provided
from the drive must be specified as accurately as possible. Depending on the
control type, this is either realized additively after the speed controller or by
dynamically adjusting the torque limits.
In both cases, starting from the weight of the wound material, the appropriate
torque must be calculated using its moment of inertia (wound material) and
transferred to the drive.
As an alternative to the method integrated in this block, the integrated friction
characteristic of the drive system (SINAMICS) can also be used.
NOTICE The precise setting of the compensation is especially important for indirect
tension control. This is so that the torque-generating current emulates, as far as
possible, the material tension.
Calculations
The function block FBWITorquePrecontrol calculates the following physical
quantities:

V1.2.0, Item-ID: 58565043 121
Quantity Formula
Mass of the wound Density Width diamActVal 2 DiamMin 2

material Mass
4
Moment of inertia of the diamActVal 2 DiamMin 2
wound material VariableInertia Mass
8 GearRatio 2
Total moment of inertia JMandrel
TotalInertia VariableInertia JMot JFix
GearRatio 2
Maximum mass of the Density Width diamMax 2 DiamMin2
wound material massmax
4
Maximum moment of DiamMax 2 DiamMin 2
inertia of the wound variableInertiamax mass max
material 8
Maximum moment of variableIn ertiamax JMandrel
inertia MaxInertia JMot JFix
GearRatio 2
Angular acceleration of lineAcceleration GearRatio
the roll 2
diamActVal
Acceleration torque M accel TotalInert ia

Friction torque M frict f (n)
Tension torque tensionSetpo int tensionAdjust diamActVal

M tension
2 gearRatio
This friction torque is internally determined using the function block TableChar. The
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user is responsible for providing valid and sensible values in the appropriate data
fields. If the factor FrictionAdjustment is set to 0.0, TableChar is not called and
therefore a frictional torque is not added.
The pre-control torque of the motor, the sum of all pre-control torques and the
tension torque are calculated depending on the winder type. The total torque is
always the sum of the preCtrlMotor and tensionTorque.
The winding mode is always defined assuming a positive line speed. If the leading
value becomes negative the winding mode will be inverted automatically (a
rewinder becomes an unwinder and vice versa). The same applies for winding from
above and from below. This inversion is automatic.
Winding mode Total torque
Rewind from above MpreCtrlMotor = Macc + Mfrict MtensionTorque = MtensionTorque
Rewind from below MpreCtrlMotor = - Macc + Mfrict MtensionTorque = - MtensionTorque
Unwind from above MpreCtrlMotor = Macc + Mfrict MtensionTorque = - MtensionTorque
Unwind from below MpreCtrlMotor = - Macc + Mfrict MtensionTorque = MtensionTorque

V1.2.0, Item-ID: 58565043 122
Block diagram
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V1.2.0, Item-ID: 58565043 123
Warning Messages
ErrorID Description
16#0000_0000 No Warning


Error Messages
ErrorID Description
16#0000_0000 No error
of points.
16#4102_8005 One or more configuration values are invalid – Check Min values, max
values and other settings.
gearRatio 0.0
density < 0.0
diamMin 0.0
diamMax diamMin
width < 0.0
fillFactor 0.0
Jfix < 0.0
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Jmandrel < 0.0

Jmot < 0.0
typeOfWinder < 0
typeOfWinder > 3
enable.
Friction characteristic pointer is not addressing a data block.
16#4102_8006 Invalid diameter

diamActVal 0.0
diamActVal < diamMin
4.8.5 RestLengthCalc
Calculation of the rest length of the coil

The function can be called in any task. ID:4001

V1.2.0, Item-ID: 58565043 124

webThickness IN REAL M 0.0001 [ m or inch ] Thickness of the material
actualDiameter IN REAL M 0.0 [ m or inch ] Actual diameter of the coil
targetDiameter IN REAL M 0.0 [ m or inch ] Target diameter/end diameter of

the coil
offset IN REAL O 0.0 [ m or inch ] Offset of rest length of the coil

RET_VAL OUT REAL - - [ m or inch ] Rest length of the coil
Functionality
Depending on the roll parameters that have been entered, the function calculates
the remaining length of the material on the roll. To do this the following data is
required – the thickness of the material on the roll (webThickness), the actual
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diameter (actualDiameter) and the diameter to be reached (targetDiameter). In this

case, the target diameter represents the end of the roll or the diameter to be
reached. Depending on whether the target diameter is greater than or less than the
actual diameter, the length of the material on the roll or the length of the material
still to be wound is output. The thickness of the material web (webThickness) is
limited using the internal constants MIN_THICKNESS and MAX_THICKNESS.
RET _ VAL * actualDiameter ² t arg etDiameter² offset
4 * webThickness

V1.2.0, Item-ID: 58565043 125
Winder mode Actual diameter Target diameter
winder d1 < d2 d2 (full roll, max. diameter)
unwinder d2 < d1 d1 (empty roll, min. diameter)
4.8.6 RestDiameterCalc
Calculation of the rest diameter of the coil



webThickness IN REAL M 0.0001 [ m or inch ] Thickness of the material
actualDiameter IN REAL M 0.0 [ m or inch ] Actual diameter of the coil

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length IN REAL M 0.0 [ m or inch ] Length to unwind/rewind
rewind IN BOOL O FALSE FALSE: Unwinder

TRUE: Rewinder
RET_VAL IN REAL - - [ m or inch ] Remaining diameter to be

coiled
Functionality
The function uses the input parameters to calculate the target diameter of the roll.
The calculation relies on the material thickness (webThickness), the actual roll
diameter (actualDiameter) and the material length to be wound or unwound
(length). The winding mode is defined using the windingMode input. The material
thickness (webThickness) is internally limited (MIN_THICKNESS,
MAX_THICKNESS).
In case of a too high material length input the function result is zero.
Winder:
actualDiameter² webThickness length
RestDiameterCalc 2
4

V1.2.0, Item-ID: 58565043 126
Unwinder:
actualDiameter² webThickness length
RestDiameterCalc 2
4
Winder mode Actual diameter Target diameter
Winder d1 < d2 d2 (full roll, max. diameter)
Unwinder d2 < d1 d1 (empty roll, min. diameter)

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4.8.7 Taper
Calculation of a reduction factor for the tension setpoint of a winder as a function of

the diameter

V1.2.0, Item-ID: 58565043 127

type Value
enable IN BOOL M FALSE FALSE: Function block is disabled

TRUE Function block is enabled
taperMode IN INT M - Selection of the taper mode:

0: No taper
1: Linear taper characteristic
2: Hyperbolic taper characteristic (max.
reduction at target diameter)
3: Hyperbolic taper characteristic (max.
reduction at infinite diameter)
4: Breakpoint Table
diamActVal IN REAL M 0.0 [ m or inch ] Actual diameter value
upperLimitTaper IN REAL O 100.0 [ % ] Max. taper value
lowerLimitTaper IN REAL O 0.0 [ % ] Min. taper value
taperRatio IN REAL O 0.0 [ % ] Reduction factor

taperDiameterStart IN REAL O 0.2 [ m or inch ] Diameter starting value for the

tension reduction
taperDiameterMax IN REAL O 1.0 [ m or inch ] Max. diameter value
dbPointer IN ANY O - Pointer to breakpoint table of the taper

characteristic
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.. .. .. ..
busy OUT BOOL - FALSE FALSE: Taper block inactive

TRUE: Taper block active

identification
errorId OUT DWOR - 16#000 Error identification, refer to error messages

D 0_0000 errorID 16#0000_8000: warning
tensionTaper OUT REAL - 1.0 Taper reduction factor, typically

0 < tensionTaper < 1.0
Functionality
The tension taper characteristic is used to define with which tension the material
should be wound onto the roll as a function of the roll diameter. The tension taper
characteristic is only used when rewinding in order to wind the inner layers tightly.

V1.2.0, Item-ID: 58565043 128
For dancer roll controls, the tension taper characteristic can be used to reduce the
pressure setpoint for the dancer roll support. In this case, the output of the
characteristic must be multiplied with the tension setpoint and made available for
the dancer system interface, e.g. analog output.
The block is activated using the enable input. Depending on the mode selected at
input tensionTaperMode, the tension reduction factor is calculated as a function of
the diameter present at diamActVal and output in tensionTaper.
The way in which the reduction factor is processed depends on the mode that has
been selected.
Calculation mode Description
0 = No taper No tension taper mode is defined, the function block outputs 1.0 (no reduction
factor).
1 = Linear taper From a starting diameter that has to be entered (taperDiameterStart), the reduction
characteristic factor is linearly reduced to the maximum diameter (taperDiameterMax) with a
reduction defined by the parameter taperRatio.
diamActVal < r32TensionTaperDiameterStart:
tensionTaper 1.0
taperDiameterStart < diamActVal < taperDiameterMax:

taperRatio diamActVal taperDiamet erStart
tensionTaper 1
100 taperDiame terMax - taperDiame terStart
diamActVal > taperDiameterMax:
tensionTaper (1 taperRatio / 100.0)
2 = Hyperbolic From a starting diameter that has to be entered (taperDiameterStart) the reduction
taper factor is reduced as hyperbolic function with taperRatio to the maximum diameter
characteristic 1 (taperDiameterMax). In this case, the reduction is at a maximum when the
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maximum diameter has been reached.

diamActVal < taperDiameterStart:
tensionTaper 1.0
taperDiameterStart < diamActVal < taperDiameterMax:
taperRatio diamActVal taperDiameterStart

1
100 diamActVal
tensionTaper
taperDiameterMax
taperDiameterMax taperDiameterStart
diamActVal > taperDiameterMax:
tensionTaper (1 taperRatio/ 100.0)
3 = Hyperbolic From a starting diameter that has to be entered (taperDiameterStart) the reduction
taper factor is reduced as hyperbolic function with taperRatio to the maximum diameter
characteristic 2 (taperDiameterMax). In this case, full reduction is never reached.
diamActVal < taperDiameterStart:
tensionTap er 1 .0
taperDiameterStart < diamActVal:
taperRatio taperDiame terStart
tensionTap er 1 1
100 diamActVal

V1.2.0, Item-ID: 58565043 129
Calculation mode Description
4 = Breakpoint The reduction factor is determined by characteristic defined as a breakpoint table.

table The breakpoint table consists of pairs of values diameter/reduction factor. The
factor is linearly interpolated between the breakpoints of the characteristic.
Warning Messages
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ErrorID Description
16#0000_0000 No Warning


Error Messages
ErrorID Description
16#0000_0000 No error
of points.

V1.2.0, Item-ID: 58565043 130
ErrorID Description

upperLimitTaper < lowerLimitTaper
lowerLimitTaper < 0.0
Additionally for mode 1 – 3:
taperDiameterStart < 0.0
taperDiameterMax taperDiameterStart
taperRatio < 0.0
taperRatio > 100.0
enable.
Mode 4:
16#4101_8006 Invalid diameter

diamActVal 0.0
16#4101_C000 Invalid selection of the calculation mode

taperMode < 0
taperMode > 4
4.8.8 WinderConfigSetup
This function block is used to enter individual configuration data into a winder
configuration data structure used by the winder.
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The function block can be called in any task. ID: 4003

V1.2.0, Item-ID: 58565043 131

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V1.2.0, Item-ID: 58565043 132

type value

TRUE: Metric
jogVelocity IN REAL O 10.0 [ LU/min ] Jog velocity setpoint (no ramp)
speedMatchRamp IN REAL O 0.5 [ s ] Ramp time for acceleration to line speed

Time
typeOfDiameterCalc IN INT O 2 Selection of diameter calculation method:

0: Division
1: Thickness addition
2: Integral calculation
3: External diameter determination.
Input via diameterSetValue.

Used as external diameter source.
webThickness IN REAL O 0.001 [ m or inch ] Web thickness

If integral diameter calculation is used the
calculated thickness is displayed here.
minDia IN REAL O 0.01 [ m or inch ] Minimum diameter
maxDia IN REAL O 2.0 [ m or inch ] Maximum diameter
minLineVelocity IN REAL O 0.5 [LU/min ] Minimum line velocity for diameter

calculation
minShaftSpeed IN REAL O 2.0 [ rpm ] Minimum shaft speed for diameter

calculation
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lineFilterTime IN REAL O 20.0 [ ms ] Filter time for line velocity
shaftFiltertime IN REAL O 20.0 [ ms ] Filter time for shaft speed
diameterFilterTime IN REAL O 50.0 [ ms ] Diameter calculator filter time
measuringRevolution IN REAL O 2.0 [ rev ] Shaft revolution counts for integral

Count diameter calculation
kpAdaptionValue IN REAL O 0.0 TPID - Kp-Adaption signal
holdIntChannel IN BOOL O FALSE FALSE: TPID – Normal integrator operation

setIntChannel IN BOOL O FALSE FALSE: TPID - Normal integrator operation

TRUE: TPID - Set integrator channel to
intSetValue
limRampTime IN REAL O 1000.0 [ ms ] TPID - Ramp-up time for PID

controller output limiting

V1.2.0, Item-ID: 58565043 133

type value
setNominalValue IN REAL O 100.0 TPID - Normalization value for setpoint RFG
setRampTime IN REAL O 1000.0 [ ms ] TPID - Ramp up time for setpoint RFG
integTime IN REAL O 2000.0 [ ms ] TPID - Integration time constant
derivTime IN REAL O 0.0 [ ms ] TPID - Differentiation time constant
filterTime IN REAL O 10.0 [ ms ] TPID - Actual value filter time
intSetValue IN REAL O 0.0 TPID - Integrator set value
derivControlMode IN BOOL O FALSE FALSE: TPID – D-Action acts on system

deviation
TRUE: TPID - D-Action acts in the actual
value
deadBand IN REAL O 0.0 TPID - Deadband parameter
outValueFactor IN REAL O 1.0 TPID - Output scaling factor
upperLimit IN REAL O 20.0 TPID - Controller output upper limit

lowerLimit IN REAL O -20.0 TPID - Controller output lower limit
overrideVelocity IN REAL O 10.0 [ LU/min ] Speed controller bias (override,

overcontrol) for torque controlled modes
tensionAdjustment IN REAL O 1.0 1.0 = 100%

tensionReference IN REAL O 0.0 [ N or lbf ] Reference value for tension

setpoint. If set to zero the setpoint is
interpreted as absolute value instead of a
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percentage.
MaterialWidth IN REAL O 0.0 [ m or inch ] Width of the material
MaterialDensity IN REAL O 0.0 [ kg/m3 or lb/ft3 ] Material density
MaterialFillFactor IN REAL O 1.0 1.0 = 100%

Material fill factor (used in case of traversed
materials like cable)
JFixed IN REAL O 0.0 [ kgm2 or lbft/s2 ] Fixed moment of inertia,

motor side
JMandrel IN REAL O 0.0 [ kgm2 or lbft/s2 ] Fixed moment of inertia,

load side
JMotor IN REAL O 0.0 [ kgm2 or lbft/s2 ] Motor inertia
frictionAdjustment IN REAL O 0.0 1.0 = 100% Adjustment factor of the friction

compensation is off.
maxVelocty IN REAL M - [ LU/min ] Max velocity for normalization
referenceSpeed IN REAL M - [ rpm ] Normalization speed of drive (p2000)
referenceTorque IN REAL M - [ Nm ] Normalization torque of drive (p2003)

V1.2.0, Item-ID: 58565043 134

type value
logAddr IN INT M - Logical address of the drive
WinderConfig OUT Winder - - Winder configuration Data

Config
Type
Functionality
This function creates one output structure of WinderConfigType from the
configuration parameters. This is done to reduce the number of input variables on
the winder function block but still give the user easy access.
4.8.9 Winder
Function block for the control of an axial winder.


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V1.2.0, Item-ID: 58565043 135

type value

communication and saves parameters
onOFF1 IN BOOL M FALSE FALSE: Drive disabled

TRUE: Enable drive
noOFF2 IN BOOL M FALSE FALSE: Coast stop request

noOFF3 IN BOOL M FALSE FALSE: Fast stop request



TRUE: Release brake

driveKp IN REAL O 100.0 [ % ] Speed controller gain adaption value.

drive.
lineVelocity IN REAL M 0.0 [ LU/min ] Master line velocity
lineActualVelocity IN REAL O 0.0 [ LU/min ] Master line actual velocity
additionalVelocity IN REAL O 0.0 [ LU/min ] Additional velocity (always

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enabled)
typeOfWinder IN INT O 0 Specifies the winder mode:

0: REWIND_FROM_ABOVE
1: REWIND_FROM_BELOW
2: UNWIND_FROM_ABOVE
3: UNWIND_FROM_BELOW
controlMode IN INT O 0 Specifies the tension control mode:

0: DANCER_SPEED_ADAPT
1: DANCER_SPEED_ADAPT_HD
2: TENSION_SPEED_ADAPT
3: TENSION_SPEED_ADAPT_HD
4: TENSION_TORQUE_ADAPT
5: INDIRECT
6: V_CONSTANT

TRUE: Start Jog forward at Jog Sp

TRUE: Start Jog reverse at Jog Sp
speedMatch IN BOOL M FALSE FALSE: No line operation

TRUE: Line operation, follows main
setpoint

V1.2.0, Item-ID: 58565043 136

type value


frictionDbPointer IN ANY O - Pointer to breakpoint table of the friction

.. .. .. ..
Length defined by size of the data area,
min. length 16 bytes for two breakpoints.
CtrlEnable IN BOOL O FALSE FALSE: TPID and tension not enabled

TRUE: TPID enable
CtrlSetpoint IN REAL O 0.0 TPID Setpoint
CtrlActual IN REAL O 0.0 TPID actual value

diameter IO REAL M - [ m or inch ] Actual diameter
winderConfig IO winder M - This data type includes all configuration

Config data required for parameterization of the
Tpye winder function block.
busy OUT BOOL - FALSE FALSE: Block disabled, no communication

active
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_0000 errorID 16#0000_8000: Warning
driveReadyToPowerUp OUT BOOL - FALSE FALSE: Missing enables

driveReadyForMotion OUT BOOL - FALSE FALSE: Missing enables

driveZeroSpeed OUT BOOL - TRUE FALSE: Shaft speed not zero

driveFault OUT BOOL - FALSE FALSE: No drive fault

driveFaultCode OUT DINT - 0 Drive fault code, refer to drive manual for
driveSpeedActual OUT REAL - 0.0 [ rpm ] Speed actual value (r63 from the
drive)
driveTorqueActual OUT REAL - 0.0 [ Nm ] Torque actual value (r80 from the
drive)

V1.2.0, Item-ID: 58565043 137

type value
driveTorqueActualFtlbs OUT REAL - 0.0 [ ft/lbs ] Torque actual value
driveTorqueActual OUT REAL - 0.0 [ % ] Torque actual value in percent of

Percent nominal torque
actVelocity OUT REAL - 0.0 [ LU/min ] Actual velocity
pidOutValue OUT REAL - 0.0 TPID controller output
pidEffectiveKp OUT REAL - 0.0 TPID effective Kp
pidUpperLimitReached OUT BOOL - FALSE TPID at upper limit
pidLowerLimitReached OUT BOOL - FALSE TPID at lower limit

Functionality
This function block utilizes the DriveControl, SetpointChannel, WITorquePrecontrol,
DiamCalc____ and TechPID function blocks of the Simatic Converting Toolbox.
This function block checks for valid configuration data and calls the individual
function blocks to minimize application development time.
With the enable set to true, a plausibility check is done on the configuration data
and will display an error with the corresponding error id should invalid data be
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entered. This input also enables the control functionality. With the function block
enabled, the driveControl function block will become active and the busy output will
be set to true.
With the enables set true the winder will follow the sum of the lineVelocity and
additionalVelocity multiplied by the draw factor. Winders are typically made to
follow the master without any ramps. Winders with splice are an exception as they
need to be able to be detached from the running machine and therefore have
separate ramps. The programmer is responsible for proper interlocks to prevent
unwanted behavior.
The configuration data has diameter calculation parameters, gear ratio and max
line speed parameters which are used to calculate the correct surface velocity of
the winder to match the section to the master line velocity.
The actual diameter of the winder can either be calculated using one of the
DiamCalc____ function blocks (division, integral, addition) or can also be supplied
from an external source using the configuration structure of the function block.
The configuration data also has parameters for torque pre-control. Torque pre-
control is necessary for torque based tension control modes and is optional for
speed based tension control modes. Speed based tension control modes with the
_HD (high dynamic) prefix include and utilize torque pre-control.
With the enable set to true and DrvReadyForMotion and Cntrlenable then the
CntrlSetpoint will be ramped up based on configuration data. The Tension
controller correction value will be added to the total speed setpoint or additional

V1.2.0, Item-ID: 58565043 138
torque, scaled and sent to the drive using the driveControl function block as
required.
Function block output parameters allow the user to view the calculated surface
velocity of the winder (actVelocity), the actual shaft speed (actShaftSpeed), motor
actual speed in RPM (actDriveSpeed), motor torques (driveTorqueActual,
driveTorqueActualFtlbs, driveTorqueActualPercent) and pertinent PID data.
Winder operating modes

The following table shows the different winder operating modes and the direction of
velocity, tension and torque.
Operating Representation Description
mode
Rewind V: Machine velocity

from above F: Tension in material
line
n: speed of winder
nO: velocity override for
speed controller
overcontrol
Rewind Mf: Friction torque

from below MP: Pre-control torque
MT: Tension torque
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Unwind
from below
Unwind
from above

V1.2.0, Item-ID: 58565043 139
Block diagram
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Warning Messages
Warnings are indicated by the status of the outputs error and errorID:
error = FALSE and errorID <> 16#0000_0000
ErrorID Description
16#0000_0000 No Warning
16#3101_4009 Communication error while reading from bus system (DriveControl)
16#3101_400A Communication error while writing on bus system (DriveControl)

-> no matching value found (WITorquePrecontrol, friction table)

-> 2 values are identical (WITorquePrecontrol, friction table)

V1.2.0, Item-ID: 58565043 140
Error Messages
ErrorID Description
16#0000_0000 No error
16#5104_8005 Invalid configuration data

controleMode < 0
controlMode > 5
typeOfWinder < 0
typeOfWinder > 3
winderConfig.typeOfDiameterCalc < 0
winderConfig.typeOfDiameterCalc > 3
winderConfig.minDia = 0.0
winderConfig.maxDia = 0.0
winderConfig.minDia winderConfig.maxDia
winderConfig.maxVelocity = 0.0
winderconfig.gearRatio = 0.0
winderConfig.referenceSpeed = 0.0
winderConfig.referenceTorque = 0.0
winderConfig.logAddr = 0
enable.
16#3101_8005 Invalid configuration data: (DriveControl)

logAddr 0
referenceSpeed 0.0
referenceTorque 0.0
16#3101_8065 Torque Limits may not be plausible any more; a break in the web could
cause this problem. Axis runs in the opposite direction too fast. Reaction:
brake with full torque. (DriveControl)
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(SetpointChannel)
16#3102_8005 Invalid configuration data: (SetpointChannel)

maxVelocity 0.0
gearRatio = 0.0
enable.
16#1108_8001 The function block is not called in a cyclic interrupt, e.g. OB35. (TPID)
16#1108_8005 Invalid configuration data: (TPID)

setNominalValue 0.0
(DiamCalcDivision)
16#5101_8005 Invalid configuration data: (DiamCalcDivision)

minDia 0.0
maxDia 0.0
minDia maxDia
minLineVelocity 0.0
minShaftSpeed 0.0
enable.

V1.2.0, Item-ID: 58565043 141
ErrorID Description
(DiamCalcIntegral)
16#5103_8005 Invalid configuration data: (DiamCalcIntegral)

minDia 0.0
maxDia 0.0
minDia maxDia
measuringRevolutionCount 0.0
minLineSVelocity 0.0
minShaftSpeed 0.0
enable.
(DiamCalcAddition)
16#5102_8005 Invalid configuration data: (DiamCalcAddition)

minDia 0.0
maxDia 0.0
minDia maxDia
webThickness 0.0
minShaftSpeed 0.0
typeOfWinder < 0
typeOfWinder > 0
enable.
of points. (WITorquePrecontrol, friction table)
16#4102_8005 One or more configuration values are invalid – Check Min values, max
values and other settings. (WITorquePrecontrol)
gearRatio 0.0
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density < 0.0

diamMin 0.0
diamMax diamMin
width < 0.0
fillFactor 0.0
Jfix < 0.0
Jmandrel < 0.0
Jmot < 0.0
typeOfWinder < 0
typeOfWinder > 3
enable.
Friction characteristic pointer is not addressing a data block.
(WITorquePrecontrol, friction table)
16#4102_8006 Invalid diameter (WITorquePrecontrol)

diamActVal 0.0
diamActVal < diamMin
(WITorquePrecontrol, friction table)
16#4102_84B1 Data block does not exist (SFC 24 / TEST_DB) (WITorquePrecontrol,

friction table)
16#4102_84B2 Data block unlinked (SFC24 / TEST_DB) (WITorquePrecontrol, friction

table)

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4.9 Overview of Structures

Some function blocks of the SIMATIC Converting Toolbox require data that is
provided as a collection of individual elements in the form of user defined data
types (UDT). This chapter provides an overview over these specific structures and
its elements.
User defined data type Description
SectionalConfigType This data type includes all configuration data required for
parameterization of the SectionalDrive function block. ID: 6201
WinderConfigType This data type includes all configuration data required for
parameterization of the winder function block. ID: 4201
4.9.1 SectionalConfigType
Name Data Initial Description

type value
metricUnits BOOL TRUE FALSE: Imperial

TRUE: Metric
jogVelocity REAL 10.0 [ LU/min ] Jog velocity setpoint (no ramp)
speedMatchRampTime REAL 0.5 [ s ] Ramp time for acceleration to line speed
diameter REAL 1.0 [ m or inch ] Diameter value
kpAdaptionValue REAL 0.0 TPID - Kp-Adaption signal
holdIntChannel BOOL TRUE FALSE: TPID – Normal integrator operation

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setIntChannel BOOL FALSE FALSE: TPID - Normal integrator operation

TRUE: TPID - Set integrator channel to intSetValue
x1 REAL 0.0 TPID - Abscissa-1 for KP-adaption(1)
kp1 REAL 1.0 TPID - KP-adaption point(1)
limRampTime REAL 1000.0 [ ms ] TPID - Ramp-up time for PID controller output
limiting
setNominalValue REAL 100.0 TPID - Normalisation value for setpoint RFG
setRampTime REAL 1000.0 [ ms ] TPID - Ramp up time for setpoint RFG
integTime REAL 2000.0 [ ms ] TPID - Integration time constant
derivTime REAL 0.0 [ ms ] TPID - Differentiation time constant
filterTime REAL 10.0 [ ms ] TPID - Actual value fitler time constant
intSetValue REAL 0.0 TPID - Integrator set value
derivControlMode BOOL FALSE FALSE: TPID – D-Action acts on system deviation


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type value
deadBand REAL 0.0 TPID - Deadband parameter
outValueFactor REAL 1.0 TPID - Output scaling factor
upperLimit REAL 20.0 TPID - Controller output upper limit
lowerLimit REAL -20.0 TPID - Controller output lower limit
overrideVelocity REAL 10.0 [ LU/min ] Speed controller bias (override, overcontrol) for
torque controlled modes
TensionAdjustment REAL 1.0 1.0 = 100%

tensionReference REAL 0.0 [ N or lbf ] Reference value for tension setpoint. If set to
zero the setpoint is interpreted as absolute value instead of
a percentage.
JFixed REAL 0.0 [ kgm2 or lbft/s2 ] Fixed moment of inertia, motor side
JMandrel REAL 0.0 [ kgm2 or lbft/s2 ] Fixed moment of inertia, load side
JMotor REAL 0.0 [ kgm2 or lbft/s2 ] Motor inertia

frictionAdjustment REAL 0.0 1.0 = 100%

Adjustment factor of the friction characteristic output. With
0.0 friction compensation is off.
maxVelocity REAL - [ LU/min ] Max velocity for normalization
gearRatio REAL - Gear Ratio, Motor/Load
referenceSpeed REAL - [ rpm ] Normalization speed of drive (p2000)
referenceTorque REAL - [ Nm ] Normalization torque of drive (p2003)

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logAddr INT - Logical address of the drive
4.9.2 WinderConfigType

type value
metricUnits BOOL TRUE FALSE: Imperial

TRUE: Metric
jogVelocity REAL 10.0 [ LU/min ] Jog velocity setpoint (no ramp)
speedMatchRampTime REAL 0.5 [ s ] Ramp time for acceleration to line speed
typeOfDiameterCalc INT 2 Selection of diameter calculation method:

0: Division
1: Thickness addition
2: Integral calculation
3: External diameter determination. Input via
diameterSetValue.
Value is saved upon rising edge of enable of the Winder
FB.

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type value
diameterSetValue REAL 1.0 [ m or inch ] Diameter set value

Used as external diameter source.
webThickness REAL 0.001 [ m or inch ] Web thickness

If integral diameter calculation is used the calculated
thickness is displayed here.
minDia REAL 0.01 [ m or inch ] Minimum diameter
maxDia REAL 2.0 [ m or inch ] Maximum diameter
minLineVelocity REAL 0.5 [LU/min ] Minimum line velocity for diameter calculation
minShaftSpeed REAL 2.0 [ rpm ] Minimum shaft speed for diameter calculation
lineFilterTime REAL 20.0 [ ms ] Filter time for line velocity
shaftFiltertime REAL 20.0 [ ms ] Filter time for shaft speed
diameterFilterTime REAL 50.0 [ ms ] Diameter calculator filter time
measuringRevolution REAL 2.0 [ rev ] Shaft revolution counts for integral diameter
Count calculation
kpAdaptionValue REAL 0.0 TPID - Kp-Adaption signal
holdIntChannel BOOL FALSE FALSE: TPID – Normal integrator operation

setIntChannel BOOL FALSE FALSE: TPID - Normal integrator operation

TRUE: TPID - Set integrator channel to intSetValue

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limRampTime REAL 1000.0 [ ms ] TPID - Ramp-up time for PID controller output
limiting
setNominalValue REAL 100.0 TPID - Normalization value for setpoint RFG
setRampTime REAL 1000.0 [ ms ] TPID - Ramp up time for setpoint RFG
integTime REAL 2000.0 [ ms ] TPID - Integration time constant
derivTime REAL 0.0 [ ms ] TPID - Differentiation time constant
filterTime REAL 10.0 [ ms ] TPID - Actual value filter time
intSetValue REAL 0.0 TPID - Integrator set value
derivControlMode BOOL FALSE FALSE: TPID – D-Action acts on system deviation

deadBand REAL 0.0 TPID - Deadband parameter
outValueFactor REAL 1.0 TPID - Output scaling factor
upperLimit REAL 20.0 TPID - Controller output upper limit

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type value
lowerLimit REAL -20.0 TPID - Controller output lower limit
overrideVelocity REAL 10.0 [ LU/min ] Speed controller bias (override, overcontrol) for
torque controlled modes
tensionAdjustment REAL 1.0 1.0 = 100%

tensionReference REAL 0.0 [ N or lbf ] Reference value for tension setpoint. If set to
zero the setpoint is interpreted as absolute value instead of
a percentage.
MaterialWidth REAL 0.0 [ m or inch ] Width of the material
MaterialDensity REAL 0.0 [ kg/m3 or lb/ft3 ] Material density
MaterialFillFactor REAL 1.0 1.0 = 100%

Material fill factor (used in the case of materials being
traversed such as wire)
JFixed REAL 0.0 [ kgm2 or lbft/s2 ] Fixed moment of inertia, motor side
JMandrel REAL 0.0 [ kgm2 or lbft/s2 ] Fixed moment of inertia, load side
JMotor REAL 0.0 [ kgm2 or lbft/s2 ] Motor inertia
frictionAdjustment REAL 0.0 1.0 = 100%

Adjustment factor of the friction characteristic output. With
0.0 friction compensation is off.
maxVelocty REAL - [ LU/min ] Max velocity for normalization
gearRatio REAL - Gear Ratio, Motor/Load

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referenceSpeed REAL - [ rpm ] Normalization speed of drive (p2000)
referenceTorque REAL - [ Nm ] Normalization torque of drive (p2003)
logAddr INT - Logical address of the drive

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5 Application example as demonstration system
5.1 Installing the hardware and software
5 Application example as demonstration

system
All of the steps necessary to commission the standard application SIMATIC Tool
Box as demonstration system are explainded in this section.
Preparations and parameterizing operations are explained. Further, you are shown
how to handle the WinCC flexible 2008 interface of the application example step-
by-step.
Objectives
The Section of this document should provide the user with
The necessary prerequisites to use this standard SIMATIC application as
demonstration system
The preparations and parameterizing operations
The steps necessary when presenting this standard application
Tips on how to use this standard application

5.1.1 Regarding your safety
Safety information and instructions

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Pictograms, signal words and text

Every piece of safety information/instruction in this document is designated by text
graphics – compromising pictogram and signal word, and supplemented by
explanatory text. A clear classification according to the degree of the potential
hazard is provided as a result of the combination of pictogram and signal word.
Safety information/instructions are provided in front of the information regarding
activities to be executed.
Classification
There are three different stages regarding safety information/instructions. These
are designated by the same pictogram. They differ by the signal word.
This safety information/instruction indicates an immediate hazard. If the

information/instruction is not carefully followed, this results in severe
bodily injury or even death.
DANGER
This safety information/instruction indicates a potential hazard. If the

information/instruction is not carefully followed, this can result in severe
bodily injury or even death.
WARNING

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This safety information/instruction indicates a potentially hazardous

situation, which can result in slight to average bodily injury. This
pictogram/text word can also warn about potential material damage.
CAUTION
Responsibility of the operator

Correct use
The correct use of the application components exclusively relates to the control of
test set-ups that were adapted to the power/performance of the application
components. In order that the application functions perfectly, the required standard
SIMATIC components as well as also the necessary hardware and software
components must be installed.
Misuse
The following are considered to be misuse:
Inadmissible loads applied to the application components
Any application deviating from the use specified above, or applications that go
beyond the specified use
Non-observance of the safety information and instructions

If faults that could have a negative impact on the safety are not immediately
resolved/removed
Any changes/modifications to equipment/devices that are used to ensure
perfect funciton and operation, unrestricted use as well as active or passive
safety
If recommended hardware and software components are not used
If the application componentes are not in a perfect technical condition, are not
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operated conscious of safety and hazards, and not taking into account all of
the instructions provided in the documentation
The manufacturer assumes no liabilitiy for incorrect use (misuse).
Responsibility of the monitoring

The company or person operating the system is responsible in continually
monitoring the overall technical status of the application components (defects and
damage that can be externally identified as well as changes in the operating
behavior). The company/person operating the system is responsible in ensuring
that the application is only operated in a perfect state. He must check the state of
the application components before they are used and must ensure that any defect
is removed before commissioning.
Qualification of personnel
The operating company/person may only deploy trained, authorized and reliable
personnel. In so doing, all safety regulations must be carefully observed.
Personnel must receive special instructions regarding the hazards/dangers that
can occur.

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5.1.2 Hardware structure and mounting/installation
Overview
The demonstration project can be commissioned using a conventional SINAMICS
demonstration case, a SIMATIC S7 300 CPU and a PC connected via Ethernet.
Hardware element functions

Training case, SINAMICS S120 CU 320
SINAMICS S120 demonstration The SINAMICS training case comprises standard
and training case components (SINAMICS CU320, two motors) and
offers two axes. These are used to demonstrate the
application.
The case is already set-up and wired up. It only has
to be connected to the HMI system via Ethernet.
Communications
Profibus Cable The cable is used to connect the SIMATIC CPU to
the SINAMICS drive.
Ethernet Cable The cable is used to connect the SIMATIC CPU to
the HMI System (PG/PC)
SIMATIC CPU On the CPU run all the programs used for the
application
HMI system
PG/PC with Ethernet interface The PG/PC is used to run the HMI operator interface
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Procedure
Proceed as follows to configure and mount the hardware components for the
application example:
Nr. Action Comment
1. Connect the Profibus interface of the SINAMICS In the example the

CU320 to the Profibus interface of the SIMATIC CPU. SINAMICS drive has
Profibus address 8
2. Connect the Ethernet interface of your PG/PC with

the Profinet interface of the SIMATIC CPU
3. Connect the SIMATIC CPU to 24V power supply and

the SINAMICS training case to the power supply unit.
4. Switch on all devices
5.1.3 Installing the standard SIEMENS software
NOTICE If the application is only to be used for demonstrating and presenting, then
it is only necessary to install WinCC flexible 2008 Runtime.

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Min. required Versions

Component Version
STEP 7 V5.5.0.4
WinCC flexible 2008 V1.4.0.3
WinCC flexible 2008 Runtime V1.4.0.3
Starter / Scout V4.2.0.0/V4.2.1.0
Component Functions
STEP7 V5.5 HF4 STEP7 ist the basis package for the other software
packages and is used to program SIMATIC S7
WinCC flexible 2008 Advanced SP3 WinCC flexible 2008 Advanced is used to program
Upd 3 the HMI interface (screen). You cannot change the
HMI machine interface without this software
WinCC flexible 2008 Runtime SP3 WinCC flexible 2008 Runtime allows you to use a
Upd 3 PG/PC as operator panel
Starter 4.2.0.0 /Scout 4.2.1.0 Tool to parameterize and commission the

SINAMICS drive.
5.1.4 Downloading the user program and the drive parametrization into the
devices
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De-archivining the project

Open SIMATIC Manager
De-archive the project and open it in SIMATIC Manager
Resetting the devices to factory settings

In order to have a fixed starting point fot the description of the loading operation of
the demonstration case, re-establish the factory settings at the demonstration case
and the SIMATIC CPU as described in the following:
Bring the operation state switch at the SIMATIC CPU in the position “MRES”
and keep it there until the “STOP” LED is switched on permanently. In the next
three seconds you need to release the switch and bring it back to the “MRES”
position. The “STOP” LED is blinking while the CPU is reseting.
To re-establish the factory defaults to the SINAMICS you can ether delete the
folder “USER” on the CF card or reset the drive in online mode with Starter or
Scout. (to go online the “HW-Config” must be downloaded or the PG/PC needs
to be connected directly to the drive)
Set PG/PC interface

Open the interface configuration in SIMATIC Manager via Extras -> Set PG/PC
interface
Amogn the features by “Interface Parameter Assignment Used”, please select
your Ethernet card / interface of the PG/PC with “TCP/IP -> …”

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Confirm (possible) warnings with YES

Confirm your changes with OK
Return to SIMATIC Manager and open the net configuration NETPRO by using
the button or by selecting the Menu Project –> open NetPro
Double-click on PG/PC(1) to open the properties
Under the feature “Assignment” (which has already been selected
automatically), the applied Ethernet interface has to be indicated under
“Parameter assigned”. If this is already the case, you only have to select it and
put the tick in the box marked ‘S7ONLINE Access: active’.
Please, select “Compile and check everything”
Please close all possible appearing warnings
Before loading the project close NetPro and adjust the Ethernet address of you
PG/PC in the same subnet.
Set the Ethernet address of the PG/PC

Proceed as follows to set the Ethernet address of the PG/PC:
Open the window Network and Dial-Up Connections of your PG/PC, select the
applied network connection to SIMATIC and open its properties. (Right mous
click -> mark properties or symbol and then File -> Properties)
In the area “Components checked are used by this connection” please select
the “Internet Protocol (TCP/IP)” and open its properties
After setting the SIMATIC CPU to factory defaults the Profinet interface may
has the IP 0.0.0.0 and needs to be set by HW-Config or NetPro under
PLC/Ethernet/Edit Ethernet nodes.
Please set the IP of your PG/PC to an address in the same subnet. Example:
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SIMATIC CPU 192.168.0.1/255.255.255.0; PG/PC 192.168.0.2/255.255.255.0
Loading the Hardware Configuration into the device

Proceed as follows to download the hardware configuration:
Change to HW-Config and download the hardware configuration
Confirm with OK
Close the HW-Config and change to SIMATIC Manager
Load the SIMATIC program into the CPU and the SINAMICS configuration into the drive
Proceed as follows to download the project:
Download all functions and function blocks in SIMATIC Manager into the CPU
Select the SINAMICS drive in SIMATIC Manager and open the drive
configuration with Starter/Scout
Go online with Starter/Scout an download the SINAMICS Configuration into the
training case (make sure that the Profibus cable is connected and the CU has
Profibus address 8)
Save the SINAMICS Project via RAM_TO_ROM to the CF card
Switch the SIMATIC CPU to operating state “RUN”

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5.2 Using the application example

The application can be used to present SIMATIC with SINAMICS S120 and get to
know and test the functions of the CPU.
Brief instructions to demonstrate and present the application example are provided
in the following chapter.
A detailed description of all operator screens is provided in the chapter afterwards.
5.2.1 Brief instructions to demonstrate
Here in these instructions you will only be shown and explained the steps
necessary to demonstrate the application. Not all of the operator screens will be
discussed.
Prerequisites
The following prerequisites must be fulfilled in order to use the application example:
The SIMATIC project is provided online in SIMATIC CPU
SINAMICS has beed loaded with the parametrization for the applications
All devices have been powered-up
The SIMATIC CPU has beed switched to operation state “RUN”

At leas WinCC flexible 2008 Runtime is installed on the PC/PG
NOTICE WinCC flexible 2008 Runtime requires authorization. Authorization for at

least 512 power tags is required.
If there is no authorization, reference is made to this and can be
acknowledged.
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Overview of the structure

Please refer to the following diagram for the basic operator structure of the
application.
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Brief instructions
Execute the steps in the sequence as listed in the following table to demonstrate
the application example:
No. Action Comment
1 Open the file Project

folder\HmiEs\PROJECT_1\WinCCStation.fwx

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No. Action Comment
2 At the bottom left, click on AUTO (third

button from the left)
3 You are now in the AUTO mode. To start,

you must thread the material. To do this,
press the “Web THREAD IN” key. The
material will now be slowly thread-in.
4 Wait until the material has been completely

thread-in and the winder signals this with
green
5 The tension control must now be switched-in

(enabled). This is done by pressing the
“TENSION ON/OFF” button.
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The dancer roll rises to the center position.
6 You can now start the material feed! Select

the material speed using the Web Speed
Slider.
Startthe material feed using the Web START
button
7 The two shafts now start to rotate. On the

HMI you can see how the diameter of the roll
increases.
The speed of the winder shaft decreases
with increasing diameter.

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No. Action Comment
8 When the roll reaches the maximum

diameter, the material velocity is slowly
braked until both axes come to a standstill
9 The material has now been completely

wound. To change Winding mode, you have
to switch off Tension. The winding can be
restarted by pressing the “Web Start” button
until the minimum diameter is reached
10 A target diameter can be approached using

the “GO TO Target Diameter” button.
The target diameter cam be entered here.

The axis only starts if “Web START” is
selected and if the correct winding direction
to reach the target diameter was entered
11 The shafts move until the target diameter is

reached
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12 During the simulation, the quantities,

generated by the winder function block, can
be monitored in the technology screen
13 A tension taber characteristic can be

calculated in the “Tension Taper” screen.
The characteristic is selected using the
“Tension Taper Mode”
The characteristic is calculated and
visualized with “Start Tension Taper
Calculation”.

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5.2.2 Detailed operating instructions
Welcome Screen
General screen areas

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The application screens are handled using the buttons at the lower edge of the
screens and provide on every screen.

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Screen Automatic
The automatic screen is the main screen in the automatic mode of the application
example on how to use the winder.
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The application is handled/controlled in this automatic screen. The material can be

started and stopped with the buttons on the left-hand side and the tension control
and the target diameter approached, using the buttons on the right-hand side.

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Screen Technology
The technology screen is only set-up to display variables. This therefore shows the
interaction between the winder FB and the central variables – such as material
velocity, dancer roll position, roll diameter and setpooint velocity of the winder.
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The winder function block with several important input and output variables is
shown in the center of the diagram. A symbolic graphic showing the drive is located
next to it.

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Screen Control settings 1

The screen control settings 1 is used to enter parameters for the controller gain
adaption and the PID controller. The parameters that are to be set there act directly
on the winder function block. The parameters to set the PID controller also act
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directly and their effect can, in some cases, also be monitored / visualized.

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Screen Control settings 2

The “Control Settings 2“ screen allows the diameter calculation to be selected and
the moment of inertia to be calculated. A mechanical system is not connected to
the demonstration system. This is the reason that the varying diameter of the
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wound roll is simulated. This means that the selectable diameter calculation
techniques are not effective. The diameter sensing via sensor mode is permanently
set. However, various modes are connected to the HMI to show users that the
possibility does exist. The variables are directly connected to the winder FB and
can also be re-used for subsequent use at the machine.
In this case, the settings of the maximum and minimum roll diameter are important
as well as the settings of the individual moments of inertia. The total moment of
inertia is calculated from the moments of inertia of the mechanical system and load
as a function of the diameter of the roll being wound. The torque pre-control is
calculated as a function of this moment of inertia and is entered into the drive as
additive torque setpoint. This calculation can be enabled using the selection field
“ENABLE INERTIA CALC.“.

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Screen Tension taper

A tension taper characteristic can be calculated using the “Tension taper“ screen.
Using this tension taper characteristic, the tension with which the material is wound
can be changed depending on the diameter. This is required in order to achieve a
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uniform, cylindrical structure of the roll being wound. To achieve this, a higher
tension is used at a low diameter and as the diameter increases, the tension is
reduced. It only makes sense to use the tension taper characteristic for winders.
The tension setpoint, determined by the tension taper characteristic, either acts
directly on the control of a suitable dancer roll (for the winding mode with dancer
roll) – or internally on the torque limits of the drive.
5 different tension taper characteristics can be entered in the screen. No
characteristic, linear characteristic, hyperbolic characteristic typ1/typ2 as well as a
characteristic that is interpolated using a table with 10 points. For the linear and
hyperbolic characteristics, the starting diameter, the reduction as a % of the
maximum diameter as well as the magnitude of the tension reduction as a % of the
reference tension can be set.
The characteristic is only displayed after first pressing the button “start tension
taper calculation”. This characteristic is only displayed as a dancer roll is not
connected to the demonstration system.

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6 Related literature
6.1 Bibliography
6 Related literature
6.1 Bibliography
This list is not complete and only represents a selection of relevant literature.
Subject Title
/1/ STEP7 Automating with STEP 7 in STL and SCL
SIMATIC S7-300/400 Author: Hans Berger
ISBN: 978-3-89578-412-5
/2/ STEP7 Automating with STEP 7 in LAD and FBD
SIMATIC S7-300/400 Author: Hans Berger
ISBN: 978-3-89578-297-8
/3/ STEP7 Automating with SIMATIC S7-300 inside TIA Portal
SIMATIC S7-300 Author: Hans Berger
ISBN: 978-3-89578-382-1
/4/ STEP7 Automating with SIMATIC S7-1200
SIMATIC S7-1200 Author: Hans Berger
ISBN: 978-3-89578-356-2
6.2 Internet link specifications

This list is not complete and only represents a selection of relevant information.
Subject Title
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\1\ Reference to the http://support.automation.siemens.com/WW/view/de/58565043

entry
\2\ Siemens Industry http://support.automation.siemens.com
Online Support
\3\ Converting http://support.automation.siemens.com/WW/view/en/38493658/136000
standard
applications
\4\ Solutions for http://www.automation.siemens.com/converting
converting

V1.2.0, Item-ID: 58565043 162
7 Contact
7 Contact
Siemens AG
Industry Sector
I DT MC PMA APC
Frauenauracher Straße 80
D - 91056 Erlangen
mailto: tech.team.motioncontrol@siemens.com
8 History
Version Date Modifications
V1.0.0 12/2011 First version
V1.0.1 04/2013 Bug fixes
V1.0.2 03/2014 Bug fixes
V1.2.0 08/2014 v-constant added

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