Manual software para acionamneto v75

Sectional drive standard for paper- / coating machines Date: 18.Feb.2004
Module SA7SECD0 Section: 1
I&S IP PEP CS 1 / AS_EM Page: 1 of 102
AS 400 Hardware configuration T.-Vers.: V07.05.00
Copyright  Siemens AG 2004. All Rights Reserved.
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Sectional drive standard for paper- / coating machines
Engineering manual - preliminary February 2004
Module SA7SECD0
V07.05.00.En
Version for PCS7 V6.0 SP2
Author: Peter Anders
Dept.: I&S IP PEP CS 1
Tel.: +49 9131 / 7-29895
Fax: +49 9131 / 7-44410
Mail: peter.anders@siemens.com

History
Revision Date Change Sections Reason
1.0.0 2004-02-18 all sections General upgrade of information and pics
It is not permitted to distribute, copy, use and disclose the
contents of this document without specific permission.
Violations will be liable for compensation.
All rights are reserved, especially for patents or GM entries.
We have checked the contents of this document for correctness
with the described hardware and software. Deviations however,
cannot be completely avoided. Therefore no guarantee can be
given for the complete correctness of this document.
However, the contents of this document are regularly checked
and necessary corrections will be made in later revisions.
We are grateful for any suggestions for improvement.

NEW FEATURES OF VERSION 7.5
Compared to the former version 07.04.01.En, following modifications have been implemented:
• Complete migration of the standard from PCS7 V5.2 SP3 to V6.0 SP2
• All parts of the standard are integrated in one Multiproject
• Support of process objects tags
• All messages have been converted to the new PCS7 V6.0 message concept

Fault Reports + Development / Modification Requests (Change Request Management)
Via the Change Request Management (CHARM) you are able to submit Fault Reports,
Development Requests or Modification Requests, which will be processed immediately.
http://charm.erlm.siemens.de/crm_cq
Please use the following login to enter the CHARM-Tool:
IP employees Erlangen „anonymous“ users (worldwide, all users except IP employees
Erlangen)
Login I&S Network-Login
(e.g. ka012345)
crmmp6
Password ******** siemens
Database CHARM CHARM
Remarks - Do not forget to fill in your own E-mail-address in the field „2nd
Receiver“. Otherwise the submitter of the CR can not be identified!
Note: Development and Modification Requests participate at the „3i-program“ which -
when accepted - may lead to a financial reward.
Pulp & Paper Know How Exchange Board
If you have any information that might be useful to other colleagues, or if you have a question, to
which another colleague might have an answer simply post it into our new forum called „Know
How Exchange Board“.
(or you just have a look around and maybe you will discover some useful information ?)
http://forum.erlm.siemens.de/forum/is/dispatch.exe/pulp-paper
Please go there frequently and help us to make it the biggest pool of information for Pulp &
Paper technology.

Table of Contents
1 AS 400 HARDWARE CONFIGURATION 7
1.1 CPU 8
1.1.1 Profibus configuration 8
1.1.2 CPU scan cycle settings 11
1.1.3 Cyclic interrupts 11
1.2 Communication boards 13
1.3 Counter Module FM450 13
1.3.1 Parameter settings 14
1.3.2 Engineering instructions 14
2 SOFTWARE ORGANIZATION 15
2.1 Structure of CFC charts 15
2.2 Sample time evaluation 15
2.3 Allocation of resources 16
2.4 Functions and objects 17
2.4.1 Reading in the I/Os and the serial interface (xxx_IN) 17
2.4.2 The central control (CEN) 18
2.4.2.1 Starting the machine 18
2.4.2.2 The master control words 19
2.4.3 The central machine ramp function generator (SPDR) 20
2.4.4 Incoming/regenerative feedback units RR_UNIT_xx 20
2.4.5 Drive object 21
2.4.5.1 Father block: DRV_PP 22
2.4.5.2 Drive types 30
2.4.5.3 Drive charts 30
2.4.5.4 Drive Control 31
2.4.5.5 Drive Setpoint 31
2.4.5.6 Drive setpoint for single drives (e.g. pumps) 35
2.4.5.7 Automatic Friction and Acceleration Precontrol 36
2.4.5.8 Drive Messages 38
2.4.5.9 Process Control Group Messages 41
2.4.5.10 Tension control 42
2.4.6 Unwinder (coating machines or calender) 43
2.4.7 Rewinder 44
2.4.8 Configuration of the drive groups 46
2.4.9 Load sharing concept with LS_PP 47
2.4.10 CPU-CPU communication 48
3 CONFIGURATION AND ENGINEERING 49
3.1 Chart structure 49
3.2 Central control (CEN) 50
3.3 Machine speed reference (SPDR) 51

3.4 Rectifying/regenerative feedback unit (RR_UNIT) 51
3.5 Drive package (DRV_xxx) 52
3.6 Import Export Assistant (IEA) 52
3.6.1 Preparations 53
3.6.2 Processing the model file 53
3.6.3 Importing the presentation file 54
3.6.4 Modification of the standard solution 55
3.7 Interconnections in CFC-charts 56
3.7.1 Interconnection of drives and central packages 56
3.7.2 Interconnection of father blocks 57
3.7.3 Group interconnection 58
3.7.4 Interconnection of the father blocks and RR unit 59
3.7.5 Interconnection of the father blocks for felt/wire-thickness compensation 60
3.8 Run Sequence 61
3.9 Webbreak Curves 62
3.9.1 Engineering on PLC-side 62
3.9.2 Engineering on OS-side 63
3.10 Profibus Diagnosis 65
3.10.1 Engineering on PLC-side 65
3.10.2 Engineering on OS-side 67
4 OPERATING AND MONITORING 68
4.1 Touch panel MP 370 68
4.1.1 Basic engineering of MP 370 in ProTool 69
4.1.2 Basic engineering of MP 370 in CFC 71
4.1.3 Embedding of MP 370 into multiprocessor project 72
4.2 Touch panel TP170B 73
4.2.1 Basic engineering of TP 170B in ProTool 73
4.2.2 Basic engineering of TP 170B in CFC 74
4.2.3 Embedding of TP 170B into multiprocessor project 75
4.3 Operator panel OP270 75
4.3.1 Monitoring and controlling of drives from OP in different CPU 78
4.3.2 Engineering steps: 79
4.4 Panel operating messages in WinCC 80
4.5 Central operator station WinCC 81

1 AS 400 HARDWARE CONFIGURATION
Figure 1 shows the basic configuration of the AS 400. It comprises the following boards:
PS407 Power supply
CPU416-2 CPU with Profibus interfaces (up to 4/PLC)
or CPU416-3 CPU with Profibus interfaces (up to 4/PLC)
CP 443-1 CP (Industrial Ethernet) for communication to WinCC
CP 443-5 CP (Profibus/S7 functions) for communication to operator panels
in small projects without high CPU load, the CP443-5 can be substituted by
the CPU-internal DP-interface (see also chapter Local operator panels)
CP441-2 P2P serial communication with the machine vendor (optional)
M
S7- CFC
S7-400 (CR2)
n
M
~
Industrial Ethernet / TCP/IP
Operating and
Monitoring
W IN CC
Engineering
Station
PS
407
- Master
Drive
- 6 RA70
2
M
n
M
~
1
M
~
- Master
Drive
- 6 RA70
.....
21
M
~
Sectional drives concept
based on AS 416 (S7-400)
alike
n = 16
n+1...
2n
1...n 2n+1...
3n
ET200M ET200M
alike
1 m
ProfibusProfibus-DPProfibus-DP
ET200M ET200M
CP
44
3-1
CP
44
3-5
WIN CC
Client
WIN CC
Server
CPU
416-2
DP
CPU
416-2
DP
CPU
416-2
DP
CPU
416-2
DP
alike
alike
m = 12
Figure 1: Hardware concept for drive control

1.1 CPU
The number of drives per CPU depends on the kind of CPU (6ES7 416-2XK02-0AB0 has 800kB
code and 800kB data memory, while 6ES7 416-3XL00-0AB0 has 1,6MB code and 1,6MB data
memory) and the type of the machine. Guide rolls for example require less memory than other
drives, while tension controlled drives require more memory. An unwinder or rewinder package
requires as much memory as 4 regular drives.
Until now results from practical applications are still collected in order to give a good estimation.
At the moment it is recommended to keep these limits in number of drives per CPU:
CPU 416-2XK02: max. 16 drives
CPU 416-3XL00: max. 32 drives
An example might be the result of the first successful pilot application:
Project No. of drives CPU Memory occupied Cycle time OB1
Stora Enso Hagen Kabel
Coating machine 4
CPU1: 21
(incl. unwinder)
416-3XL00 code: 905k (53 %)
data: 325k (20 %)
105 ms
CPU2: 25
(incl. rewinder)
416-3XL00 code: 961k (57 %)
data: 338k (20 %)
100 ms
It is most important that all drives could handle the communication on the Profibus within 15 ms
(15 ms send + 15 ms receive = 30 ms cycle time of OB36). Using PPO type 2 and a baud rate of
1.5 Mbit/s the limit is reached at 28 drives (14.69 ms), with a baud rate of 3.0 Mbit/s the limit is
56 drives (14.77 ms).
1.1.1 Profibus configuration
The new S7-400 CPUs, from FW release V3.0 have an expanded functionality regarding
PROFIBUS-DPV1. This new Profibus standard is available since STEP7 V5.1 SP3, but is not
supported by Drive ES Basic V5.1 SP1 neither by the Pulp&Paper standard function blocks.
The critical fact is that the DPV1 mode is the default setting in the hardware configuration for all
CPUs from FW release V3.0. For this reason in the hardware configuration at the DP properties
the operating mode must be changed to S7-compatible as shown in the following picture.

Figure 2: DP operating mode
The first slave-address that is allowed to be assigned is 3. It is recommended to start from slave-
number 4 of the first converter, to avoid accidental faults, because slave-number 3 is already the
factory-setting of each converter. The ET200 stations and drives are connected directly to the
Profibus DP interface of the CPU. Telegram type PPO 21 (4 PKW | 6 PZD) is selected for all
standard drives. The PPO2 5 (4 PKW | 10 PZD) is also supported if required, but needs to
change the default parameter setting at the input L2_PPO of the father block (DRV_PP). The
process data (6 or 10 words) must be transferred in one block. Only this option of PPO types 2/5
permits the process data to be consistent in a bus cycle. The PZD_RD_PP (read process values
from drive) and PZD_WR_PP (send setpoints to drive) blocks are specifically designed for this
option of PPO types 2/5.
1 PPO 2: 4 PKW | 6PZD
4 words parameter exchange; 6 words process data
2 PPO 5: 4 PKW | 10PZD
4 words parameter exchange; 6 words process data

Figure 3: DP slave properties
The communication blocks moreover expect the I/O address range of the drive slave to be
identical:
Figure 4: Assignment of the I/O address range for a drive on the Profibus
Tip: If you define the power supply, the CPU and then - directly afterwards - the drive
slaves in that order in the hardware configuration, you will obtain a symmetrical I/O
address assignment automatically. The boards for the binary and analog inputs and
outputs should be configured in the address range above 1000, to ensure that there
is still sufficient symmetrical address range left for automatic allocation in the event
of changes.
Note: The system blocks SFC 14 and SFC 15 are used for communication with the Pro-
fibus I/Os in order to provide consistent reading and writing of data.
Important: When using the SIMOREG K 6RA24 or SIMOREG DC MASTER 6RA70, the
function block PKW_DRV_PP must be called once for each drive. The block reads

the rated motor current and rectifier current, which are necessary for calculating the
correct torque setpoint and process value.
1.1.2 CPU scan cycle settings
In the hardware configuration of the CPU, change the following default settings:
1. Increase the Scan Cycle Monitoring Time to at least 1000 ms.
2. Set the Minimum Scan Cycle Time to 30 ms.
3. Change the OB85 - Call Up to „Only for incoming and outgoing errors“
Figure 5: CPU scan cycle settings
1.1.3 Cyclic interrupts
OB1 (cycle) and several cyclic interrupts are required for the basis software.
You only have to change the default execution time of OB36 from 50 to 30 ms!

Figure 6: CPU cyclic interrupts
Organization block Priority Sample time Functions
OB1 - Cyclic Reading in the binary inputs and forming control words for the central
control and drive-specific control
Central control
Drive control (ON logic, OFF logic; generation of operating modes)
Motor potentiometer for setpoints
Grade change
Pre-processing the process values for display
Forming status values
OB33 10 500 ms Generating messages
Reading out the motor temperature
Reading out drive faults
OB34 11 200 ms Webbreak analysis
OB36 13 30 ms Central ramp function generator
Reading in the drive data from the Profibus
Multiprocessor communication (Global Data)
Pre-processing the speed setpoint for the drive
Load distribution
Tension controller
Writing the drive data
OB37 14 ms Not used (spare for extremely fast processes)

1.2 Communication boards
Interface Board Remarks
Point-to-point CP441-2 Various interface modules (TTY, RS232, RS422/485) and various proto-
cols (3964, 3964R, RK512, Modbus) are available
Profibus CP443-5 Extended Communication with operator panels takes place by means of „S7
functions“, no additional driver block necessary
Industrial Ethernet CP443-1 Only one Ethernet address need be allocated for the interface to WinCC.
PMC is an integral part of the operating system. No other inputs required
TCP/IP CP443-1 TCP
There are various methods of communication with the machine control. The configuration is
plant-specific, because the communication concept must normally be adapted to the machine
vendor's system.
1.3 Counter Module FM450
The sectional drive standard since version 7 includes already a CFC logic for calculating diame-
ter and length of the winder with a sufficient accuracy. The use of a counter module FM450 is no
longer necessary. However you still may use the FM450 for higher accuracy. The FM 450 has
two counting channels, to which pulse generator signals from a reference drive3 (e. g. the last
dryer group) and the winder drive4 are connected. Tracks A and B should be connected for each
drive, as the internal signal quadruple function is used. The input and output address ranges of
the module must be identical.
Important: The signals from the encoder to the counter card must be isolated . The FM 450
has no isolation. The Knick EGO 3 optical coupler, which can be ordered from
Siemens with a push-pull output, operates without any technical problems (Order
No.: 800779).
It is also important to ensure that the power supply for the pulse generators is al-
ways obtained from the converter, and that the pulse generators at the motors with
an isolated bearing have equal potential bonding.
If the diameters of several windings need to be calculated (e. g.: Optireel), several counter cards
can be inserted.
Important: At Multiprocessor configuration make sure that the periphery address-range of the
counter card is assigned to the correct CPU (Hardware Configuration) !
3 Signal for measuring length
4 Signal proportional to circumference

1.3.1 Parameter settings
You must have installed the „FM 350-1/450-1 Counter“ masks in the S7 system in order to set
the parameters for the FM 450.
Encoder settings:
Encoder type: 24V incremental
Signal evaluation: Quadruple (cf. default setting);
Other settings must be taken into account for the function blocks
Interface: P- switch / push-pull
Max. counting frequency: 200kHz
Operating modes:
Counting range limits: -32 to +32 bits
Counting mode: Infinite
Gate control: Gateless
All the remaining parameters are then preset.
1.3.2 Engineering instructions
The function blocks DIAM_PP and LNGTH_PP can be used to calculate diameter, caliper and
production length.. These two function blocks are designed for use with the finishing standard
block DRV_HEAD_PP. But if you use the sectional drive standard block DRV_PP or the signals
are from an encoder without drive (e. g. measuring roll without motor) or the reference-drive is
located on another CPU, then you have to use a special interface-block ENCO_PP. This block
supplies an Instance-DB number at its output, which will be connected to the following DIAM_PP
or LNGTH_PP block.

Software organization T.-Vers.: V07.05.00
2 SOFTWARE ORGANIZATION
2.1 Structure of CFC charts
The software is organized such that all the functions with a direct effect on the drive are imple-
mented in the drive package. This comprises drive control, setpoint calculations, pre-processing
of process values for visualization, web break curves, etc. Separate function packages are only
provided for central functions, such as the central control, the machine ramp function, the OP
and CPU communication.
The software can be subdivided into three parts:
• Input/output charts for the connection to the I/Os or interface of a group:
IN_.. Reading in from the I/Os
OUT_.. Outputs to the I/Os
• Central functions:
CEN Central control of the machine
SPDR Machine setpoints and central ramp function generator
RR_UNIT Control of the incoming/regenerative feedback unit
CPUx_PAR Parameters and system functions for each CPU
GD_COMx Global data communication between multiprocessing CPUs
OPx Monitoring and controlling function for operator panels
• Drive object
DRVxxx divided into several partial charts, with a content index on first page
The software must be programmed and configured by the user entirely in CFC. The function
modules, on the other hand, have been written in the most suitable language, such as STL or
SCL.
2.2 Sample time evaluation
The sample time of each OB task is automatically detected. It is evaluated in the central CFC
chart CPUx_PAR and store inside the datablock „SYSTEM_DB” (DB 99). Every function block,
that uses the sample time, will access this central DB 99 and copy the sample time into its
instance datablock.
In each CPU, in the CFC chart „CPUx_PAR”, the function „INIT” (FC 100) must be called once.
This function provides the startup information „SYSTEM_DB.C_START” which is evaluated by
many other blocks. Therefore the function „INIT” must be at the first position of the run-
sequence of OB100, OB101 and OB1.
Since version 7.1 of the standard the function „INIT“ has another feature. It supplies the global
restart counter „SYSTEM_DB.CST_CNT“, which is evaluated by all blocks with an initialization
procedure. Therefore these blocks don't have to be placed in the OB100 and the compiler code
becomes smaller.

In the same CFC chart „CPUx_PAR“, in each CPU, the function block „TASKAN” (FB131) must
be called once for each used OB. In the run sequence, the „TASKAN” must be at the first posi-
tion of each used OB, resp. right behind the call of function „INIT” (at OB100, OB101, OB1). The
function block „TASKAN” determines in each cycle the actual system time, by using the system
function „TIME_TCK” (SFC 64) , and writes it into the „SYSTEM_DB” (DB 99) inside an array. All
function blocks of Pulp&Paper libraries, that use time measurement, will read the system time
out of the „SYSTEM_DB”, and calculate the sample time. By this means scan rate and phase
offset will be detected automatically.
Every function block with time measurement has got a new boolean IN_OUT variable „INIT_T”,
which is invisible, because of the attribute {S7_visible := „false“}. The original value of this vari-
able (after first transfer into CPU) is „false“, as well as after each CPU restart. Right after the first
evaluation of the function block and after a successful initialization, the variable „INIT_T” will be
set to „true“. By manually resetting the variable to „false“, the function block will be initialized
again, without having to restart the complete CPU. This means, that during the cyclic program, a
new block could be inserted (and will be initialized automatically) or moved to a new position
inside the run sequence – different OB – (must be initialized by manually resetting the „INIT_T“ to
„false“) without interrupting the production process.
2.3 Allocation of resources
The standard libraries (std.libs) mainly use the block and function numbers specified in the table.
The settings of the CFC compiler (menu: Options/Compilation Settings) should be such that FCs
50 to 700 are disabled for it. The same should apply analogously to the data block range from 1
to 250. If you configure a plant freely, you should always keep to the ranges specified in the ta-
ble, because the other resources are either required for the standard configuration or not enabled
for the compiler. If you deviate from the table, you may encounter problems if functions are as-
signed more than once or if they are overwritten.
FB FC DB
from to from to from to
System (reserved) 0 99 0 49 0 99
MMD & Finishing 100 169 300 449 100 119
Winders 170 219 450 549 120 149
MMD 220 649 550 649 200 250
Freely configured plant 650 2048 650 699 150 199
CFC (reserved) 700 2048 251 4095
Table 1: Allocation of resources
Since the use of the system datablock „SYSTEM_DB” no flags are being used anymore.

2.4 Functions and objects
CEN central control
technological unit (former, press, dryer, reel...)
group logic
GROUP_OUT
Hardware I/O
SPDR speed reference
OP interface
drive object
GROUP_IN
D
R
V
P
P
RR_UNIT
drive control
&
Figure 7: Structure of the software
2.4.1 Reading in the I/Os and the serial interface (xxx_IN)
At least one chart is used for each technological group (wire section, press, dryer group, etc.).
The signals from the serial interface and the ET200 are grouped together in these charts and the
drive control words IN_CWA, IN_CWB and IN_CWC are formed. The signals from the interface
to the machine control are grouped in a data block. Binary signals are entered in the symbol ta-
ble. All signals are linked in the xxx_IN charts to the „bit-to-word converters“.

2.4.2 The central control (CEN)
The CEN chart contains the central control for a paper or coating machine.
This chart interconnects the central inputs, such as emergency stop, web break indicators and all
commands relating to the central control word CWCEN (e. g. error acknowledgement, threading
CM, run CM, etc.).
The status word SWG from all drives is OR-connected on the SWG_OR block.
At the end of the CEN chart on chart partition K there are a couple of dummy blocks for easy
connection of the signals coming from or going to the winder typicals, if existing.
Note:
In the standard software there are two CEN charts, one in the small demo project, the
other in the CPU1 of the AS1. In order to separate both in WinCC, the CEN chart in
CPU1 was renamed to CEN_. During engineering of a project, this chart must be re-
named back to CEN, while the other chart in the demo project should be renamed to
e. g. CEN_demo.
2.4.2.1 Starting the machine
The CEN chart also contains the start enable logic. When an operating mode is selected (on the
panel or OS), the drive control sends a start request to the central control. The siren time (5 sec)
is started there, followed by a delay (10 sec). After the delay, the central control returns the start
enable to the drive control for 30 seconds. The drive is switched on when the mode is selected
again.

2.4.2.2 The master control words
The master control words A and B are generated in the CEN chart. There is also a master control
word C, which contains the possible web paths. This information is related to the project and
could be used to activate different properties of the machine.
BIT MCWA MCWB MCWC
0 OFF plant part 1 ON central (CM) Web path 1
1 OFF plant part 2 OFF central (CM) Web path 2
2 OFF plant part 3 Fast stop central (CM) Web path 3
3 OFF plant part 4 Stop central (CM) Web path 4
4 OFF plant part 5 Thread central (CM) Web path 5
5 OFF plant part 6 Run central (CM) Web path 6
6 OFF plant part 7 Wash central (CM) Web path 7
7 OFF plant part 8 Grade change run Web path 8
8 STOP plant part 1 E-STOP Web path 9
9 STOP plant part 2 Web path 10
10 STOP plant part 3 Drive Simulation Web path 11
11 STOP plant part 4 Web break Web path 12
12 STOP plant part 5 Web path 13
13 STOP plant part 6 Start enable Web path 14
14 STOP plant part 7 Reset Fault Web path 15
15 STOP plant part 8 Commissioning speed adjustment Web path 16
16 Switch-on-inhibit plant part 1 Enable load limit monitoring
17 Switch-on-inhibit plant part 2 Enable tension limit monitoring
18 Switch-on-inhibit plant part 3
24
25
26
27
28
29
30
31
Table 2: Control words of the central control

2.4.3 The central machine ramp function generator (SPDR)
The SPDR chart contains the ramp function generator for the complete machine. The leading
setpoint can be determined by the local operator panel, by the OS (WinCC) or by the QCS.
Coating machines also have a setpoint switch, depending on the operating mode. When the
machine is started up (thread and run), the setpoint delay function delays the through-connection
of the speed setpoint to the ramp function generator by 3 sec (variable). This delay is useful for
starting up the machine, because the magnetization times of the asynchronous motors cannot be
synchronized exactly and may otherwise result in unwanted variations in the tension. The
controllers are activated for the duration of this delay period, so that they can eliminate any
breakaway torque (churning forces caused by nip load) before the start of the actual ramp.
The minimum-evaluator connected upstream of the ramp function generator limits the speed of
the machine, for example if the maximum speed of a winder drive is reached. Each winder tells
the ramp function generator its maximum permitted peripheral speed, which varies according to
its diameter.
2.4.4 Incoming/regenerative feedback units RR_UNIT_xx
This chart contains the ON/OFF logic for the incoming/regenerative feedback unit, the logic for
the DC link reduction and the blocks required for Profibus communication. The incoming/
regenerative feedback units are activated by the start request of one of the assigned drives. If all
of the assigned drives are switched off, the incoming/regenerative feedback unit is deactivated
automatically after a programmable time.

2.4.5 Drive object
Figure 8: Typical concept
In order to present a single drive-interface for operating, monitoring and messages, a special
concept has been developed for the paper and coating machines. This „typical concept“ includes
a „father block“, which serves as the database for the complete drive package.
Interface blocks read the inputs of the father block and make them available in the chart
partitions. The father block is merely the database. The current drive data is written back to the
father block at the end of the chart partitions. The advantage of this concept is that the drive
software can be written using CFC, yet only one block is needed to represent the complete drive.
All parameter settings and all connections are made on the father block. The software has been
designed so that no changes are necessary inside the chart partitions. The connection between
the father block and the functions inside the chart partitions is done by means of a line from the
„DI_NO“ output (DB number) on the father block and the „DI_NO“ input at the first interface
block. All other blocks that also use DI_NO are connected to the first interface block.

2.4.5.1 Father block: DRV_PP
The drive properties are set on the father block by parameterizing the inputs. The typical
DRV_PP satisfies the various requirements for coating and paper machines. The correct control
box is opened automatically in WinCC when you select the drive type (draw, load, tension, etc.).
Figure 9: Father block DRV_PP

PAR_1 Remarks
0 type: draw Drive with adjustable draw, e. g. dryer group, guide roll
1 type: droop/compensation Drive with load distribution by means of droop and compensation. The
droop and compensation are equal and set at the father block.
The load distribution can be adjusted with the load factor
2 type: load distribution Drive with load distribution by means of overdrive and limiting.
The speed controller is overdriven and the drive is controlled by the positive
torque limit. The load distribution can be adjusted with the load factor
3 type: tension Drive with tension controller. The tension and draw setpoints can be varied
4 type: ind. tension Drive with load control: The speed controller is overdriven. The load/tension
setpoint is the positive torque limit. The load/tension setpoint is set to the
actual load process value when the indirect tension control is activated, and
then ramps up to the preset value
5 type: main drive Leading drive for the complete machine (no adjustments possible)
6 type: center winder like type 3, but no draw adjustment; tension values display only
7 type: single drive like type 5, but with input of speed setpoint; e. g. pumps
8 No I/R-unit Display of IR-unit status in Faceplate (WinCC) is deactivated
9 pulse generator monitoring Enables monitoring of tachometer operating hours
10 felt monitoring Enables monitoring of the felt run-length in kilometers
11 Enable grade change Enables the grade change functionality
12 Bypass interlock for drive fault Bypasses the group interlock if a drive fault occurs
13 Bypass interlock for safety
switch
Bypasses the group interlock if the safety switch is closed
14 Deactivate interlock Deactivates the group interlock, i. e. the drive is activated by means of the
group control, but the drives are not interlocked
15 Simulation mode Simulation of the drive is enabled
WARNING! If converter exists, it may be in undefined state !

Bit PAR_2 Remarks
0 Motor operation only The drive cannot brake, i. e. it is switched off immediately with OFF2
1 Starting permit if n<>0 Enables a flying restart
2 No start enable necessary A start enable is not required (e. g. for a spool starter in AUTO mode)
3 Automatic friction compensation
enable
Enables the automatic friction compensation for drives of type
droop/compensation (e. g. size press, calender)
4 Drive before leading drive
(speed cascade)
The drive is located upstream of the leading drive, i. e. the sign for the draw
setpoint and process value and the tension controller output is inverted
5 Jog without braking When Jog command is reset, the controller release is reset, too.
6 Load sharing with proportional
part
Load sharing is using the proportional part of the master speed controller
output
7 Enable auto. switch on tension
controller after photo cell and
length
After detection of paper from the photocell and after a defined web-length,
the tension controller and the automatic take-up function are enabled.
8 Central STOP at fast-stop ramp A central stop command (MCWA Bit 8-15) will switch to fast ramp
9 Drive is fix-assigned to the
master
All operation-modes will be taken from the master (e. g. used for guide roll
groups or other auxiliary drives with a group master)
10 Remote cable without start
warning
No start warning or start permission is required to start the drive from re-
mote-cable.
11 Disable ON-feedback to central
control
The drive does not send back the status „drive ON” to the central control.
(used at CM for rope drive, tambour starter or applicator roll)
12 Enable central ON-/OFF-com-
mand
The drive can be switched on/off from the central control word (CM)
13 Enable tension controller by
external contact
The tension controller is switched on and off by the „blade positioned“ signal
from the control word IN_CWC. During threading of paper the functions
„ease-off” from tension controller and „automatic take-up” are disabled. (e.
g. for coater and calender)
14 Group fault is STOP-condition A group fault will stop the drive by braking (default is OFF command)
15 Enable auto webbreak
detection
Enables automatic detection of web breaks. If the tension controller is on
and the tension process value falls below a 10 % threshold over a defined
period of time, a web break is detected automatically

Bit PAR_3 Remarks
0 mode run / OP Enables run mode on OP
1 mode crawl / OP Enables crawl mode on OP
2 mode crawl reverse / OP Enables crawl reverse mode on OP
3 mode jog / OP Enables jog mode on OP
4 mode jog reverse / OP Enables jog reverse mode on OP
5 mode wash / OP Enables wash mode on OP
6 1 (do not change) Bit 6 must always be set to 1
7 1 (do not change) Bit 7 must always be set to 1
8 mode run / OS Enables run mode for WinCC
9 mode crawl / OS Enables crawl mode for WinCC
10 mode crawl reverse / OS Enables crawl reverse mode for WinCC
11 not used not used
12 not used not used
13 mode wash / OS Enables wash mode for WinCC
14 take up enable Enables take-up
15 ease off enable Enables ease-off
Input Format/
unit
Comment Remarks Interconnection
CONVERT INT Converter type type: 0=none, 1=6SE70_CU2, 2=6RA24,
3=6SE70_CUVC, 4=6RA70
L2_SLNO INT Slave no. on Profibus Must coincide with hardware configuration
of drive
L2_PPO INT PPO type 2 = 4PKW | 6PZD, 5 = 4PKW | 10PZD
Must match the hardware configuration
DROOP_1 REAL [%] Speed droop value 1 This value is always active
DROOP_2 REAL [%] Speed droop value 2 This value is activated with bit 11 in CWC
or when load-control (droop) is active
MCWA DWORD Master control word A MCWA contains the central interlocks CEN, chart J1, MCWA
MCWA_M DWORD Mask Master control word A This filters out to which plant section the
drive is connected.
MCWB DWORD Master control word B MCWB contains the central commands CEN, chart J2, MCWB
IL_GRP DWORD Group control interlock word The IL_DRV output of the chart of a single-
drive group is short-circuited with the
IL_GRP input
OUT output of the
GROUP_PP or
GROUP_MODE_PP block
IN_CWA WORD Control word A of the serial
interface of process I/Os
Output of BIT-to-WORD
converter in IN_xxx
package
IN_CWB WORD Control word B of the serial
converter in IN_xxx
package
IN_CWC WORD Control word C of the serial
converter in IN_xxx

Input Format/
unit
package
SAFE_SW BOOL Interlock OFF 1 This first OFF interlock is reserved for the
Safety Switch !
Interconnected with binary
inputs or serial interface
IL_OFF2-4 BOOL Interlock OFF 2-4 Text 0 is displayed as a comment in the
diagnosis view of the faceplate
IL_STOP1-4 BOOL Interlock STOP 1-4 Text 0 is displayed as a comment in the
IL_FSTOP1-4 BOOL Interlock FASTSTOP 1-4 Text 0 is displayed as a comment in the
IL_CRWL1-2 BOOL Interlock for crawl mode Text 0 is displayed as a comment in the
IL_RUN1-2 BOOL Interlock for run mode Text 0 is displayed as a comment in the
IR_SW WORD Status word for incoming/
regenerative feedback unit
RR_UNITxx
/SW_RR_UNIT,
chart B6
PCCW_ADP WORD Control word for automatic
precontrol adaption
SPDR, chart B4
D_RF_HL REAL [%] High limit for draw setpoint Default +5 %
D_RF_LL REAL [%] Low limit for draw setpoint Default –5 %
D_RMP_T REAL
[1/s]
Ramp adjustment speed
(steepness)
Default 0.002 1/s
TQ_RF_HL REAL [%] High limit for load setpoint Default 150 %
TQ_RF_LL REAL [%] Low limit for load setpoint Default 50 %
TQ_RMP_T REAL
[1/s]
(steepness)
Default 0.2 1/s
TQ_NOM REAL
[Nm]
Nominal drive torque, used by
LS_PP for load-sharing
Default 100 Nm
TQ_ADD REAL [%] Additional torque Input for additional torque setpoint, 1.0 =
100 % Mn (e. g. CM when the blade is
applied)
TQ_HL REAL Torque high limit to converter
(PCD 5)
Default 1.0 = 100 % Mn
TQ_LL REAL Torque low limit to converter
(PCD 6)
Default -1.0 = -100 % Mn
AC_RF REAL [%] Acceleration setpoint SPDR/RFG/AC_N
CASC_IN REAL [%] Setpoint cascade input DRVxxx/CASC_OUT of
corresponding drive ac-
cording to setpoint cas-
cade or central ramp
function generator for
leading drive of machine
SPDR/S_RF_M/OUT
TN_NOM REAL Scaling of Tension-Display This value means 100 % range of bar
graph.
GD_T_PV REAL [%] Elapsed time, grade change SPDR/GD_T_PV/Y
UTILITY STRING Location Tag shown in faceplate

Input Format/
unit
OP_NM STRING Drive name for display on
operator panel
Same name as for „Block Object
Properties/General/Comment“
OP_TAG STRING TAG name for display on
operator panel
e. g. DRV0001
TU_EO_IN REAL Additional speed-setpoint for
take-up and take-down
from previous in the speed
cascade
DRVxxxTU_EO_OUT
V_OD REAL [%] Additional speed-setpoint for
load sharing mode.
Only for type „LOAD” or „IND. TENS.”
Default +2 %
V_NOM REAL
[m/min]
Nominal speed for scaling the
drive speed
T_UP REAL [s] Ramp-up time for internal
speed ramp
Default 120 s
T_DN REAL [s] Ramp-down time for internal
speed ramp
Default 120 s
T_RND REAL [s] Ramp-rounding time for
internal speed ramp
Default 4 s
T_DN_FSTP REAL [s] Ramp-down time for internal
speed ramp at FASTSTOP
Default 60 s
T_RND_FSTP REAL [s] Ramp-rounding time for int.
speed ramp at FASTSTOP
Default 0,5 s
MA_MODE WORD Operating mode from master only if fixed assigned to the master (PAR_2
- bit 9)
DRVxxx/MODE of group
master for load sharing
MA_V_SP REAL Speed setpoint from master for „LOAD“ and „DROOP“ type DRVxxx/V_SP of group
MA_A_SP REAL Acceleration setpoint from
master
for „LOAD“ and „DROOP“ type DRVxxx/A_SP of group
MA_TQ_PV_S REAL [%] Smoothed actual load of
master – only for display
Only required for „LOAD“ type DRVxxx/TQ_PV of group
MA_V_PV REAL
[m/min]
Speed process value of
reference drive
for monitoring the speed difference against
the group master (type „LOAD“) and for
calculating draw process value (type
„DRAW“ and „TENSION“)
DRVxxx/V_PV of
corresponding drive ac-
cording to setpoint cas-
cade
MA_YI_PV REAL [%] Integral component of master
speed controller output for
load distribution
depending on PAR_2 - Bit 6 DRVxxx/YI_PV of group
MA_V_RF REAL
[m/min]
Speed setpoint from master for display DRVxxx/V_PV of group
master
MA_Y_PV REAL [%] output of master speed con-
troller for load distribution
including proportional part
depending on PAR_2 - Bit 6 DRVxxx/Y_PV of group
REF_V_PV REAL
[m/min]
Speed process value of refer-
ence drive for calculating
speed difference
„S_DIFF [m/min]“
for display DRVxxx/V_RF of corre-
sponding drive
TN_RF_HL REAL
[%]or
[N/m]
High limit for tension setpoint Default +100 %
TN_RF_LL REAL
[%]or
[N/m]
Low limit for tension setpoint Default +20 %

Input Format/
unit
TN_RMP_T REAL
[1/s]
(steepness)
Default 0.1 1/s
TN_INFL REAL [%] Influence of tension controller
on speed process value
Default 2 % means: 100 % controller output
changes 2 % of maximum speed
BAS_DIAM REAL
[mm]
Roll diameter for commission-
ing
Attention ! This value must not be
changed during machine running !
OS_DIAM REAL
[mm]
New roll diameter after roll
replaced (preset by WinCC)
BAS_DIAM and OS_DIAM must have the
same value after commissioning
BAS_GEAR REAL Gear factor for commissioning Attention ! This value must not be
OS_GEAR REAL New gear factor after gear
replaced (preset by WinCC)
BAS_GEAR and OS_GEAR must have the
same value after commissioning
Table 3: Inputs of the father block
Output Format/
unit
DI_NO INT Instance data block number of
drive object
Interconnected with
RD_W1_PP.DI_NO_IN or
with interface block for OP
communication
OFF_CAUSE STRING last OFF-cause (8 buffers) can be selected by the input SEL_DIAG
OFF_TIME STRING time/date of OFF-cause
SWA WORD Status word A
SWB WORD Status word B
SWC WORD Status word C
SWD WORD Status word D
SWF WORD Status word F
SWG WORD Status word G Central control CEN, chart
F4, SWG_OR
Incoming/regenerating unit
RR_UNITxx, chart B1,
/DRV_SWG
IL_DRV DWORD Control or interlock word for
group control
The IL_DRV output of the chart of a single-
drive group is short-circuited with the
IL_GRP input
INx input of the
GROUP_PP or IL_DRVx
input of block
GROUP_MODE_PP
MODE WORD operating mode to slave drive MA_MODE
V_RF REAL
[m/min]
Speed setpoint to slave drive MA_V_RF
V_SP REAL Speed setpoint to slave drive MA_V_SP
A_SP REAL Acceleration setpoint to slave drive MA_A_SP
V_PV REAL
[m/min]
Speed process value to slave drive MA_V_PV
D_PV REAL [%] Draw process value

TQ_PV REAL [%] Load process value MA_TQ_PV_S of slave
drive
YI_PV REAL [%] Integral component output of
speed controller
MA_YI_PV of slave drive
CASC_OUT REAL [%] Setpoint cascade output CASC_IN on next drive in
setpoint cascade
TU_EO_OUT REAL Additional speed-setpoint for
take-up and take-down
to following drive in the
speed cascade
DRVxxxTU_EO_IN
V_DIFF REAL
[m/min]
Speed difference as compared
with „REF_V_PV“ speed
TP_PV REAL [°C] Motor temperature
TN_PV REAL [%]
or [N/m]
Tension process value
TN_OUT REAL [%] Tension controller output
Y_PV REAL [%] Output of speed controller
including proportional part
to MA_Y_PV of slave drive
Table 4: Outputs of the father block

2.4.5.2 Drive types
There are six different type of drives that all use the same father block, but differ in the amount
and quality of functions. For each there is a typical available as shown in the following table:
Name of typical speed control load control tension control draw adjust-
ment
load factor
adjustment
direct load
setpoint
draw x x
droop & compensa-
tion
x x
load distribution x x x
tension x x x
ind. tension x x x x
main drive x
center winder x x x
single drive x
Table 5: Drive types
2.4.5.3 Drive charts
The drives are actually controlled and the setpoints calculated in the drive charts. Communica-
tion with the drive via the Profibus is an integral part of the drive object. The PZD_RD_PP block
reads process data from the drive and PZD_WR_PP sends the setpoints to the drive. The mod-
ules write the process data in the I/O address area automatically. The user does not need to care
about these system functions, but must simply enter converter type, slave number and the PPO
type. All these settings must be done in the hardware configuration of the AS and on the father
block of the drive object. The object functions communicate regularly with the drive as if the con-
verter were an integral part of the software. Fixed drive parameters are important for such close
links between the drive object and the drive.
Essential part of the drive charts:
Reading the drive data and the data of the father block
Splitting the control words into bits
Drive-specific control
Processing the speed and load setpoints incl. ramping
Processing the messages for WinCC
Tension controller function: control, processing of setpoints and process values
Writing the setpoints to the drive and transferring the actual drive data to the father block

2.4.5.4 Drive Control
Operating modes:
The local operating modes are generated by the „OPMOD_PP“ block. The drive is switched on
with an operating mode. The „PAR_3“ parameter defines which modes can be selected from the
OP and WinCC. This also depends on whether the drive is on or off. If the drive is already on, it
can be toggled between Run, Crawl and Wash mode. To prevent accidental operation there will
be an additional pop-up window at the touch panels for confirming the command. At the OP270
the drive, once in Run mode, can only be switched to Crawl or Wash mode by keeping the button
pressed for a minimum time parameterized at the input DEL_TIME of the function block OP_PP.
The Jog and Crawl Reverse modes can only be selected when the motor is off. Once in Jog
mode, the drive can be toggled between Jog Forward and Jog Reverse.
ON/OFF logic:
The drive is started with an operating mode and stopped with either a STOP, FASTSTOP or OFF
command. When an OFF command is given, the drive is switched off immediately, using bit 1 in
drive control word 1 (OFF2). STOP and FASTSTOP commands will decelerate the drive until
zero speed before switching it off. The difference between STOP and FASTSTOP are the
different ramp times parameterized at the father block.
All interlocks and commands that shall stop the drive are collected at the block OFF_STOP on
chart D6. These commands are monitored by the function block OFF_DIAG_PP on chart E2
where they are time-stamped and stored (max 8) for later diagnosis. Using two data blocks
DB240 and DB241 the block creates text strings which are displayed in the faceplate and the
OP270 help picture or the MP370 diagnosis picture. Optionally the texts can be sent to the
WinCC message archive by setting the input EN_MSG to True. By using the mask at input
MSK_MSG some WinCC messages can be filtered out.
Note:
In the Source File Folder of the BasisDrive program there are two sources of the text
DBs in German and English. If you need other languages, make a copy of the
source, then translate and compile it. So the DB numbers will not change, you just
have to copy the two DBs in all block folders of the project.
2.4.5.5 Drive Setpoint
The block SP_PP is used for changing the draw / load / tension setpoint. This block has a motor
potentiometer function for the +/- adjustment from the operator panel. The setpoints can also be
entered directly via WinCC (OS) or the serial link (SL). The block also calculates the linear
equation for the grade change.
Speed setpoint:
The speed setpoint for the Run mode is managed by the S_CAS_PP cascade block. This block
calculates the influence of the draw setpoint and the tension controller output as well as slack-
take-up and take-down. There is a CASC_IN input on the father block. The output of the central
ramp function generator is connected there for the leading drive of the machine. The speed set-
point for all other drives is obtained from the main drive (output CASC_OUT on the father block)
of the previous group, depending on the structure of the setpoint cascade.

A multiplexer passes on the valid speed setpoint according to the selected operating mode.
The speed controller of drives with a load distribution by overdriving and limiting, receives an
additional setpoint „V_OD“ and consequently runs at its torque limit, which is controlled by the
master.
If there is no autotransformer in the regenerative feedback unit, the DC link voltage must be re-
duced while energy is being regenerated. The „DC_LINK_PP“ block takes care about this func-
tion and will give the command for DC link voltage reduction when the setpoint is changed to
lower value.
The sense of rotation can be reversed by using Bit8 of control word CWC. All setpoints and
actual values are inverted inside the PZD blocks (invisible). Following fig. shows how to prevent
reversing when the drive is ON.
Figure 10: Reversing of drives

Speed Setpoint
x +
x
:
+
+
influence tension
regulator
output tension
controller
TN_OUT
2%
draw reference
D_RF
100%
0
+2m/min
take up
take down
-2m/min
speed setpoint from cascade
CASC_IN
100%
DVLD
drive before
leading drive
S_CAS_PP
mode run
S_SP_CL
mode crawl
S_SP_CLR
mode crawl rev.
S_SP_JOG
mode jog
S_SP_JOGR
mode jog rev.
S_SP_WASH
MUX
load distribution
0%
2%
+
S_OD
SP
main setpoint
mode wash
x
-
integral part speed controller
Master
MA_YI_PV
DROOP1
DROOP2
load setpoint
L_RF
Load on
speed setpoint to cascade
CASC_OUT
RFG
integral part speed controller
YI_PV
x
Figure 11: Speed setpoint

Additional torque setpoint:
The additional torque setpoint is used to give the speed controller of the drive an extra torque
compensation in order to increase the accuracy.
Additional Torque Setpoint TQ_ADD
x +
TQ_JP
torque step
J_COMP
AC_N
friction
TQ_ADD
[%]
additional torque
acceleration
compensation
S_PV
speed process
value
Figure 12: Additional torque setpoint
x
output speed controller
Master
MA_Y_PV
load setpoint
TQ_RF
load setpoint
TQ_RF
TQ_MUX
load distribution
ON
ind. tension
ON
100 %
torque upper limit
TQ_HL
Torque Upper Limit TQ_HL
Figure 13: Positive torque limit

2.4.5.6 Drive setpoint for single drives (e.g. pumps)
The setpoint for a single drive is calculated as follow:
Internal setpoint V_SP_MAN (rpm):
SP = V_SP_MAN / s_max * V_CORR (where V_CORR ~ s_max / V_NOM)
That means: SP ~ V_SP_MAN / V_NOM
External setpoint CASC_IN:
SP = CASC_IN * V_CORR i.e. SP ~ CASC_IN * s_max / V_NOM
To get a standardization on V_NOM, the interconnected value at CASC_IN must be a
standardized size related to s_max.
If an external setpoint is provided in rpm, then the value must be divided by s_max before the
connection to the DRV_PP.
If the external setpoint is provided as standardized size on the maximum speed, then the factor
V_NOM / s_max must be multiplied before connecting to DRV_PP.
V_NOM must be equal to the maximum speed of the drive.
Display of the actual value:
PV = RECV_PZD2 * s_max / V_CORR i.e. PV ~ RECV_PZD2 * V_NOM

2.4.5.7 Automatic Friction and Acceleration Precontrol
Since standard version 7.2 a new function was implemented which is useful especially for coat-
ing machines.
In the central SPDR chart on sheet B4 a new block PREC_M_PP is located.
Figure 14: Precontrol Master block
After starting the measuring procedure by setting the input AUT_ADP to True, this block takes
control of the speed setpoint and controls all drives connected to the output PCCW_ADP by the
identically named input at the father block. Six speed setpoints (X1 - X6) are given each held for
a period of time set at input ADP_XTI, followed by a number of acceleration and deceleration
ramps parameterized at input ADP_INR.
All drives that should participate the measuring procedure must be switched on and in Run
mode.
In each drive package on chart H2 a new block PREC_S_PP is located.

Figure 15: Precontrol Slave block
The drive's measuring sequence is controlled by the control word PCCW_ADP. All measured
values including inertia are written into the data block DB195. All drives in one CPU share the
same data block, internally separated by their Profibus Slave number.
For further detailed information about the two precontrol blocks, please refer to the block
description PP_DRIVES_AS_Lib_v7_11_xx.pdf or read the online-help by selecting the block
and pressing F1.
Important: In order to protect all measured values from being overwritten by a complete re-
loading of the program, the data block DB195 must be copied back from the Online
block folder into the Offline block folder of the project. This must be done for each
CPU.

2.4.5.8 Drive Messages
The messages for the drive are generated by the function block DRVMSG_PP. This block calls
internally the system function Alarm8 (SFB34). The block is connected to the father block via the
message number (EV_ID). The advantage of the DRVMSG_PP block is, that all messages could
be delayed by a time which is parameterized at the input DEL_x.
Two other blocks with messages are used:
1) OFF_DIAG_PP which will display the OFF-cause of the drive
2) ERR_WRN_PP which will display the fault / alarm message of the converter
The message texts are stored at the father block. They are already pre-configured in English and
German. If you need to add another language, please follow the procedure described below:
1. In the plant hierarchy select the folder BasisDrives, that includes all the standard drives, and
from the context menu (right-click) chose „Charts/Edit messages...“ (Fig. 16)
2. Press the button „Exporting texts...“ save the CSV file and close the editor.
3. Start Microsoft Excel and open the CSV file from there, translate the texts (copy & paste)
4. Now in the Simatic Manager create a new language:
from the menu /Options/Display language... to install the required language
5. Define the new language as the default language.
6. Select again the folder BasisDrives, that includes all the standard drives and from the con-
text menu (right-click) chose again „Charts/Edit messages...“
7. Now press the button „Importing texts...“ and load the edited CSV file.
8. The new texts are imported for the default language.
9. Now you can start to copy the drive charts, including the new translated texts.

Figure 16: Open the Edit Messages function
The message text1 and text3 are used for the drive messages. Text1 normally has the value
$$AKZ$$, which is a system function. It consists of the following elements:
Folder name / chart name / block name /
As the folder name is not wanted in the messages, you have to uncheck the attribute „Name of
hierarchy folder is part of the plant designation“ in the hierarchy folder properties. (see Fig. 24:
Hierarchy folder attributes)
The chart name could be the TAG name, e. g. DRV086, the block name (father block) is always
DRV.

Figure 17: Message text structure
In text3, right before the actual message, there is a dummy called „objectcomment :“. This one
should be replaced by the technological name of the drive, e. g. „dryer section 5“.
(you could use the same function for this as shown in Fig. 16)
So the message should look like this:
Text 1 Text 3
DRV068/DRV dryer section 5 : load PV Warning High

2.4.5.9 Process Control Group Messages
During the process of „mapping“ (Transfer PLC-OS connection data) the system will add by
default 21 process control system messages. These messages are e. g. „Synchronous PLC error
entering state“ or „Module error entering state“. As these messages do not provide any useful
information, but tend to increase confusion, we recommend not to use these messages. There is
a way to prevent creation of these messages:
In the component view select the Special Object Properties of each CPU and SET the option
„Suppress Process Control Group Messages“ ! After the next „mapping“ (Transfer PLC-OS
connection data) the system messages will not exist anymore.
Figure 18: Suppress Process Control Group Messages

2.4.5.10 Tension control
The chart of a drive with tension control has an additional sheet F including
Reading in data from the father block
Reading in the tension process value
Web break detection
ON/OFF logic of the tension controller
Tension setpoint calculation
PI controller of the tension controller
Pre-processing status information
Writing data into the father block
The tension controller is always enabled. Switching off the tension control just means to set the
upper limit of the controller output to zero. Though the lower limit is always „open“ to -100 %,
which will help to release high tension while threading paper.
Setting the bit 7 at the input PAR_2 of the father block will enable the tension controller and the
automatic take-up function, after detection of paper from the photocell and after a defined length
of web path.
Bit 13 in PAR_2 will enable switching on and off the tension controller with the „blade positioned“
signal from the control word IN_CWC, e. g. for on-line coater and calender, while during thread-
ing of paper the functions „ease-off” from tension controller and „automatic take-up” are disabled.

2.4.6 Unwinder (coating machines or calender)
The standard includes a drive typical for unwinder. It consists of four CFC charts, which are
already interconnected with each other:
DRV_PWUW Primary winder of unwinder
DRV_SWUW Secondary winder of unwinder
DRV_ROPE Rope drive
TEN_UW Common tension control and splice logic of unwinder
Because of the ready pre-configured interconnections between the charts, no package should be
copied or moved to another CPU separately.
The data block DB233 belongs to the unwinder and contains all necessary data for control and
visualization.
TEN UW
DRV ROPE
DRV_
PWUW
DRV_
SWUW
Figure 19: The unwinder packages
Internal functions:
• TEN_UW Tension
Machine speed & acceleration, Dmin, Dmax, tension actual value and scaling, light gate,
clutch signals, gear ratio, torque ratio, nominal speed, web cut, tension setpoints, set di-
ameter, PW & SW mode, PW & SW stop and faststop, control words, maneuver setpoint,
splice control CC1, tension control ON/OFF logic, density, webbreak detection, tension
controller, remaining time & length calculation, status words.

• DRV_ROPE Rope drive (standard drive DRAW with modifications)
Father block DRV_PP, set crawl mode when over max. rope speed, control words, read
process data from drive, MCWA, MCWB, interlocks, mode selection, ON command and
controller release, OFF logic, speed cascade, draw setpoint, speed setpoint, ramp gen-
erator, additional torque, write process data to drive, status words.
• DRV_PWUW Primary unwinder
Father block DRV_PP, control words, read process data from drive, V_act, N_act, MCWA,
MCWB, interlocks, mode selection, ON command and controller release, OFF logic, status
word F, diameter calculation, speed limiting, synchrony detection, calculating variable inertia
and acceleration torque, speed setpoint, ramp generator, additional torque, torque limits,
write process data to drive, status words.
• DRV_SWUW Secondary unwinder
(identical with DRV_PWUW )
2.4.7 Rewinder
The standard also includes a drive typical for rewinder (e. g. „Optireel“, „Sirius“). It consists of
four CFC charts, which are already interconnected with each other:
DRV_DRUM Reel drum (pope)
DRV_PWRW Primary winder of rewinder
DRV_SWRW Secondary winder of rewinder
TEN_RW Common tension control and splice logic of rewinder
Because of the ready pre-configured interconnections between the charts, no package should be
copied or moved to another CPU separately.
The data block DB232 belongs to the unwinder and contains all necessary data for control and
visualization.

TEN RW
DRV_
DRUM
DRV_
PWRW
DRV_
SWRW
Figure 20: The rewinder packages
Internal functions:
• TEN_RW Tension
Machine speed & acceleration, Dmin, Dmax, tension actual value and scaling, light gate,
clutch & nip signals, gear ratio, torque ratio, nominal speed, web cut, tension setpoints, set
diameter, PW & SW mode, PW, SW & DRUM stop and faststop, control words, maneuver
setpoint, splice control CC1 & CC2, tension control ON/OFF logic, density, webbreak detec-
tion, tension controller, winding force control, length calculation, status words.
• DRV_DRUM Reel drum (standard drive DRAW with modifications)
Father block DRV_PP, control words, read process data from drive, MCWA, MCWB, inter-
locks, mode selection, ON command and controller release, OFF logic, speed cascade,
draw setpoint, speed setpoint, ramp generator, additional torque, write process data to drive,
status words.
• DRV_PWRW Primary rewinder
Father block DRV_PP, control words, read process data from drive, V_act, N_act, MCWA,
MCWB, interlocks, mode selection, ON command and controller release, OFF logic, status
word F, diameter calculation, speed limiting, synchrony detection, calculating variable inertia
and acceleration torque, speed setpoint, ramp generator, additional torque, torque limits,
write process data to drive, status words.
• DRV_SWRW Secondary rewinder
(identical with DRV_PWRW )

2.4.8 Configuration of the drive groups
The control commands from the OP, the OS and the I/O devices are merely through-connected
via the drive package during the first cycle and made available at the IL_DRV output. This inter-
lock word contains the control commands and additional status information relating to the drive.
Up to four drives can be interconnected to form a group with the aid of the GROUP_PP block. If
more drives need to be linked together, the GROUP_PP block can be cascaded. The control
commands (bits 0 to 15) are „OR-connected“ and the status information (bits 16 to 31) are „AND-
connected“.
The interlock word for the drive group is made available at the GROUP_PP/OUT output. This
output is then itself interconnected to the IL_GRP inputs on the father blocks. The IL_GRP con-
trol commands are necessary in order to switch the drive on and off. (See also Fig. 31: Group
interconnections)
If the group interconnection needs to be variable, the „GROUP_MODE_PP“ block can be used.
This block enables up to eight drives to be connected together in one or two independent groups
(main group, sub group). Up to five different group configurations can be selected.
Those drives that are deselected by the GROUP_MODE_PP block can be operated separately
or interlocked by parameterization.
If the group configuration needs more flexibility, then a customized group configuration must be
created manually, using the blocks MUX_DW_PP and GROUP_PP.
Note:
The block GROUP_MODE_PP must be installed in the OB1 run group
OB1_”group”_OUT behind the OB1_DRV_x run groups.

2.4.9 Load sharing concept with LS_PP
Since version 7.2 of the standard a new function block LS_PP can be used to improve the
operating and monitoring of load shared drives and groups.
Figure 21: Load Sharing with LS_PP
The block reads the surface-force setpoints entered by the operator and calculates the load-
factor which must be connected to the input OS_TQ_SP of the father blocks. In this calculation
the nominal torque, the gear factor and the roll diameter of each drive is considered. Actually the
surface-force setpoints are without dimension and the block calculates them into relative
setpoints which all added together result in 100 %.
The advantage of this solution is that the load of groups with more than two drives can easily be
configured. Besides the faults resulting from motor-size differing from RDC load (recommended
drive capacity) is compensated.
Simply place the block LS_PP in the group chart (OB1) and connect the father blocks output
DI_NO from all drives of the group to the inputs DI_NO_x and connect the outputs TQ_SP_x
back to the father blocks input OS_TQ_SP (invisible by default). Finally enter the number of the
drive which is the group master and its minimum load (between 0,1 and 0,5) which should not fall
below.
Note:
The block LS_PP must be installed in the OB1 run group OB1_”group”_OUT behind
the OB1_DRV_x run groups.
Inside the MP370 operator manual PP_SECD_MP370_OM_v7_4_xx.doc or inside the OP270
operator manual PP_SECD_OP270_OM_v7_4_xx.doc you will find a screenshot of the picture
and a short description of the operation philosophy.
For further detailed information about the LS_PP block, please refer to the block description
PP_DRIVES_AS_Lib_v7_11_xx.pdf or read the online-help by selecting the block and pressing
F1.

2.4.10 CPU-CPU communication
The Global Data function is used for communication between the processors. A data block
(GD_DB) is reserved in the basis software for this communication mode. Each CPU has a send
buffer and several receive buffers for this purpose. The send buffer of one CPU is used as a re-
ceive buffer by all the other CPUs. The basis software includes two special function blocks
(SND_CPU_PP and RCV_CPU_PP) which help to read and write data to the Global Data Table.
The data exchange is event-driven, i. e. the Global Data is read at the start of the fast cyclic inter-
rupt (OB36) and written at the end of it.
The standard project already contains a pre-configured Global Data Table. Inside this Table the
CPUs have to be assigned.
Important! After changing the CPU or the project name, all CPUs must be reassigned !
By selecting the MPI network in the Simatic Manager, the Define Global Data function becomes
available in the Options menu. By double-clicking on the head of a column (ViewScan Rates
must not be selected!), the CPU can be assigned. If less than four CPUs are needed, the addi-
tional rows and columns should be deleted.
Important! Due to a system fault, after deleting CPU-assignments and compiling, some
Sample Rate factors might have changed. It’s strongly recommended to check
them and, if changed, reset them to zero !
Important! The Global Data must be loaded separately. It is not loaded automatically with
the hardware configuration (select MPI Options/Define Global Data) Compile
Download
Figure 22: Global data table
If more signals are needed, you can also extend the Global data table.

Configuration and Engineering T.-Vers.: V07.05.00
3 CONFIGURATION AND ENGINEERING
3.1 Chart structure
Since almost all the functions are assigned to the drive packages, most of the programming work
concerns parameterizing and duplicating these packages.
First of all, you should check whether the functionality of the basis software is adequate or
whether special functions need to be programmed to take account of customer requirements.
You should also check whether the standard texts (English, German) are sufficient.
The hardware configuration of the basis software includes four CPUs. You should delete any
CPUs that are not needed. (After that clean-up the Global Data as described in chapter 2.4.10
CPU-CPU communication)
You can select two different views from the menu item „View“ in the Simatic Manager:
• Component View (standard hierarchy)
• Plant View (plant hierarchy)
The next step is to subdivide the plant according to technical criteria.
Figure 23: Example of a plant hierarchy
It is recommended to assign one hierarchy folder to the complete machine (Demo_PM in this
example). Another folder (0_CENTRAL) below should be used for all the central functions, such
as CEN or SPDR. Separate folders should also be provided for the technological groups (e. g.
A_FORMER). Each „group folder“ should contain the group-mode chart, the group-input/output
chart and a drive folder for each drive with the technological name (e. g. AA_WIRE_ROLL). Fi-
nally this drive folder includes the CFC chart of the drive named by the TAG (e. g. DRV001).

In order to sort the sequence of the hierarchy (e. g. according to the speed cascade), a letter
should be added in front of the folder name.
Important: Make sure that in each hierarchy folder property the plant designation is unchecked
! (see Fig. 24: Hierarchy folder attributes)
Figure 24: Hierarchy folder attributes
The hierarchy folders must also be assigned to the appropriate chart folder for the standard hier-
archy under Properties / PLC and OS Assignment. (A higher hierarchy folder can include other,
subordinate hierarchy folders which are assigned to different CPUs.)
3.2 Central control (CEN)
All signals that act across different groups (e. g. emergency stop) are processed by the central
control. The interlock signals are wired directly to the appropriate blocks in the CEN chart (see
chapter The central control (CEN))

3.3 Machine speed reference (SPDR)
Only a few parameters need to be set in this chart.
Settings Block Connection Unit
Maximum machine speed
Minimum machine speed
S_REF
S_REF
SP_MAX_IN
SP_MIN_IN
m/min
m/min
Maximum machine ramp time
Minimum machine ramp time
S_REF
S_REF
RAMP_MAX_IN
RAMP_MIN_IN
sec
sec
Threading speed (CM only) S_REF SP_THR m/min
Maximum Threading speed (CM only) S_REF THR_MAX_IN m/min
Washing speed (CM only) S_REF SP_WSH m/min
Acceleration time T_UP FIX
(input select=1)
sec
Deceleration time T_DOWN FIX
(input select=1)
sec
Paper or coating machine S_REF PAR5_IN bit 0
1: Paper machine
0: Coating machine
Table 6: SPDR settings
3.4 Rectifying/regenerative feedback unit (RR_UNIT)
The following parameters must be set:
Settings Block Connection Unit
Profibus address
(converter and PPO type remain unchanged)
RR_xx L2_SLNO
Energy regeneration with or without autotransformer RR_xx PAR_IN
Bit 0 = 0 with
autotransformer
or no energy regeneration
Bit 0 = 1 without
autotransformer, i. e. with
DC link reduction
Simulation enabled RR_xx PAR_IN
Bit 1 = 0 without
simulation
Bit 1 = 1 with simulation
OFF delay if all drives are switched off T_OFF T (chart B3) sec
Table 7: RR_UNIT settings
All status words SWG of the drives concerned are connected on the DRV_SWG block. The
status word of the incoming/regenerative feedback unit block SW_RR_UNIT output OUT is inter-
connected to the drives as feedback.
You also have to connect the master control word B from CEN, chart J2, MCWB to
RR_UNITxx.MCWB.

3.5 Drive package (DRV_xxx)
A hierarchy folder with the different drive types (draw, droop, tension, etc.) has been installed in
the Basic drive software. Each of these charts contains the complete logic for the drive. The fa-
ther block on the first sheet of that chart is preset according to the drive type.
Figure 25: Basic drive charts
3.6 Import Export Assistant (IEA)
Paper or coating machines often have many identical kinds of drives, e. g. guide rolls or dryer
sections. In order not to have to copy and connect the basic chart from the basic folder for every
drive, a so-called „model“ is created for each type, which then serves as a pattern for all equal
drives. This model must then only be imported. The copies of the model then result by the import.
In the sectional drives standard you will find a model for each type of drive. They are located in
the folder IEA_files of your project. Use Windows Explorer to open one of them by double-click-
ing on it.
Note!
The model includes also the message texts which are in English by default. If you
need other language texts, switch the display language and then create/modify the
model again.

3.6.1 Preparations
Before you begin, first think about the structure of the machine. The structure of the technological
hierarchy should already be clear before beginning. This structure is not yet needed to be made
out in PCS7, this is finished by the IEA. Secondly a presentation of all drive data which also
contains the parameters of the father block should exist. This list is then used for the final prepa-
ration of the standard solution. An Excel data sheet could be used for this. I&S MP 6 is now pre-
paring a standard Excel data sheet including all data relevant to project engineering, computing
also the parameters for the father block. The release will be soon.
3.6.2 Processing the model file
In the IEA file all inputs and parameters are presented in columns. Open the file in the IEA editor:
Figure 26: IEA editor
Now the first line must be copied as often as there are drives of this type in the project. This is
done best by selecting „duplicate row“ from the menu Edit. In the window following now, you en-
ter the factor, i. e. how many copies you would like to make (minus the first already available
line).
Figure 27: IEA editor after copying
Now you can start to fill out the columns, referring the project data sheet.
The column „Hierarchy“ defines the chart folder in the technological view, in which the copy will
be created. The folders themselves don't need to be created, this is done by the import function
described later. The column „Chart“ defines the name of the chart which will be created as a
copy of the model. The following columns contain the values and connections for this chart.

It is possible to make connections directly between two blocks in CFC. For this you must
first delete the column „SymbolName“ and then chose from the menu „Edit / Extend Column
Group...“ with the option „Textual Interconnection“ (TextRef). This will create a new column called
TextRef in which you can insert the destination address of the connection like this: <chart
name><block name>.<in/output name>. e. g. CENMCWB.OUT
Note!
Connections can not be made across several CPU's, only inside one CPU.
Connecting the speed and acceleration setpoint from the central RAMP chart is only important
for coating machines. At paper machines the speed setpoint is connected via speed cascade.
After entering all the information the file can be saved. Later modifications are still possible (look
at 3.6.4).
3.6.3 Importing the presentation file
Back in the Simatic Manager inside the plant view right-click on the folder with the model chart
and chose „Import...“ from the Import/Export Assistant menu.
After selecting the import file and, in the next context window, selecting a Log-file the import
function can be started by pressing the button „Finish“. Now the creation of the folders, charts
and connections is done.

Figure 28: Import the IEA model
In the Log-file you could see, whether mistakes occurred during the import. This is mostly the
case if connections should be made at inputs or outputs which are not switched visible. If blocks
for connections do not exist, this leads first to mistakes while compiling!
After finishing the import, the newly created chart folders have to be assigned to a CPU.
3.6.4 Modification of the standard solution
If connections or parameters have changed, these modifications could be done easily in the IEA
file. After that the IEA file is imported again. Only the new or changed connections / parameters
are created. The rest of the project remains unchanged.
A little more complicated is the modification of the model itself, e. g. adding inputs or outputs. In
this case a new model must be created.
In order not to lose all existing connections and parameters, the old IEA file should be copied into
a backup folder. After creation of the new model, the old and the new IEA files are opened to-
gether with the IEA editor. Now the old connections and parameters can be copied and pasted
into the new IEA file. Only the new added connections and parameters have to be supplied.
Before importing the new IEA file, the old folders and charts, which have been created by the
Import/Export Assistant, must be deleted. After that the import should work without problems and
all folders and charts are created again.
Now the individual steps of engineering the project can be done.

3.7 Interconnections in CFC-charts
3.7.1 Interconnection of drives and central packages
SPDR.RFG: V_OUT
(machine master or CM)
SPDR.RFG: A_OUT
(only coating machine)
SPDR.GD_T_PV:Y
CEN.MCWA:OUT
CEN.MCWB:OUT
CEN.SWG_OR
ALL DRIVES
DRV_PP
CASC_IN
SWG
AC_RF
GD_T_PV
MCWA
MCWB
Figure 29: Interconnection of the father block ←→ central package

3.7.2 Interconnection of father blocks
MASTER
(MAIN)
DRV_PP
CASC_INSPDR.RAMP.V_OUTCASC_OUT
V_PV
TU_EO_OUT
DRV_PP
CASC_INCASC_OUT
V_PVMA_V_PV
UE_EO_INV_SP
A_SP
MODE
Y_PV/YI_PV
TQ_PV
DRV_PP
CASC_IN
MA_V_PV
DRV_PP
CASC_IN
MA_V_PV
MASTER
(TENSION/DRAW)
MASTER
(TENSION/DRAW)
SLAVE
(LOAD/DROO)P)
MA_V_SP
MA_A_SP
MA_MODE
MA_Y_PV/MA_YI_PV
MA_TQ_PV_S
V_RF
MA_V_RF
Figure 30: Interconnection of the father blocks

3.7.3 Group interconnection
Group configuration
GROUP_PP
IN1
IN2
IN3
IN4
OUT
FFFF0000
Father block drive 1
DRV_PP
IL_GRP IL_DRV
DRV_PP
IL_GRP IL_DRV
DRV_PP
IL_GRP IL_DRV
Figure 31: Group interconnections

3.7.4 Interconnection of the father blocks and RR unit
DRV_PP
DRV_PP
IR_SW SWG
IR_SW SWG
IN1
IN2
DRV_SWG SW_RR_UNIT
OUT
RR_UNIT chart
Figure 32: Interconnection of the father blocks and the incoming/regenerative feedback unit

3.7.5 Interconnection of the father blocks for felt/wire-thickness compensation
If a felt or wire is between the paper web and the roll, the thickness of the felt or wire must be
taken into account for the calculation of the correct web speed. The input of the thickness is
released at one drive of the group (preferably the group master) with the parameter PAR_1.Bit10
(felt/wire monitoring). The value is distributed by means of CFC-interconnections between those
father blocks, which are affected by the thickness compensation, including the master itself.
Father block group master
DRV_PP
MA_FW_THICK FW_THICK
OS_FW_THICK
Father block slave 1
DRV_PP
OS_FW_THICK
Father block slave 2
DRV_PP
OS_FW_THICK
Figure 33: Felt or wire thickness compensation interconnections

3.8 Run Sequence
The following screenshot shows the typical structure of the run sequence. It is important that the
drive packages of a group are called in the sequence „master first - slave next“. The sequence
should be according to the speed cascade. If there is more than one CPU in the project, the
GD_COM_RCV chart must be called first, the GD_COM_SND last. The OP_PP block should be
called after the drives.
Figure 34: Run sequence

3.9 Webbreak Curves
3.9.1 Engineering on PLC-side
All signals of the webbreak sensors (light gates) are collected inside the CFC chart CEN and
then connected to the block WB_DETECT_PP. This block monitors the signals and detects a
webbreak if at least one bit of the input words changes from FALSE to TRUE. The bit, that has
triggered the webbreak detection is stored in the output words WB_FST0_15 and
WB_FST16_31. These outputs have the attribute „S7_m_c := TRUE” and could therefore give
the information to WinCC for visualization. The collective signal is connected from the output WB
to the bit 11 of MCWB.
Note:
The block WB_DETECT_PP starts monitoring the webbreak sensors after the EN in-
put has changed to TRUE. When the signal changes to TRUE, all sensors that have
not detected paper in that moment, are excluded from monitoring. They will be indi-
cated at the outputs Wbdef0_15 and Wbdef16_31 and the color in WinCC changes to
gray (inactive).
The block WB_DETECT_PP has another internal function: it supplies the system data words
WB_TIME1 ... WB_TIME4 (DRV_SYS_DB, DB199) with the information about date and time of
the webbreak. This information is required by the blocks WB_PP in the CFC drive charts, sheet I.
Attention: In multiprocessor operation the block WB_DETECT_PP must be called once in
each CPU, in order to supply the system data words WB_TIME1 ... WB_TIME4
(DRV_SYS_DB, DB199) in each CPU (see charts GD_COM2...GD_COM4).
Each CFC drive charts calls one webbreak block WB_PP on sheet I4. The block can read up to 5
input values each cycle and stores them in a buffer. In case of a webbreak further values for an-
other 50 cycles are stored and after that the altogether 151 values inside the buffer are trans-
ferred to WinCC by the integrated system function AR_SEND (SFB37). Because of the cycle-
time of the WB_PP block (OB 34 = 200 ms), the time range of the webbreak-curve is 30 seconds
(20 seconds before and 10 seconds after the webbreak). To avoid all WB_PP blocks to send
their data to WinCC simultaneously, which would overload the system, a special system data bit
TOKEN (DRV_SYS_DB, DB199) is used to coordinate a sequential procedure of transmission.
At the start of a transmission the TOKEN is set TRUE (this blocks all other WB_PP blocks from
sending their data), and after successful transmission the TOKEN is set back to FALSE.
Note:
If there is no communication to WinCC (server down or wrong configuration) the
block retries 25 times to send the data. After this retry the block detects an error and
resets the TOKEN, so that the other blocks in the run sequence could try to send
their data.

3.9.2 Engineering on OS-side
After mapping (transfer PLC-OS connection data) you have to create the process value archives
in WinCC Tag-Logging.
The size of each process value archive must be defined from the menu item properties. The size
must be 151 or an even-numbered multiple of 151. For example a value of 1510 means, that the
archive could contain 10 webbreak curves.
Figure 35: Size of process value archive
Inside the process value archive enter a process controlled tag. Each process controlled tag
must be assigned to the correct raw data tag ProgramName#RawArchive.
Attention: In multiprocessor operation you must assign the raw data tag, which corresponds to
the correct CPU, because each CPU has its own raw data tag – check program
name !!!

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