SITRAIN Training for Automation and Drives SINAMICS S120 / S150
4,035 610 18MB
ENGLISH Pages 236 Year 2008
Polecaj historie
Table of contents :
0 Register1_20_10.pdf......Page 1
1 01 SIN Family.pdf......Page 5
1 02 SIN Power-Mod.pdf......Page 13
1 03 SIN El-Mod.pdf......Page 25
1 04 Comm AOP.pdf......Page 40
1 05 Tools.pdf......Page 56
1 06 Comm STARTER.pdf......Page 62
1 07 Diagnostics.pdf......Page 87
1 08 Setpoint.pdf......Page 98
1 09 Control.pdf......Page 108
1 10 Optimization.pdf......Page 123
1 11 Comm_CTW.pdf......Page 143
1 12 Options.pdf......Page 154
1 13 EMC.pdf......Page 171
1 14 Power_comp.pdf......Page 177
1 15 Powerblock Repair.pdf......Page 195
1 16 Methods.pdf......Page 215
1 17 Spares_WEB.pdf......Page 229
Citation preview
1. Drive family and system overview
2. System components / Power modules
SITRAIN Training for Automation and Drives
SINAMICS S120 / S150 SIMOREG 6RA70 Service and Commissioning Course for
4. Commissioning with AOP30 5. Tools and project design 6. Commissioning with STARTER 7. Diagnostics 8. Speed setpoint channel
National Petroleum Construction Company AL: N
3. System components / Electronic modules
ECCN: N
9. Open and closed loop control 10. Optimization
Export Regulations AL Number of European resp. German export list. Goods with labels not equal to ”N” are subject to export authorization. ECCN Number of US export list (Export Control Classification Number). Goods with labels not equal to ”N” are subject to re-export authorization for export to certain countries. Indication Goods labeled with ”AL not equal to N” (here: technical documentations) are subject to European or German export authorization when being exported out of the EU. Goods labeled with ”ECCN equal to N” (here: technical documentations) are subject to US re-export authorization. Even without a label, or with label ”AL:N” or ”ECCN:N”, authorization may be required due to the final whereabouts and purpose for which the goods are to be used. Decisive are the export labels stated on order acknowledgements, delivery notes and invoices. This document was produced for training purpose. Siemens assumes no responsibility for its contents. The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable to damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved.
11. Basics of communication with PROFIBUS 12. Options and “functions“ 13. EMC / Electromagnetic compatibility 14. Power section components / Replacement 15. Power block / Power circuit / Repair
© SIEMENS AG 2007
16. Troubleshooting methodology Name:
___________________________
Course: from
____________ to ____________
17. Technical support / Spare parts
Instructor:
18. “On-board“ technology Infoline
Tel: 01805 23 56 11 Fax: 01805 23 56 12 Internet: http://www.siemens.de/sitrain
19. Hardware and wiring
ID-Nr.: Release V A2.4
20. Documentation and training
Folder 1
1. Practical training
2. Overview diagrams S150 3. Custoner cabinet drawings S150 4. Cabinet drawings S150 5. Power block frame size F 6. Power block frame size G 7. Power block frame size J 8. Power block frame size H 9. Excerpt of function diagrams SINAMICS S 10. Notes for STARTER V4.0 SP1
11. Basics of DC-drives 12. Hardware and commissioning 13. Software and function diagrams 14. Tool Drive Monitor 15. Excerpt of Operating Instructions
Drive family and system overview SINAMICS Training objectives: You are informed about • the SINAMICS drive family system concept • the family members and their corresponding tasks • the design-types “compact drive” and “modular drive configuration”
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 1 - 1
SITRAIN Training for Automation and Drives
Drive family and system overview SINAMICS Content
Page
Drive systems presently still in use................................................................................................... Currently valid / future drive systems................................................................................................ The new generation......................................................................................................................... SINAMICS offers a solution ............................................................................................................. Ordering data - MLFB structure....................................................................................................... Product profile General Purpose / Compact.................................................................................... Product profile High Performance / Compact.................................................................................. Product profile High Performance / Modular................................................................................... SINAMICS Low voltage converters................................................................................................... SINAMICS Medium voltage converters............................................................................................. V/Hz-control and Vector-control........................................................................................................ Operating types SERVO / VECTOR................................................................................................. Range of motors..............................................................................................................................
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
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3 4 5 6 7 8 9 10 11 12 13 14 15
SITRAIN Training for Automation and Drives
Drive systems presently still in use y da r e y st da e y to +
Machine tools and production machines Simodrive
Masterdrives up to 200 kW Siemens
Drivecontroller
Motorola 5600 xx
Software
Simodrive
Masterdrives
Power stack
Simodrive V3
Compact + Compact Chassis
Simocom U Simopro
Drive Monitor Path
Engineering
Motors
Standard drives Midimaster Micromaster up to 250 kW up to 250 kW
C161
Hitachi H8
TMS 320
Micromaster
Micromaster Version 3 + 4
Date: File:
Siemens AG 2007. All rights reserved.
Masterdrives above 200 kW Siemens
C161
TMS 320
Masterdrives
Standard
Cabinets
Chassis
Drive Monitor (Vers. 3 + 4) STARTER (Vers. 4)
Drive Monitor Path
Standard motors
Standard / HV-Motors
Servo / Standard motors
SINAMICS
Midimaster Version 3 + 4
Large drives
SITRAIN Training for
06/03/2007 ABU DHABI: Page 1 - 3
Automation and Drives
Currently valid / future drive systems
Basic
Software
General Purpose
High Performance
Scalable Runtime Software
Medium voltage 2.3 to 7.2 kV 0.7 to 28 MVA
Low voltage 230 to 690 V 0.12 to 6000 kVA
Power stack
SIZER / STARTER, SCOUT with STARTER_Integrated Engineering Engineering / Commissioning (Visualisation)
Motors
Unified processor
+ y w da rro to o m to
Drive controller
Common SW-Pool
Unified power stacks for low and medium voltage
Common engineering tool for all drive products
Standard motors to linear motors; Low voltage and high voltage motors
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 1 - 4
SITRAIN Training for Automation and Drives
The new generation Ready to run cabinet units (high power ratings)
Strategy of SINAMICS : unified scalable drive system unified engineering for all drive families Integration of all drives into the automation environment Merger of SIMODRIVE, MASTERDRIVES, SIMOVERT MV, MICROMASTER
Flexible chassis units (high power ratings) Modular chassis units (high power ratings) Modular booksize units (low to medium power ratings) Compact blocksize units (low power ratings)
SINAMICS G110 / G120 , ET200S-FC / G130 / G150 Compact drive units of all frame sizes for standard applications with induction motors
G… S… …M
SINAMICS S120 / S150 Modular or compact drive units for sophisticated tasks with synchronous or induction motors
-
General Performance High Performance Medium voltage
SINAMICS GM150 / SM150 Medium voltage drives without (1Q) / with (4Q) active infeed for sophisticated tasks with synchronous or induction motors
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06/03/2007 ABU DHABI: Page 1 - 5
Automation and Drives
SINAMICS offers a solution ...
G110
G120
S120
G130
S120
SINAMICS
SINAMICS
SINAMICS
... for every power range
S120
0,12 kW
G150 / S150
GM150 / SM150
1,5 MW
30 MW
SINAMICS
SINAMICS
... for every application
G110/120 Standard drives
SINAMICS Siemens AG 2007. All rights reserved.
G130 G150 / GM150
S150
Sophisticated standalone drives
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06/03/2007 ABU DHABI: Page 1 - 6
SM150
S120 + (D4xx / T-CPU / SL) Coordinated drives / MC High performance drives
SITRAIN Training for Automation and Drives
Ordering data - MLFB structure 1 = Booksize 2 = Blocksize 3 = Chassis 7 = Cabinet SINAMICS 1. Generation
A = with customer options C = compact size -- = chassis
version
0 = Air-cooled 5 = Liquid-cooled
options
6SL3 720 – 1TE 36 – 1 A A0 – Z 1 = AC/AC unit 2 = Motor Module 3 = Line Module
Output current 3 = Faktor 100 100 * 6,1 = ca. 610A Line E = 380 ... 480 V F = 500 … 600 V G = 660 ... 690 V
1 = MM or Basic Infeed 6 = Smart Infeed 7 = Active Infeed
T = DRIVE-CLiQ interface (without CU320) G = G150, G130 General Purpose Vector L = S120, S150 High Performance
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06/03/2007 ABU DHABI: Page 1 - 7
Automation and Drives
Product profile General Purpose / Compact AC/AC units for single axis applications 0,55 – 90 kW Blocksize
2 DO
2 AI
PM-D FX1
315 – 800 kW Chassis
75 – 1500 kW Cabinet
G130
G150A, G150C
xB1
IPM25
SF
ICU24F
PWR
SG1
SG2
Stat
SG4 SG5
SG6
DC LINK ON 1 5 1 6
2 2 2 3
2 6 1 3
G110, G120, ET200S-FC
SINAMICS G / Compact: the new drive system for general drive tasks designed for single axis applications
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 1 - 8
SITRAIN Training for Automation and Drives
Product profile High Performance / Compact AC/AC units for single axis applications 0,25 – 90 kW Blocksize
75 – 250 kW Chassis
75 – 1200 kW Cabinet
S120
S120
S150
SINAMICS S / Compact: the new drive system for demanding drive tasks designed for single axis applications
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
SITRAIN Training for
06/03/2007 ABU DHABI: Page 1 - 9
Automation and Drives
Product profile High Performance / Modular DC/AC units for multi-axis applications 1,6 – 107 kW Booksize
75 – 1200 kW Chassis
75 – 1200 kW Cabinet segments
S120
S120
S120
SINAMICS S / Modular:
SINAMICS Siemens AG 2007. All rights reserved.
the new drive system for sophisticated drive tasks designed for multi-axis applications (i.e. in machine construction) and for multi-motor drive-group applications Date: File:
06/03/2007 ABU DHABI: Page 1 - 10
SITRAIN Training for Automation and Drives
SINAMICS
SINAMICS Low voltage converters
G110
G120
G130
Ready to run
G130 G150
S150
Modular
Ready to run
Ready to run
Chassis
Standard cabinet
Standard cabinet
1AC, 230 V 0.12 – 3 kW
3AC, 400 V 0.37 – 250 kW
3AC, 400/500/690 V 315 – 800 kW
3AC, 400/500/690 V 75 – 1500 kW
3AC, 400/690 V 75 – 1200 kW
S120
S120
S120
SINAMICS
SINAMICS
Blocksize
SINAMICS
Blocksize
S120 Modular
S120 Ready to run
Booksize
Chassis
Cabinet segment
Blocksize
Chassis
3AC, 400 V 1.6 – 107 kW
3AC, 400/690 V 132 – 1400 kW
3AC, 400/690 V 132 – 1500 kW
1/3AC, 230/400 V 0.12 – 90 kW
3AC, 400 V 75 – 250 kW
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06/03/2007 ABU DHABI: Page 1 - 11
Automation and Drives
SINAMICS Medium voltage converters
GM150
SM150
Single quadrant operation on the line side
Four quadrant operation on the line side
IGBT-Inverter / air cooled 2.3/3.3/4.16/6.0/6.6/7.2 kV 700 – 7 900 kVA IGBT-Inverter / water cooled 2.3/3.3/4.16/6.0/6.6/7.2 kV 2 000 – 10 000 kVA IGCT-Inverter / water cooled 3.3 kV 10 000 – 28 000 kVA
IGCT-Inverter / water cooled 3.3 kV 5 000 – 28 000 kVA
The drive solution for single motor applications of very large power ratings and high voltage. Vector control with/without encoder; SIMOTION-technology integrated in SM150.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 1 - 12
SITRAIN Training for Automation and Drives
V/Hz-control and Vector-control V/Hz-characteristic
voltage
U f
RFG
frequency
f
speed setpoint
n
M speed controller
speed setpoint
active current controller Iset, q
- Iact, q
- nact
V
P field current controller
K
Phi
Iset, d
- Iact,d
IUVW motor model
M
SINAMICS
Date: File:
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06/03/2007 ABU DHABI: Page 1 - 13
SITRAIN Training for Automation and Drives
Operating types SERVO / VECTOR Within the modular system SINAMICS S120 an “operating type” can be selected as a match to the type of motor used (via parameters): • operating type SERVO for
Synchronous and Asynchronous Servo Motors / Torque- and Linear Motors
• operating type VECTOR for
Asynchronous-, Synchronous- and Reluctance Motors
Operating type SERVO
Operating type VECTOR
- Drives requiring extremely dynamic operation - Angular synchronism with isochronous bus operation
- Speed- and torque controlled drives requiring high static accuracy, - In particular in sensorless operation
1 Active Line Module / 6 Motor Modules current controller: speed controller:
125 μs 125 μs
1 Active Line Module / 2 Motor Modules current controller: speed controller:
250 μs 1000 μs
1 Active Line Module / 2 Motor Modules current controller : 62.5 μs speed controller: 62.5 μs
1 Active Line Module / 4 Motor Modules current controller: speed controller:
400 μs 1600 μs
1 Active Line Module / 10 Motor Modules current controller: speed controller:
500 μs 2000 μs
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 1 - 14
SITRAIN Training for Automation and Drives
Range of motors Asynchronous motors
1L_, 1M_, 1PQ 1PH, 1PM, 1PL
Synchronous motors
1FT6, 1FK7
1FE
1FW
1FN
0,09 – 1200 kW
3,7 – 160 kW
0,19 – 32,5 kW
4 – 103 kW
0,3 – 13800 Nm
23,6 – 750 Nm
0,4 - 175 Nm
5 – 820 Nm
6.000 rpm
12.000 rpm
6.000 rpm
40.000 rpm
430 rpm
520 m/min
self-ventilated
forced-ventilated water-cooled
natural convection
water-cooled
water-cooled
water-cooled
frame motor
frame motor frameless motor
frame motor
frameless motor
frameless motor
frameless motor
Synchronous Servo motors
Mounting spindle
Standard motors Norm motors
Asynchronous Servo motors
Low voltage motors
Main spindle motors
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 1 - 15
96 – 8570 Nm 150 – 10375 N
Torque motors
Linear motors
SITRAIN Training for Automation and Drives
System components / Modules in the power section
Training objectives: You are informed about • the electrical design of the powermodules • the options for 4Q-operation • the components for the modular design of the device types: - Booksize - Chassis / Cabinet segments • overload capability, cable lengths and attainable output voltage
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
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SITRAIN Training for Automation and Drives
System components / Modules in the power section Content
Page
Component overview, example SINAMICS S120............................................................................. Motor Module (Combination Booksize/Chassis possible on same CU320)........................................ Electrical design of the power modules............................................................................................. Pulse frequency / Active Line Module, Motor Module........................................................................ Overview of infeed units................................................................................................................... Electrical design of the power module S150..................................................................................... Active Line Module / Circuit design: Chassis.................................................................................... Electrical design of the power modules G130, G150......................................................................... Basic Line Module / Circuit design: Chassis..................................................................................... Smart Line Module / Circuit design: Chassis..................................................................................... DC-link components......................................................................................................................... DC-link components......................................................................................................................... DC-link connection........................................................................................................................... Electronic draw-out unit for chassis / Cabinet................................................................................... Current actual value sensing / Thermal model.................................................................................. System components on the motor-side............................................................................................. Overload capability of Booksize-units............................................................................................... Overload capability of Chassis-units................................................................................................. Multi-parallel operation of converters S120 / AIM,ALM + MoMo........................................................ Cable lengths................................................................................................................................... Overall cable lengths of Booksize-units (per motor).......................................................................... Attainable output voltage..................................................................................................................
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
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3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
SITRAIN Training for Automation and Drives
Component overview, example SINAMICS S120
• SINAMICS S120 solves complex drive tasks for a large range of industrial applications and is therefore designed as a modular system. • The user can choose from many harmonized components and functions to create a solution that best meets his requirements.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
SITRAIN Training for
06/03/2007 ABU DHABI: Page 2 - 3
Automation and Drives
Motor Module (Combination Booksize/Chassis possible on same CU320) Booksize Single MM 1.6 – 107 kW
Booksize Double MM 2x1.6 – 2x9.7 kW
Chassis
110 – 1405 kW
FS F
Booksize / special features
Diagnostic LEDs short circuit and earth fault proof integrated safety functions “Safe standstill” and ”Safe brake control“ integrated motor brake control (up to 132 A) 1
400V
FS G
Chassis
690V
85 – 1270 kW
FS H
sine filter 90-200 kW (400V/4kHz/SVM)
FS J dv/dt filter; VPL1 75-1200 kW
choke 75-1200 kW
Voltage Peak Limiter
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 2 - 4
SITRAIN Training for Automation and Drives
Electrical design of the power modules U, f = constant
U
U, f = variable
Udc
AC - DC
i.e. 3AC, 400V, 50 Hz
DC - AC
U
depending on line voltage or controlled
Rectifier
DC-link
Inverter
U1 V1 W1
U2 V2 W2
M
depending on line module
Line
Line Module
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
DC-link
Motor Module
Motor SITRAIN Training for
06/03/2007 ABU DHABI: Page 2 - 5
Automation and Drives
Pulse frequency / Active Line Module, Motor Module
2 kHz --> 500 µs Pulse width modulation / Active Line Module
Pulse width modulation / Motor Module
Framesize
Switching frequency Active Line Module
Switching frequency Motor Module
Current contr. sample time
F, G (400V)
4.0 kHz
2.0 kHz (.... 8.0 kHz)
250 μs
F, G (690V)
4.0 kHz
1.25 kHz (.... 5.0 kHz)
400 μs
H, J (400V)
2.0 / 4.0 kHz
1.25 kHz (.... 5.0 kHz)
400 μs
hing Switc
s losse
forma c per i m a Dyn
nce
1,25 pulse frequency (kHz) Booksize
8.0 kHz
SINAMICS Siemens AG 2007. All rights reserved.
2.5 / 4.0 kHz (.... 16 kHz)
Date: File:
8
400 / 250 μs
06/03/2007 ABU DHABI: Page 2 - 6
SITRAIN Training for Automation and Drives
Overview of infeed units Active Infeed
=
• Active Interface Module (AIM) • Active Line Module (ALM) Actively controlled IGBT rectifier
Infeed Infeed AC AC // DC DC
Smart Infeed
=
• Line connection with choke • Smart Line Module (SLM) Line commutated IGBT rectifier
Basic Infeed
=
• Line connection with choke • Basic Line Module (BLM) Line commutated B6-circuit rectifier
Properties Operating mode Line supply fluctuations Line feedback Harmonics Reactive power compens. available for
Basic Infeed 1Q operation / uncontrolled influence V_DC no to be considered no G130, G150 S120 (type-depending)
SINAMICS
Date: File:
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Smart Infeed 4Q operation, uncontrolled influence V_DC yes to be considered no S120 (type-depending)
Active Infeed 4Q operation, controlled are compensated yes can be neglected yes S150 S120 (type-depending)
SITRAIN Training for
06/03/2007 ABU DHABI: Page 2 - 7
Automation and Drives
Electrical design of the power module S150 U, f = constant
U
U, f = variable
Udc
AC - DC
i.e. 3AC, 400V, 50 Hz
Pre-charging
DC - AC
U
controlled to setpoint voltage
Rectifier
DC-link
U1 V1 W1
Inverter
U2 V2 W2
M
Motor
Line DC-link
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
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SITRAIN Training for Automation and Drives
Active Line Module / Circuit design: Chassis
Main features: Controlled rectifying / regenerating unit with IGBT technology Unrestricted regenerative operation Boost operation enables controlled DC-link voltage and sinusoidal line current Power factor control to obtain cos φ = 1
Chassis 400 / 690 V 132-900 / 560-1400 kW
Booksize 16 - 120 kW
Power block with IGBT‘s, DC caps Current transformer Electronic draw-out unit CIB, CU320 Fan FS J
SINAMICS
Date: File:
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SITRAIN Training for
06/03/2007 ABU DHABI: Page 2 - 9
Automation and Drives
Electrical design of the power modules G130, G150 U, f = constant
U
U, f = variable
Udc
AC - DC
i.e. 3AC, 400V, 50 Hz
constant
U
appr. 1,35 * 400V = 540V DC
Pre-charging
U1 V1 W1
DC - AC
Rectifier
DC-link
RVL
Inverter
U2 V2 W2
M RVL
Line
Motor DC-link
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
Braking Chopper
06/03/2007 ABU DHABI: Page 2 - 10
SITRAIN Training for Automation and Drives
Basic Line Module / Circuit design: Chassis
Main features:
Chassis 400 / 690 V 200-710 / 250-1100 kW
Booksize under prep.
Line commutated rectifier unit with thyristor technology (B6 circuit) No line feedback possible
Thyristors and Thyristor control Power block
S120 chassis and cabinet segments with pre-charging by means of firing angle control.
Slot for CU320, electronic draw-out unit Fan
S120 Booksize and G130/G150 with pre-charging via diode rectifier and pre-charging resistors.
Fan fuses FS G
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06/03/2007 ABU DHABI: Page 2 - 11
Automation and Drives
Smart Line Module / Circuit design: Chassis Smart Line Module
Line supply
DC+
T1
u1
u2
LN
LN
LN
LN
LN
LN
T2
D2
T3
D3
Cd
EMC basic suppression
u3
3 AC 380-690V 50/60Hz
D1
(for bypass contactor precharging line choke line fuses)
T4
D4
T5
D5
T6
D6 DC-
Line connection
Main features: Uncontrolled rectifying / regenerating unit with IGBT technology The use of IGBT modules prevents commutation failure as consequence of line supply failure
Chassis 400 / 690 V 140-800 / 132-1400 kW
Booksize 5, 10 kW
Power block with IGBTs, DC-capacitors Current transformer Electronic draw-out unit CIB, CU320 Fan FS H
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 2 - 12
from 06/2006 SITRAIN Training for Automation and Drives
DC-link components Braking Module and Braking resistors Module operates autonomously When triggered, the DC-link energy is dissipated into heat via external braking resistor. Two braking resistors are available: Booksize: 0,3 kW continuous braking power (25 kW peak braking power) 1,5 kW continuous braking power (100 kW peak braking power)
Chassis:
25 kW continuous braking power (125 kW peak braking power) 50 kW continuous braking power (250 kW peak braking power)
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 2 - 13
SITRAIN Training for Automation and Drives
DC-link components Braking Module and Braking resistors Module operates autonomously When triggered, the DC-link energy is dissipated into heat via external braking resistor. Two braking resistors are available: Booksize: 0,3 kW continuous braking power (25 kW peak braking power) 1,5 kW continuous braking power (100 kW peak braking power) Chassis: 25 kW continuous braking power (125 kW peak braking power) 50 kW continuous braking power (250 kW peak braking power)
Capacitor Module Increases the DC-link capacity to cover up for short time line supply interruptions and to better tolerate regenerative operation
Control Supply Module Generates the 24 VDC supply from the line or from the DC-link voltage
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 2 - 14
SITRAIN Training for Automation and Drives
DC-link connection 24V terminal adapter
Direct DC-supply 24V
DC-connection for chassis
DC-link bus bar 2DC
Line Module
Motor Module
Motor Module Motor Module
DC connection for Chassis-units 3-stage isolator switch with two switch positions ( 0 / 1 ) 0= Off isolator contacts are open 1= Pre charging pre charging resistor is switched on; pre charging is completed after about 2.5 s Operation with the on command for the Motor Module the third switching position is automatically activated
SINAMICS
Date: File:
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SITRAIN Training for
06/03/2007 ABU DHABI: Page 2 - 15
Automation and Drives
Electronic draw-out unit for chassis / Cabinet Fib re-o ptic
3a
2
Powersupply
3 3b
3 DRIVE-CLiQ sockets
1
3 Communication Interface board 3a Adaptation Interface board 3b Power Stack Adapter
CIB AIBO PSA
Base plate
(shunts, limit value monitoring) (generation of the inverter pulse pattern)
Extended functionality of the CIB-FW starting with V2.3 and CIB-MLFB ...-3 (starting with HW-version M): edge triggered modulation / safe stop / parallel operation of power sections up to 4xLM and 4xMM per CU320
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 2 - 16
SITRAIN Training for Automation and Drives
Current actual value sensing / Thermal model Current actual value sensing Powerstacks of the SINAMICS Motor Modules detect all three output phase currents A fault current is detected through summation (earth fault monitoring) The current transformer (CT) calibration is performed in the factory by means of shunt resistors and powerstack data on the CIB board.
Thermal model The converter‘s thermal protection is activated when the rated current is exceeded over a longer period of time or when the heat sink temperature becomes too high. This leads to a failure shut down or to an automatic influence of the control (reduction of pulse frequency or of current limit) to reduce the converter‘s thermal load.
SINAMICS
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SITRAIN Training for Automation and Drives
System components on the motor-side Motor reactors
dv/dt – filter
Sine filter
SINAMICS Siemens AG 2007. All rights reserved.
Limiting of capacitive charging-, discharging currents Reduction of voltage gradient dv/dt Typical uk about 1,5 % For Motor Modules of power ratings 75 – 1200 kW Limiting of voltage gradient to values < 500 V/µs Limiting of phase-to-phase voltage to the value of the DC-link voltage For Motor Modules of power ratings 75 – 1200 kW
Provides near sinusoidal motor voltage (voltage noise 5 – 7%) Only for space vector modulation; in consequence only 90 % motor voltage as compared to “no sine filter” Required pulse frequency of the Motor Module: 4 kHz For voltage range 660 – 690 V not available For Motor Modules of power ratings 90 – 200 kW Date: File:
06/03/2007 ABU DHABI: Page 2 - 18
SITRAIN Training for Automation and Drives
Overload capability of Booksize-units
S6 duty cycle with base load
S1 operation with overload
Catalogue D21.2 / chapter 2 duty cycle without base load
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06/03/2007 ABU DHABI: Page 2 - 19
Automation and Drives
Overload capability of Chassis-units Small overload at base load current IL 150 % for 10 sec resp. 110 % for 60 sec Example
High overload at base load current IH 160 % for 10 sec resp. 150 % for 60 sec
I L*150%
ohne G1_kurz G1_lang G2_kurz G2_lang I *160% H Überlast 150% 110% 170% 150% I_G, A 320 280I H*150% 330 320 280 Zeit_2, s 300 290 240 290 240 I_Max, A 0 480 352 476 420 Zeit_1, s 0 10 60 10 60 I L*110% I_N, A 330 327 327 289 313
(700A)
(500A)
I N_eff IL 300 s 10
60
300 s 300
10
Values for IL and IH taken from catalogue
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
60
without overload I_B, A 330 Time_2, s 300 I_Max, A 0 Time_1, s 0 I_N, A 330
06/03/2007 ABU DHABI: Page 2 - 20
IH 300
IL_short 150% 320 290 480 10 327
IL_long 110% 320 240 352 60 327
T [sec.]
IH_short 160% 280 290 448 10 287
IH_long 150% 280 240 420 60 313
SITRAIN Training for Automation and Drives
Multi-parallel operation of converters S120 / AIM,ALM + MoMo
Infeed units
Active Infeeds AIM+ALM Current balance control is
Decoupling reactors Infeed 1
Infeed 2
provided Infeed 4
Symmetrical wiring of power
Infeed units in parallel
cables is recommended
Decoupling by means of reactors of the Clean Power Filter rsp. motor reactors Current derating in parallel operation (5% as compared to a single unit ALM)
Control Unit
CU320 CU320
MoMo 1
MoMo 2
MoMo 4
Motor Modules MoMo Current balance control is
Motor modules In parallel
provided
Decoupling reactors Motor connection 690V / 5600 kW
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
06/03/2007 ABU DHABI: Page 2 - 21
SITRAIN Training for Automation and Drives
Cable lengths DRIVE-CLiQ cables
70 m 100 m 50 m
Standard within the cabinet MOTION-CONNECT 500 MOTION-CONNECT 800
Power cables Chassis / Cabinet - Any combination (without / with reactor; without / with sine-filter without / with dv/dt-filter 1) ) screened 300 m (525 m) 2) unscreened 450 m (785 m) 2)
Sensor cables
SMC10 - sensor:
resolver
SMC20 - sensor: SMC30 - sensor:
Sin/Cos, absolute HTL, TTL HTL with A+/A- ..
130 m for 2-pole resolvers: 50 m for multi pole resolvers: 100 m 100 m 300 m
1) with “dv/dt-filter + VPL” (Voltage Peak Limiter) as output filter 2) with two reactors in series; second reactor possible only outside the cabinet
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 2 - 22
SITRAIN Training for Automation and Drives
Overall cable lengths of Booksize-units (per motor) Cable length Rated current
50 m
100 m
150 m
3A, 5A
always allowed
use 9A module
9A
always allowed
use 18A module
always allowed
18A
max. 150% Irated (continuous max. 95% Irated)
200 m
>=250 m
not allowed use 30A module
use 30A module always allowed
always allowed
max. 135% Irated (continuous max. 90% Irated)
max. 110% Irated (continuous max. 85% Irated)
always allowed
always allowed
max. 175% Irated (continuous max. 90% Irated)
max. 150% Irated (continuous max. 85% Irated)
always allowed
always allowed
max. 135% Irated (continuous max. 95% Irated)
max. 110% Irated (continuous max. 90% Irated)
always allowed
always allowed
max. 125% Irated (continuous max. 95% Irated)
max. 110% Irated (continuous max. 90% Irated)
30A
45A, 60A
85A, 132A
200A
not allowed
With Active Line Module and high efficiency line reactor: overall length of all power cables = 1000 m
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
06/03/2007 ABU DHABI: Page 2 - 23
SITRAIN Training for Automation and Drives
Attainable output voltage The maximum output voltage is defined by the DC-link voltage and the inverter modulation depth. The DC-link voltage level depends on the Line Module used in the application. For Basic Line Module and Smart Line Module and for G130/G150 : V.DC = 1.32...1.41 * V.Line
with p0210 = 380 – 480 VAC
For Active Line Module / Booksize : V.DC = 600 VDC with p0210 = 380 – 400 VAC / Active Mode [V.DCÆp3510] V.DC = 625 VDC with p0210 = 401 – 415 VAC / Active Mode [V.DCÆp3510] V.DC = 1.32...1.41 * U.Line with p0210 = 416 – 480 VAC / Smart Mode p3510 = 1.42 up to 2.0 * p0210 For Active Line Module / Chassis and for S150 : V.DC = 1.5 * V.Line
with p0210 = 380 – 480 VAC / p3510 = 1.42 up to 1.6 * p0210
The maximum modulation depth that can be set is defined by the “operation type” of the Motor Module. For “operation type” Servo (S120 / only space vector modulation) V.out max.rms = 0.67 * V.DC For “operation type” Vector (S120, G150, S150 / space vector mod. and edge triggered mod.) V.out max.rms = 0.72 * V.DC
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
> FW V2.3 and CIB-MLFB ….-3 (HW-version > M)
06/03/2007 ABU DHABI: Page 2 - 24
SITRAIN Training for Automation and Drives
System components / DRIVE-CLiQ and electronic modules
Training objectives: You are informed about • the internal drive bus DRIVE-CLiQ • the electronic modules • the operating types, the software architecture and its functions
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
SITRAIN Training for
06/03/2007 ABU DHABI: Page 3 - 1
Automation and Drives
System components / DRIVE-CLiQ and electronic modules Content
Page
Component overview SINAMICS S120 ............................................................................................ Connection of components via communication................................................................................. DRIVE-CLiQ connections (example: S120 Booksize-units)............................................................... DRIVE-CLiQ connections (example: Cabinet-unit S150)................................................................... DRIVE-CLiQ connection cable......................................................................................................... Electronic rating plates..................................................................................................................... “Must“ Rules for DRIVE-CLiQ Connections (generally)..................................................................... “Can“ rules for DRIVE-CLiQ connections.......................................................................................... “Must“ rules for DRIVE-CLiQ connections (additionally for Chassis)................................................. Multi-drive configuration / example Booksize-unit........................................................................... Control Units of the SINAMICS family.............................................................................................. Control Unit CU320.......................................................................................................................... Motion Control with SINAMICS S120 and SIMOTION C or P............................................................ Combination of SIMOTION and SINAMICS S120............................................................................. Control Units of the “SINAMICS-integrated“ family............................................................................ Direct means of communication / BOP20....................................................................................... Direct means of communication / AOP30.......................................................................................
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
continued on page 3
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 3 - 2
SITRAIN Training for Automation and Drives
System components / DRIVE-CLiQ and electronic modules Content Page Extension modules for Control Units................................................................................................. 21 Terminal-modules for SINAMICS and SIMOTION D......................................................................... 22 Properties of Terminal-Modules TMxx.............................................................................................. 23 Sensor Module (SMC)...................................................................................................................... 24 Connection of encoders................................................................................................................... 25 Modular software-architecture.......................................................................................................... 26 Drive objects.................................................................................................................................... 27 Configuration, Topology tree, Objects and Components................................................................... 28 Access to information and functions of objects.................................................................................. 29
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
SITRAIN Training for
06/03/2007 ABU DHABI: Page 3 - 3
Automation and Drives
Component overview SINAMICS S120
• SINAMICS S120 solves complex drive tasks for a large range of industrial applications and is therefore designed as a modular system. • The user can choose from many harmonized components and functions to create a solution that best meets his requirements.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 3 - 4
SITRAIN Training for Automation and Drives
Connection of components via communication ET 200
Controller
PG/PC
HMI
CPU 317T-2 DP
PROFIBUS / PROFINET SITOP DRIVE-CLiQ DC 24 V
Line filter
ET 200S 3AC 380 ... 480 V
3AC 0 …360V
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06/03/2007 ABU DHABI: Page 3 - 5
Automation and Drives
SMC10/ SMC20
Motor Module
Motor Module
Motor Module
Motor Module
CU320
Line Module
DRIVE-CLiQ connections (example: S120 Booksize-units)
SMC30
TM31
Digital/Analog Interface
Motor with DRIVE-CLiQ Interface
Motor without DRIVE-CLiQ Interface
DRIVE-CLiQ Encoder
Conventional Encoder (TTL/HTL)
All components connected to the CU320 via DRIVE-CLiQ operate with firmware of their own. If required the component firmware can be updated from the CF-card of the CU320.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 3 - 6
SITRAIN Training for Automation and Drives
DRIVE-CLiQ connections (example: Cabinet-unit S150)
VSM
CIB ALM
CU320
Active Line Module
SINAMICS
SMC
Motor Module
Date: File:
Siemens AG 2007. All rights reserved.
CIB MM
TM31
Both power units (ALM, MM) are controlled from one CU320 via module CIB through the internal drive bus DRIVE-CLiQ.
06/03/2007 ABU DHABI: Page 3 - 7
SITRAIN Training for Automation and Drives
DRIVE-CLiQ connection cable „Drive Component Link with Intelligence Quotient“
DRIVE-CLiQ
The new connection to link drive components is based on the worldwide spread Ethernet technology with 100 Mbps.
Additionally to the standard Ethernet connections, the extended RJ45 plugs and sockets provide two additional contacts to distribute the 24 VDC voltage.
The Control Unit CU320 contains a database with “electronic rating plates“: during booting the Control Unit recognizes the components that are connected via DRIVE-CLiQ; it is no longer necessary to input the rating plate data input manually.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 3 - 8
SITRAIN Training for Automation and Drives
Electronic rating plates
• All the components connected via DRIVECLiQ have an electronic rating plate. • The respective technical data are automatically loaded to the Control Unit. • A manual input of the rating plate data is no longer necessary.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 3 - 9
SITRAIN Training for Automation and Drives
“Must“ Rules for DRIVE-CLiQ Connections (generally)
maximum of 8 components in series, maximum of 16 per port, maximum of 198 per CU320 (via HUB-multiplier DMC20)
no ring wiring, no double wiring
only one Active Line Module per Control Unit CU320 (parallel operation excepted)
Double Motor Modules count as two single components
maximum of 9 Sensor Modules
Mixed operation of “Servo” and “Vector” on separate ports
Active Line Module + Motor Module “Vector” on separate ports (typically)
The compliance with the ”must“ rules is a condition for faultless operation SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 3 - 10
SITRAIN Training for Automation and Drives
“Can“ rules for DRIVE-CLiQ connections CU 320
CU 320
Active Single Single Motor Motor Line Module Module Module
Active Single Double Motor Motor Line Module Module Module
X203
X2: motor 2 X1: motor 1 X500
X500
X500
X500
X500
X500
Encoder for motor 1 Encoder for motor 2
• Motor Modules may always be continued from port X201 to port X200 • Sensor Module or DRIVE-CLiQ motor should be on corresponding Motor Module port X202 • Double Motor Modules: Sensor Module or DRIVE-CLiQ motor assigned to corresponding Motor Module FW2.3: • Active Line Module and Motor Modules in operation type Servo can be operated in line topology (X201 – X200 / X201 – X200)
FW2.1 / 2.2: • Active Line Module and Motor Module on separate CU-Ports • On Active Line Module no further components
The compliance with the “can“ rules allows an automatic topology configuration SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06/03/2007 ABU DHABI: Page 3 - 11
Automation and Drives
“Must“ rules for DRIVE-CLiQ connections (additionally for Chassis) S150
Active Line Module
Drive 1
Control Unit
Drive 2
X400
X100
X400
X400
X400
X401
X101
X401
X401
X401
Active Line Module
X102
Single Motor Module
Single Motor Module
Single Motor Module
X402
X402
X402
X402
250 µs
X103
Control Unit
X500
X500
Sensor Module
S120 Chassis
400 µs
400 µs
250 µs (400 µs)
Drive 3
X500
Sensor Module
X500
Voltage Sensing Module
M 3~
M 3~
M 3~
Active Interface Module
Chassis FS F or G
Chassis FS H or J
Chassis FS H or J
Sensor Module
- Active Line Module and drives on different ports in operating types “Vector“ or “mixed“ - Within a DRIVE-CLiQ branch only one current controller cycle time rsp. an integer multiple - Voltage Sensing Module on port X402 of the Active Line Module (Æ S120 comm. manual 2-33ff)
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 3 - 12
SITRAIN Training for Automation and Drives
Multi-drive configuration / example Booksize-unit number of motors 6
FW 2.3 number of axes
+
5
current speed controller controller
6 Servo
125μs
125μs
2 Vector
250μs
1000μs
4 Vector
400μs
1600μs
6 V/Hz
400μs (limit+comp)
10 V/Hz
500μs (limit+comp)
4
3
Low / Vector – Vector Medium / Vector – V/Hz
Medium / Servo Low / Vector – V/Hz
2
5 Servo and V/Hz (mixed types)
Medium / Vector – Vector 1
number of axes includes Active Line Module
100
55 ALM
CU-load [%] On exceeding 55% CU-load a performance-extension is required SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06/03/2007 ABU DHABI: Page 3 - 13
Automation and Drives
Control Units of the SINAMICS family SINAMICS G110:
CPM110 V/Hz
SINAMICS G120:
CU220 (DP) V/Hz
CU230 (DP)
CU240 (DP) (F)
V/Hz+ FCC
Vector
ET200S-FC: ICU2x (F) SIEMENS
PM-E
SF
4 DI
4 DI
2 DO
2 DO
2 AI
PM-D FX1
xB1
IPM25
SF
BF ON FRCE RUN STOP ICU24F
IM 151 CPU
PWR
SG1
SG2
Stat
SG4 SG5
SG6
DC LINK ON 1 5
2 2
1 6
2 3
2 6 1 3
SINAMICS S120:
CU310
(AC/AC Powerblocks) DP
PN
CU310
SINAMICS G130: SINAMICS G150: SINAMICS S120:
CU320 CUA31
SINAMICS S150: SINAMICS GM150:
CU320 BOP20
SINAMICS SM150:
SINAMICS Siemens AG 2007. All rights reserved.
CUA31 CUA31
PM340
CU adapter for S120 AC/AC
D445 + CX32 Date: File:
06/03/2007 ABU DHABI: Page 3 - 14
SITRAIN Training for Automation and Drives
Control Unit CU320 44 DRIVE-CLiQ DRIVE-CLiQ ports ports for for communication communication with with further further drive drive components: components: Active Active Line-, Line-, Motor Motor Module; Module; Terminal-, Terminal-, Sensor Sensor Module Module
Mounting Mounting device device Integrated Integrated side side mounting mounting slot slot
88 digital digital inputs inputs 88 bidirectional bidirectional DI/DO DI/DO (6 (6 of of which which as as fast fast DI: DI: 5µs) 5µs)
Cover Cover 44 “3-coloured” “3-coloured” status status LEDs LEDs
24VDC 24VDC input input for for electronic electronic power power supply supply
33 measuring measuring sockets sockets to to observe observe signal signal values values
Option Option slot slot for for interface interface extension extension (TB30, (TB30, CBP10, CBP10, CBC10, CBC10, CBE30) CBE30)
V02.02.01
Compact Compact Flash Flash Card Card for for the the software software and and for for parameter parameter settings settings
PROFIBUS PROFIBUS DP DP interface interface
PROFIBUS PROFIBUS address address switch switch below below cover; cover; connection connection for for BOP20 BOP20 (basic (basic operator operator panel) panel)
RS232/PPI RS232/PPI interface interface for for AOP30; AOP30; HyperTerminal HyperTerminal
The Control Unit CU320 manages the communication, operation and control functions for one or several Motor Modules and one Active Line Module if equipped. Control Units CU320 are generally designed for multi-axis operation.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 3 - 15
SITRAIN Training for Automation and Drives
Motion Control with SINAMICS S120 and SIMOTION C or P
oder
Ethernet
SINAMICS S120 with SIMOTION C or P
SINAMICS S120 in SIMOTION D435
The modular platform principle extends into the fusion of Drive and Motion Control functionality (SINAMICS S120 and SIMOTION) into one single component (D425, D435, D445).
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 3 - 16
SITRAIN Training for Automation and Drives
Combination of SIMOTION and SINAMICS S120 DRIVE-CLiQ
11
10
SIMOTION C230 for max. 16 SIMOTION axes
SIMOTION D445 for max. 16 SIMOTION axes
SINAMICS S120 with CU320; each for typically 6 axes
SINAMICS integrated typ. 6 axes
12
CX32 each for typ. 6 axes
3 4
SIMOTION D435 for max. 16 SIMOTION axes
SINAMICS S120 with CU320; each for typically 6 axes
SINAMICS integrated typ. 6 axes
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
5
SITRAIN Training for
06/03/2007 ABU DHABI: Page 3 - 17
Automation and Drives
Control Units of the “SINAMICS-integrated“ family Drive based SIMOTION D:
D 425
CX32
Drive
Drive
CX32
Drive
D 435
CX32
Drive
CX32
Drive
Simotion Runtime
D 445 Simotion Runtime
Simotion Runtime Drive Drive
Drive based SINUMERIK (Solution Line):
NCU 710
BOP20
NCU 730
NC-Kernel / HMI / PLC
NC-Kernel / HMI / PLC
NX10
Drive
NX10
Drive
NX10
Drive
NX10
Drive
NX10
Drive
NX10
Drive
Drive
NCU 720
NX10
Drive
NC-Kernel / HMI / PLC Drive
Drive
NX10
Drive
6 DRIVE-CLiQ
Panel based SINUMERIK (Solution Line):
SINAMICS Siemens AG 2007. All rights reserved.
Technology max. 31 axes
8 DRIVE-CLiQ
802DSL
840DISL
Drive
MCI 2
Date: File:
Drive
CU320
06/03/2007 ABU DHABI: Page 3 - 18
CU320
CU320
i.e. 6 axes (Medium / Servo)
SITRAIN Training for Automation and Drives
Direct means of communication / BOP20
active drive in state RUN
selection and indication of drives in fault condition identification of BICO-inputs: bi, ci BICO-outputs: bo, co
active drive object
BICO-source of an object other than currently active
indication of parameters, indices, values, faults, alarms
S request to save in non-volatile memory Fn
P
P
acknowledgeable parameter
C request to initiate an internal system routine
function depends on current indication
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06/03/2007 ABU DHABI: Page 3 - 19
Automation and Drives
Direct means of communication / AOP30 Main menu
Operating menu F1 help
Parameterization • pending faults • pending alarms • help texts • history
Fault & alarm memory Comm. / Service Language
Status indication via LEDs ¾ On green ¾ Alarm yellow ¾ Fault red
Function buttons with menu controlled function assignment Numeric keypad
¾ ¾ in in operating operating mode mode “Local“ “Local“ the the control control priority priority is is assigned assigned to to the the AOP30 AOP30 ¾ ¾ any any other other access access in in operating operating mode mode “Remote” “Remote”
Access Access ¾ ¾ key key Local/Remote Local/Remote Æ Æ Local Local ¾ access “Local“ can be ¾ access “Local“ can be blocked blocked
SINAMICS Siemens AG 2007. All rights reserved.
Drive control ¾ Local / Remote ¾ On, Off ¾ Reversing ¾ Inching, Up, Down
Date: File:
06/03/2007 ABU DHABI: Page 3 - 20
SITRAIN Training for Automation and Drives
Extension modules for Control Units Terminal Board TB30
CU320 D425, D435, D445
Digital In/outputs: 4 DI, 4 DO
Analog In/outputs: 2 AI, 2 AO, i.e. for analog setpoint interface
Communication Boards
CAN-Bus interface with CAN protocol according to CANopen drive profile CBC10
Second PROFIBUS interface CBP10
PROFINET (IRTE)
CBE20 (for CU320) CBE30 (for D4xx)
TB30
CBC10, CBP10
SINAMICS CU320
SIMOTION D4xx
CBE 20
CBE 30
yes
yes
Device TCP, RT, IRT
Controller TCP, UDP, RT, IRT
CBE20, CBE30
IRTE = Isochronous Real Time Ethernet
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 3 - 21
SITRAIN Training for Automation and Drives
Terminal-modules for SINAMICS and SIMOTION D
Terminal Module TM31 and TM41
Terminal Module TM15 and TM17 High Feature
Terminal module TM31 offers a large number of additional I/O and a PTC/KTY interface.
Extension for additional DI/DO, probes and cams (with 1µs resolution on TM17).
For SINAMICS cabinet-units it serves as central customer interface for digital and analog in- and outputs.
Module TM17 can only be used in conjunction with SIMOTION D4xx, as cam and probe functions are programmed by means of SIMOTION technology objects.
Terminal module TM41 additionally offers an encoder-emulation (for any signal source).
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 3 - 22
SITRAIN Training for Automation and Drives
Properties of Terminal-Modules TMxx TM15
24 bidirectional digital channels
TM17
16 bidirectional digital channels
TM41
1 analog input 4 digital inputs 4 bidirectional digital channels encoder emulation
TM31
2 analog inputs 2 analog outputs 8 digital inputs 4 bidirectional digital channels 2 contactor outputs temperature sensor evaluation PTC, KTY84
AA / n.set
AI / X523
INC s.act
INC / X520
analog control
r4055
n.set / p1055
speed controller
r0479
position actual
filter / dead time / no. of increments p4420
encodersignals
TM41
CU320
filter / dead time / no. of increments encodersignals
INC / X520
p1155
any setpoint
TM41 SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
06/03/2007 ABU DHABI: Page 3 - 23
SITRAIN Training for Automation and Drives
Sensor Module (SMC) Sensors and sensor modules: • Incremental encoder sin/cos 1 Vpp TTL/HTL • Absolute value encoder EnDat • Resolver - multi pole - 2-pole • Motors with DRIVE-CLiQ interface (EWN-range)
4) same number of poles as motor
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 3 - 24
SITRAIN Training for Automation and Drives
Connection of encoders SMI20
Faster and more simple commissioning with SMI • Automatic identification of motor and encoder • Storage of the data of the equivalent circuit diagram and encoder in the motor
direct position measurement
1
SME20
1
Integration of direct position measurement systems • Use of measurement systems with DRIVE-CLiQ interface • Use of SMC/SME modules for signal conversion to DRIVE-CLiQ
SMC20
Integration and parameterization of third party encoders and motors • Integration via SMC/SME modules • Parameterization by graphical masks
3 2
SMC20 Sensor Module for encoder evaluation SMI 20
Sensor Module with integrated DRIVECLiQ connection (as external encoder or built into the motor)
SME20
Sensor Module for encoder evaluation (like SMC20, with higher protection level)
1
SMI20
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06/03/2007 ABU DHABI: Page 3 - 25
Automation and Drives
Modular software-architecture PROFIBUS synchronous terminals
multi-drive operatingsystem
measuring sockets
communication
DRIVE-CLiQ connection scheme
drive object n – TM31 drive object 2 – Servo / axis 2 drive object 1 – Servo / axis 1 TM
motorpotentiometer
setpointchannel
ramp function generator
closed loop control
MM
MM
M
M
control
UP
x
&
x
DN
Bpos / Free functions DCC
B
faults
TM31 functiongenerator
trace
Servo axis
safety
external sensor
B
components
A
drive device
drive object m – CU320
objects
drive device The modular software-architecture offers a very high degree of flexibility
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 3 - 26
SITRAIN Training for Automation and Drives
Drive objects CU320
ALM
drive objects i.e. SINAMICS S150
MM
X103 X102
X402
X402
TM31
TM31
X101
X401
X401
X501
X501
X100
X400
X400
X500
X500
4
5
VSM
1
SMC
M Netz X500
~
2
X500
3
A Drive object is an independent and autonomous software functionality with its own parameters, faults and alarms.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
SITRAIN Training for
06/03/2007 ABU DHABI: Page 3 - 27
Automation and Drives
Configuration, Topology tree, Objects and Components Configuration
“Wiring” of components
Parameters for the component number p0121[P]: Power unit p0131[M]: Motor p0141[E]: SMx p0142[E]: Encoder p0151 TM31 p0161 TB30
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
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SITRAIN Training for Automation and Drives
Access to information and functions of objects
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Date: File:
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SITRAIN Training for Automation and Drives
Commissioning with AOP30 Training objectives: You are able to • commission the drive with the AOP30 • parameterize the setpoint channel using the function diagrams • configure the internal cabinet interface and the customer interface • save the parameterization on the CF card • recreate the factory settings • manage relevant data on the CF card
SINAMICS Siemens AG 2007. All rights reserved.
V02.01.01
RAM
Date: File:
SITRAIN Training for
06/03/2007 ABU DHABI: Page 4 - 1
Automation and Drives
Commissioning with AOP30 Content
Page
AOP30 Overview.............................................................................................................................. Start menu....................................................................................................................................... Status indication, parameterization and diagnosis with the AOP30................................................... Status indication, parameterization and diagnosis with the AOP30................................................... Object-scheme of parameters.......................................................................................................... Selection and ”Reading” of parameters (i.e. topology request).......................................................... Basic commissioning........................................................................................................................ Entering parameter values (example: motor data)............................................................................ Selection of pre-assignment macros / Final acknowledgement......................................................... Pre-assignment of command- and setpoint-sources starting with SW 2.1......................................... Selection and indication of Command Data Sets.............................................................................. Drive Data Sets (DDS) / Motor Data Sets (MDS).............................................................................. Overview of available command sources (p0700) starting with SW 2.1............................................. Pre-assignment of command sources.............................................................................................. Connection (”wiring“) of signals........................................................................................................ Binectors and connectors................................................................................................................. Overview of available setpoint sources (p1000) starting with SW 2.1................................................
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
continued on page 3
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SITRAIN Training for Automation and Drives
Commissioning with AOP30 Content Page Control via terminals / TM31 (customer interface)............................................................................ 21 Command via terminals / TM31 [631].............................................................................................. 22 Internal Interface of the CU320......................................................................................................... 23 Pre-assignment of the internal interface of the CU320 ..................................................................... 24 Pre-assignment of the internal interface of the CU320...................................................................... 25 Motor identification........................................................................................................................... 26 Volatile and non-volatile memory...................................................................................................... 27 Save and restore parameter sets..................................................................................................... 28 Structure of the Compact Flash Card (S120).................................................................................... 29 Additional parameterization in commissioning the ALM (S150)......................................................... 30 Additional parameterization when using an encoder......................................................................... 31
SINAMICS
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SITRAIN Training for Automation and Drives
AOP30 Overview Each SINAMICS cabinet unit is equipped with a graphics-capable display offering following features: ¾ easy-to-use menu for guided commissioning of the drive ¾ plain text and bar-graphics indication to read process values ¾ LEDs for the indication of operating status ¾ help functions with descriptions of causes and remedies of alarms and faults ¾ control of the drive from AOP via LOCALREMOTE selection ¾ multilingual
Status indication via LEDs ¾ On green ¾ Alarm yellow ¾ Fault red
Function buttons with menu controlled function assignment Numeric keypad
¾ ¾ in in operating operating mode mode “Local“ “Local“ the the control control priority priority is is assigned assigned to to the the AOP30 AOP30 ¾ ¾ any any other other access access in in operating operating mode mode “Remote” “Remote”
Access Access ¾ ¾ key key Local/Remote Local/Remote Æ Æ Local Local ¾ access “Local“ can be ¾ access “Local“ can be blocked blocked
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Drive control ¾ Local / Remote ¾ On, Off ¾ Reversing ¾ Inching, Up, Down
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SITRAIN Training for Automation and Drives
Start menu
S
Offline Online Save please
Commissioning F1
F2
F3
F4
F5
The The power power supply supply is is switched switched on on for for the the first first time time after after delivery. delivery.
S
Controlling Parameterizing Diagnosing The The power power supply supply is is switched switched on on after after previous previous commissioning; commissioning; the the drive drive is is ready ready to to be be switched switched on. on.
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SITRAIN Training for Automation and Drives
Status indication, parameterization and diagnosis with the AOP30 ¾ Indication of the operating status and of significant actual values either in numerical values or by analog-like bar graphic ¾ Display type of the operating mask can be defined at will (values, bar graphic, combi)
¾ Well-structured menu for easy access to drive and service functions ¾ Integrated wizard for initial commissioning and optimization
¾ Clear text messages of alarm and fault conditions ¾ Help functions with descriptions of causes and remedies for alarms and faults
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SITRAIN Training for Automation and Drives
Menu structure of the AOP30 DO-selection
SINAMICS G/S150, SW V2.4
1: CU_GM
Main menu
Operating menu
2: B_INF 3: VECTOR_MV
F1
etc.
r0001 = ……. r0002 = ……. r0003 = ……. etc.
help individual “Drive Object“
Parameterization • pending faults • pending alarms • help texts • history
Fault & alarm memory
all “Drive Objects“ data set selection save parameters permanently
store in Compact Flash Card
Comm. / Service Language commissioning / drive commissioning / unit AOP30-settings
p0010 = ……. basic commissioning complete commissioning motor identification reset fan runtime p0009 = 1 ... 30 copy “CFC Æ RAM“
AOP30-diagnostics control settings
access access levels levels without without key key code: code: 11 :standard :standard // 22 :: extended extended // 33 :: expert expert access access levels levels with with key key code: code: 44 :: service service // code: code: AOP30 AOP30 == 2816, 2816, STARTER STARTER == 37483 37483
SINAMICS
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SW, data bank
display settings
battery
operating masks
keypad
date / time
LED-test
AOP default settings
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SITRAIN Training for Automation and Drives
Object-scheme of parameters Parameterization
individual “Drive Object“ all “Drive Objects“ data set selection save param. permanently DO-selection
r0002 CU_GM
1: CU_GM
r0002 B_INF
2: B_INF
r0002 VECTOR
3: VECTOR_MV
r0002 TM31_1
etc.
etc.
Each Each object object has has its its own own specific specific parameters parameters IfIf an an individual individual object object is is selected selected only only parameters parameters of of this this object object are are shown shown IfIf all all objects objects are are selected, selected, identical identical parameters parameters may may be be listed listed for for several several objects. objects. The The object object belonging belonging to to the the highlighted highlighted parameter parameter is is indicated indicated on on the the upper upper left. left.
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SITRAIN Training for Automation and Drives
Selection and ”Reading” of parameters (i.e. topology request) Selection Selection of of aa parameter parameter via via -- ”scrolling” ”scrolling” with with keys keys ”higher ”higher // lower” lower” -- direct direct entry entry of of the the parameter parameter number number and and acceptance acceptance with with
On On confirmation confirmation of of the the indicated indicated parameter parameter (with (with ) ) the the values values of of its its indices indices are are shown shown
In In case case of of bit-coded bit-coded values values aa more more detailed detailed explanation explanation of of the the individual individual bits bits is is listed listed after after selection selection of of
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SITRAIN Training for Automation and Drives
Basic commissioning
During During initial initial commissioning, commissioning, motor motor data data have have to to be be entered entered using using the the operator operator panel. panel. Use Use the the data data shown shown on on the the motor motor rating rating plate. plate.
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SITRAIN Training for Automation and Drives
Entering parameter values (example: motor data) The The first first menu menu requests requests the the selection selection of of the the preferred preferred type type of of entry entry of of the the motor motor data data in in kW kW (IEC) (IEC) or or hp hp (NEMA). (NEMA). Change Change the the value value with with . Select the line with // .
Acknowledge Acknowledge the the selection selection with with Enter Enter the the motor motor data data as as per per rating rating plate. plate. BE BE SURE SURE to to enter enter the the correct correct motor motor current current (in (in case case of of sensorless sensorless vector vector control control as as defaulted defaulted up up to to 60% 60% of of the the parameterized parameterized motor motor current current are are forced forced into into the the motor). motor).
Changeover Changeover to to the the next next menu menu after after selection selection of of ”Continue” with
”Continue” with
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SITRAIN Training for Automation and Drives
Selection of pre-assignment macros / Final acknowledgement
F1
F2
F3
F4
F5
Starting Starting with with SW SW V2.1 V2.1 p0700: pre-assignment p0700: pre-assignment of of command command sources sources 5: 5: S/G150 S/G150 PROFIBUS PROFIBUS 6: 6: S/G150 S/G150 TM31 TM31 7: 7: S/G150 S/G150 NAMUR NAMUR p1000: p1000: pre-assignment pre-assignment of of setpoint setpoint sources sources 1: PROFIBUS 1: PROFIBUS 2: 2: TM31:AI TM31:AI 00 3: 3: Motorpotentiometer Motorpotentiometer 4: 4: Fixed Fixed setpoints setpoints Essential Essential basic basic parameter parameter settings settings are are requested. requested. Further Further definitions definitions of of settings settings in in the the setpoint setpoint channel channel by by detailed detailed parameterization, parameterization,
Final Final acknowledgement acknowledgement To To permanently permanently store store the the parameter parameter values values in in the the non-volatile non-volatile memory memory (Compact (Compact Flash Flash Card) Card) aa final final acknowledgement acknowledgement is is requested requested via via . If the key is pressed longer than 1 s after changing any parameter value, the mask for permanent parameter storage can be called up at any time.
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SITRAIN Training for Automation and Drives
Pre-assignment of command- and setpoint-sources starting with SW 2.1 p0700 [0], [1] = 1: G130 Profibus 2: G130 TM31 3: G130 CU Terminals 4: G130 PB/TM31 5: S/G150 Profibus 6: S/G150 TM31 7: S/G150 NAMUR 8: G150_V1.3 CDS0 9: G150_V1.3 CDS1 p1000 [0], [1] = 1: Profibus 2: TM31_AI0 3: Motorpotentiometer 4: Fixed setpoints p0015= 1: Standard: p0700[0]= 6 TM31 p0700[1]= same as before p1000[0]= 2 TM31_AI0 p1000[1]= same as before 2: Standard acc. G150_V1.3 p0700[0]= 8 G150_V1.3 DP p0700[1]= 9 G150_V1.3 TM31
Pre-assignment of Command sources via p0700 with p0700[0]
CDS0
with p0700[1]
CDS1
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ON/OFF1 OFF2 OFF3 INV enable etc.
Pre-assignment of Setpoint sources via p1000 with p1000[0]
CDS0
with p1000[1]
CDS1
p0810 main setpoint (p1070)
Command Data Sets (CDS) Selection of a CDS Indication of the active CDS
via p0810 Bit 0 ... 2 (currently only Bit 0) via r0050
Identification of CDS-parameters i.e. p0840[C] = r4022.00 Identification of the indicated CDS-Index “upper right“ Selection of the CDS-index via
p1000[0]= 1 Profibus p1000[1]= 4 Fixed setpoints
p0810
C:0 for CDS 0 C:1 for CDS 1
“Data set selection, column AOP”
Please note: if p15 = 2 (V1.3), DO11 has to be programmed to logic “H” (p0741 = 1) Date: File:
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SITRAIN Training for Automation and Drives
Selection and indication of Command Data Sets
The The menu menu ”Data ”Data set set selection” selection” indicates indicates for: for: -- Max Max -- Drive Drive -- AOP AOP
the the highest highest available available data data set set number number the the currently currently activated activated data data set set the the data data set set used used for for the the display display of of parameter parameter values values on on the the AOP AOP
Values Values indicated indicated for for parameters parameters supplemented supplemented with with ”c” are assigned to CDS1: p0840c ”c” are assigned to CDS1: p0840c Æ Æ p0840[1] p0840[1]
After After selecting selecting the the values values of of both both indices are displayed. indices are displayed.
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SITRAIN Training for Automation and Drives
Drive Data Sets (DDS) / Motor Data Sets (MDS) Via Via AOP AOP parameter parameter values values are are indicated indicated for: for: CDS CDS 11 Command-DS Command-DS DDS DDS 11 Drive-DS Drive-DS MDS MDS 00 Motor-DS Motor-DS
d:1 d:1
p1120d p1120d Æ Æ p1120[1] p1120[1]
m:0 m:0
p0305m p0305m Æ Æ p0305[0] p0305[0]
Motor Motor data data sets sets cannot cannot be be selected selected ”by ”by themselves”; themselves”; they they are are called called up up as as an an assigned assigned part part of of aa DDS. DDS.
c:1 c:1
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p1000c p1000c Æ Æ p1000[1] p1000[1]
SITRAIN Training for
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Automation and Drives
Overview of available command sources (p0700) starting with SW 2.1 6
Panel AOP30
Selection at AOP Local / Remote
SINAMICS
SIEMENS
Hauptmenu
8
9
0
4
5
6
.
1
2
3
+/-
7
local Remote
AOP 30
Local: Local: AOP AOP [610]
Internal signals for: • sequence control • setpoint channel • faults
PROFIBUS P700 = Profibus
Remote: Remote: PROFIBUS PROFIBUS (5) (5)
Selection of command sources
[620-622]
CDS0
Terminals TM31 P700 = TM31
Remote: Remote: TM31 TM31 (6) (6) [630-632]
Namur-terminals X2 P700 = Namur
p0810
Remote: Remote: Namur Namur (7) (7)
CDS1 Display of active CDS in r0050
[641]
¾ In Local mode the command source is assigned to the AOP30. ¾ For Remote mode a selection of external command sources can be linked to internal command signals; these links are stored as a command data set, CDS. (STARTER can also serve as command source.) ¾ Presently two command data sets (CDS0 / CDS1) are available.
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SITRAIN Training for Automation and Drives
Pre-assignment of command sources PROFIBUS p0700 = 5 PCD1
Control command source
target
internal control
Terminals / TM31 p0700 = 6
Bit 0
p2090.0
Æ
p0840
ON / OFF 1
Bit 1
p2090.1
Æ
p0844
No OFF 2
Bit 2
p2090.2
Æ
p0848
No OFF 3
Bit 3
p2090.3
Æ
p0852
Inverter enable
Bit 4
p2090.4
Æ
p1140
Ramp function generator enable
Bit 5
p2090.5
Æ
p1141
Ramp function generator start
Bit 6
p2090.6
Æ
p1142
Speed setpoint enable
Bit 7
p2090.7
Æ
p2103
Acknowledge fault
Bit 10
p2090.10
Æ
---
Command source PLC
Bit 11
p2090.11
Æ
p1113
Change direction of speed
Bit 13
p2090.13
Æ
p1035
MOP higher
DI 1
Bit 14
p2090.14
Æ
p1036
MOP lower
DI 2
DI 0
DI 4
DI 3
With pre-assignment “PROFIBUS“ an automatic configuration is made according to Standard telegram 1
SINAMICS
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Automation and Drives
Connection (”wiring“) of signals Connectors (for “analog signals”) p1070 SUM p1002
Fixed setpoint
r1024 r1024
r1114 r1114
p1075
p1075 = 1024
Binectors (for binary signals)
Switch DI 1
r 4022.1
p1035
Motorpot.
r1050 r1050
p1035 = 4022.1
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SITRAIN Training for Automation and Drives
Binectors and connectors Binectors
Binectors are freely interconnectable binary signals (BO = Binector Output). They represent a bit of a "BO-reading parameter“ (i.e. bit 15 of r0723).
Connectors
Connectors are freely interconnectable “analog signals" (i.e. percent values, speed values). Connectors are reading parameters as well (CO = Connector Output). Source
Destination BI
binector input
selects the source of a binary signal
BO
binector output
is available as a binary signal for further connection
CI
connector input
selects the source of an analog signal
CO
connector output
is available as an analog signal for further connection
r 1050
CO/BO
connector/binector output
is available both as an analog and as a binary signal for further connection
r 0722.0
p840
p1070
r 0722.0
r 0722
SINAMICS / MICROMASTER
MASTERDRIVES
SINAMICS
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Automation and Drives
Overview of available setpoint sources (p1000) starting with SW 2.1 Pre-assignment according to p1000
p1001 Fixed setpoints
p1002
r1024 r1024
p1000 p1070 p1075
p1015
p1042
Motorpot.
r1050 r1050
1 Profibus r2050 0
0 Main Setp. r1024 r1050 r2050 r4055
Automatic setpoint
2 AI 1 r4055 0
0 Suppl.Setp. r1024 r1050 r2050 r4055
PROFIBUS
Analog inputs
r4055 r4055
4 FS r1024 0
Speed setpoint, scaling, direction of speed p1070 Setpoint channel [630]
r2050 r2050
3 MOP r1050 0
r1114 r1114
p1075 Inching p1059
Additional setpoints
p1059
p1155 p1160
By means of p1000 a selection of different setpoint sources can be assigned very easily.
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SITRAIN Training for Automation and Drives
Control via terminals / TM31 (customer interface)
DI0 DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI/DO8 DI/DO9 DI/DO10 DI/DO11 DO0 DO1 AI0 AI1 AO0 AO1
AI 24VDC external - +
DI
AO KTY PTC DI/O
DI
G150 V1.3
G150 >V2.1
ON/OFF1 MOP higher MOP lower Acknowledge fault CDS selection Disable LOCAL MODE FS 0 FS 1 Ready to start LOCAL MODE active free Enable pulses Pulses enabled No fault Main setpoint free n_act I_act
ON/OFF1 MOP higher / FS 0 MOP lower / FS 1 Acknowledge fault Inverter enable free free free Ready to start free free free Pulses enabled No fault Main setpoint free n_act I_act
DO
With the factory settings and pre-assignment via p0700 (p0015) the signals are pre-assigned as indicated.
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SITRAIN Training for Automation and Drives
Command via terminals / TM31 [631]
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SITRAIN Training for Automation and Drives
Internal Interface of the CU320 PT100 PT100 evaluation evaluation device device Alarm Alarm
Digital terminals for internal cabinet options: ¾ Thermistor protection ¾ PT100 ¾ Emergency stop functions
Thermistor motor protection Alarm (1)
PT100 PT100 evaluation evaluation device device Fault Fault
I/O
Function
DI 0
External alarm 1: PTC/PT100
DI 1
External fault 1: PTC/PT100
Thermistor motor protection Fault Emergency Emergency stop stop Category Category 11 (OFF3ÆOFF2) (OFF3ÆOFF2)
I/O
Function
DI 2
OFF3
Emergency stop Category 1
Emergency Emergency stop stop Category Category 00 (OFF2) (OFF2)
DI 3
OFF2
Emergency stop Category 0/1
DO..
DC 24 V
¾ In the standard configuration the digital in-/outputs are used for connection of the cabinet options. (wire break safe: 1 = no alarm/fault) ¾ The parameters for these internal functions are set automatically during the first commissioning. ¾ For missing options the inputs are wired to 24VDC (1)
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Automation and Drives
DI DI/O
DI DI/O
DI 0
External alarm 1:
PT100
DI 1
External fault 1:
PT100
DI 2
OFF3
Emergency stop Cat. 1
DI 3
OFF2
Emergency stop Cat. 0, 1
DI/O 8
P24: External alarm 1
DI/O 9
P24: External fault 1
DI/O 10
P24: Emergency stop Cat. 1
DI/O 11
P24: Emergency stop Cat. 0, 1
DI 4
External fault 2: Chopper
DI 5
Spare
DI 6
Spare
DI 7
Spare
DI/O 12
P24: External fault 2
DI/O 13
P24:
DI/O 14
P24:
DI/O 15
Acknowledge: Chopper
without options: set jumpers
Pre-assignment of the internal interface of the CU320
These DI/DO should not serve as customer terminals Depending on the selected options, a specific wiring exists for these internal signals
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SITRAIN Training for Automation and Drives
Pre-assignment of the internal interface of the CU320
p2112 = r722.0 p2106 = r722.1 p0849 = r722.2 p0854 = r722.3
X122:7 is assigned P24 via X122:8 X122:10 X122:11
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p738 = 1 p739 = 1 p740 = 1 p741 = 1
/ / / /
p728.08 = 1 p728.09 = 1 p728.10 = 1 p728.11 = 1
06/03/2007 ABU DHABI: Page 4 - 25
/ / / /
p748.08 = 0 p748.09 = 0 p748.10 = 0 p748.11 = 0
SITRAIN Training for Automation and Drives
Motor identification 1. 1. Activating Activating the the measurement measurement at at standstill: standstill: •• Select Select mode mode LOCAL LOCAL (wait (wait till till the the LED LED within within the the LOCAL-key LOCAL-key lights lights up) up) and and •• Press Press the the ON-key; ON-key; wait wait for for the the routine routine to to finish finish •• Press Press the the OFF-key OFF-key The measurement improves the quality of control by identifying the true values of the substitute elements of the motor circuit; manufacturing tolerances are irrelevant. 2. 2. Activating Activating the the measurement measurement while while running: running: •• Select mode LOCAL (wait till the Select mode LOCAL (wait till the LED LED within within the the LOCAL-key LOCAL-key lights lights up) up) and and •• Press Press the the ON-key. ON-key. The running measurement identifies the data required for the optimization of the speed controller (i.e. moment of inertia). Additionally the magnetizing characteristic and the rated magnetizing current of the motor are measured. IfIf the the motor-identification motor-identification is is aborted aborted via via , , current current and and speed speed controller controller are are tuned tuned to to the the data data of of the the motor motor name name plate plate instead instead to to the the actual actual values values of of the the motor motor circuit. circuit.
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SITRAIN Training for Automation and Drives
Volatile and non-volatile memory
Offline
Online
RAM
RAM
Save project
V02.02.03
HD
Copy RAM to ROM Save parameters
Load to target
Open project
Reboot Parameter reset
Load to PG
PG / PC
SINAMICS CU
SINAMICS
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SITRAIN Training for
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Automation and Drives
Save and restore parameter sets PF1 (at restart / with RESET button) Target device > Copy RAM to ROM (all RAM data in PF1)
Data on CU320 CF-Card
V02.02.03
Data in CU320 RAM
PF1: PF1: User User data data PF10, PF10, 11, 11, 12: 12: Customer Customer data data
Copy RAM to ROM P977 = 1, 10, 11, 12 (all RAM data in File 1..12) Drive Unit
Copy ROM to RAM: P009 = 30, parameter reset P976 = 1, 2, 10-12, (20-26) all parameters P976 = 100 only BICO
Drive Object Copy RAM to ROM P971 = 1 (RAM data of one Object in PF1 Drive Object DO x
PF20 PF20 .... 26: 26: factory: factory: reserved, reserved, read read only only access access
Copy ROM to RAM: P010 = 30, parameter reset P970 = 1 Object parameter P970 = 100 only BICO in Object
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SITRAIN Training for Automation and Drives
Structure of the Compact Flash Card (S120) System data
License key
V02.02.03
CU Firmware
FW for components
GSD Data User data
1 user parameter file
Data on the Compact Flash Card are grouped as follows: • USER the user data • SIEMENS the system data
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+
n back-up parameter files
For example: PS xx00= General PS xx01= Object 1: CU PS xx02= Object 2: Drive PS xx03= Object 3: TM31 PS xx99= General
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SITRAIN Training for Automation and Drives
Additional parameterization in commissioning the ALM (S150) Enter Enter the the line line supply supply voltage voltage in in V V and and the the line line frequency frequency in in Hz. Hz. Change Change the the values values with with Acknowledge Acknowledge the the values values with with Key Key also also triggers triggers the the step step into into the the next next mask. mask.
After After entering entering the the respective respective values values for for the the Active Active Line Line Module Module aa “final “final acknowledgement” acknowledgement” is is requested. requested. Key Key triggers triggers aa return return to to the the previous previous mask. mask. With With key key the the parameter parameter values values programmed programmed for for the the Active Active Line Line Module Module are are transferred transferred to to the the Flash Card (ROM). Flash Card (ROM). This This sequence sequence can can take take aa few few seconds. seconds.
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06/03/2007 ABU DHABI: Page 4 - 30
SITRAIN Training for Automation and Drives
Additional parameterization when using an encoder IfIf module module SMC30 SMC30 for for the the encoder encoder evaluation evaluation is is connected, connected, the the module module is is identified identified and and the the AOP30 AOP30 prompts prompts aa mask mask to to enter enter the the encoder encoder data. data. Bit-levels Bit-levels of of p0404 p0404 have have following following meaning: meaning: Bit meaning value Bit meaning value 00 value value 11 20 voltage No Yes 20 voltage 55 V V No Yes 21 voltage No Yes 21 voltage 24 24 V V No Yes Bit-levels Bit-levels of of p0405 p0405 have have following following meaning: meaning: Bit meaning value Bit meaning value 00 value value 11 00 signal unipolar signal unipolar bipolar bipolar 11 level HTL TTL level HTL TTL 22 track A/B track monitoring monitoring no no A/B -A/B -A/B 33 zero-pulse zero-pulse 24 24 V V unipolar unipolar like like A/B-track A/B-track
CAUTION After commissioning of the encoder the programmed supply voltage (5/24 V) will be activated on the SMC30 module. If a 5 V-encoder should be used and the supply voltage is programmed incorrectly via p0404 (Bit 20 = “Yes", Bit 21 = "No"), the encoder may be damaged.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 4 - 31
p0404 = 0 0 2 0
0 0 0 8 Hex
Bit 21 = H
SITRAIN Training for Automation and Drives
Tools and project design
Training objectives: You are informed about • the configuration tool SIZER • the commissioning tool STARTER • the SIMOTION tool SCOUT
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
SITRAIN Training for
06/03/2007 ABU DHABI: Page 5 - 1
Automation and Drives
Tools and project design Content
Page
The SINAMICS tools environment.................................................................................................... Common workbench concept for all tools......................................................................................... What is SINAMICS MICROMASTER SIZER ?.................................................................................. SIZER in conjunction with other configuration tools........................................................................... What is STARTER ?........................................................................................................................ STARTER ”Stand-alone” or ”integrated”........................................................................................... What is SIMOTION SCOUT?........................................................................................................... SIMOTION device or individual drive?.............................................................................................. One tool for all SIMOTION HW-platforms.........................................................................................
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 5 - 2
3 4 5 6 7 8 9 10 11
SITRAIN Training for Automation and Drives
The SINAMICS tools environment
Pre-Sales
Workbench (unified Look&Feel) parts list
Project
SIZER
SAP-VSR CA01 Mall
STARTER standalone Post-Sales
or STARTER integrated SCOUT, TCONFIG, STEP 7 (Drive ES),
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
SITRAIN Training for
06/03/2007 ABU DHABI: Page 5 - 3
Automation and Drives
Common workbench concept for all tools
Menu bar/Tool bar: For fast navigation and opening of the functions
Project navigator: Shows the elements and objects of the project
Work area: Shows configuration wizards, graphical configuration masks, Lists
Detail view: Shows specific information (faults, online-help)
•
Standard Look & Feel for SCOUT, SIZER, STARTER
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 5 - 4
SITRAIN Training for Automation and Drives
What is SINAMICS MICROMASTER SIZER ?
• •
• •
This tool already supports you in the preliminary phase when engineering the hardware and software components required for the project. One engineering tool for all drives belonging to the new generation • SINAMICS G, SINAMICS S, MICROMASTER 4 • SIMOTION D • SINUMERIK SL SIZER covers the engineering of the complete drive system with options and accessories for single and multi-motor applications. Updates issued twice a year contain the most recent modules available.
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06/03/2007 ABU DHABI: Page 5 - 5
Automation and Drives
SIZER in conjunction with other configuration tools Data of the mechanical system, application
Motor calculation
Selecting the converter and supplementary components
Converter calculation
Selecting the motor with options
SIZER
Ordering part list
Ordering
Mall, SAP
PATH PLUS (Masterdrives) SIDIM (Simodrive) SD configurator for Standard drives
Mall, SAP
For all new Siemens Drives
SIZER
With the tool SIZER, you configure the motors and the new Siemens converters based on load calculation (import, input), you define the required components and you initiate the order via SAP
CA01 / SD-Config.
With the SD configurator, you define the ordering data of the motor with Z options and you obtain the complete pre-sales documentation. Z-options for the motor are integrated in SIZER. With CA01 you complete your order with additional components and -when working without SIZER- you initiate your order via the Siemens Mall or SAP.
PATH Plus
With this tool you configure motors and MASTERDRIVES converters based on load calculation and you define the required components. Load duty cycle export to SIZER is possible.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 5 - 6
SITRAIN Training for Automation and Drives
What is STARTER ?
¾ ¾ ¾ ¾ ¾
One commissioning tool for all drives belonging to the new generation SINAMICS G, SINAMICS S, MICROMASTER 4 Easy to follow, menu-guided commissioning and graphic configuration Test tools for the optimization of the drive Standalone or integrated into the engineering tools of higher-level automation environments (SIMOTION SCOUT, T-CONFIG, SIMATIC DriveES) Integrated PROFIBUS interface (SINAMICS G110, G120 via RS232/USS)
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
06/03/2007 ABU DHABI: Page 5 - 7
SITRAIN Training for Automation and Drives
STARTER ”Stand-alone” or ”integrated” SINAMICS stand alone
SINAMICS integrated in a higher-level control SIMOTION
SIMATIC S7
T-CPU
SINAMICS
TCONFIG
STARTER V4.0
new STARTER by installation
SINAMICS Siemens AG 2007. All rights reserved.
STEP 7 DRIVE ES V5.3 Basic V5.4.0 with STARTER new STARTER by installation Date: File:
SCOUT V4.0 STARTER integrated
TCONFIG STARTER integrated
new STARTER by means of new SCOUT / T-CONFIG
06/03/2007 ABU DHABI: Page 5 - 8
SITRAIN Training for Automation and Drives
What is SIMOTION SCOUT?
¾ ¾ ¾
SIMOTION SCOUT is the engineering tool for all SIMOTION applications Simple, guided commissioning and graphically supported programming Integrated test functions to optimize the application
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
06/03/2007 ABU DHABI: Page 5 - 9
SITRAIN Training for Automation and Drives
SIMOTION device or individual drive?
SIMOTION device
Individual drive (i.e. via STARTER)
refer to STARTER
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 5 - 10
SITRAIN Training for Automation and Drives
One tool for all SIMOTION HW-platforms
SIMOTION C or P
SIMOTION D
SINAMICS integrated
SINAMICS S120
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 5 - 11
SITRAIN Training for Automation and Drives
Commissioning with STARTER
Training objectives: You are able to commission and parameterize the drive system SINAMICS using the tool STARTER.
Operating Manual List Manual Equipment Manual - Booksize - Booksize Coldplate - Chassis Equipment Manual for Control Units and Additional System Components
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 6 - 1
SITRAIN Training for Automation and Drives
Commissioning with STARTER Content
Page
Required pre-conditions................................................................................................................... Wiring generalities............................................................................................................................ DRIVE-CLiQ connection G150 / G130.............................................................................................. Compliance with the DRIVE-CLiQ wiring rules.................................................................................. Connection of the Line Module “Ready“-signal.................................................................................. Setting up the PROFIBUS communication....................................................................................... Setting up the PG/PC interface......................................................................................................... SINAMICS firmware and STARTER software................................................................................... Software versions............................................................................................................................. Creating a project with STARTER.................................................................................................... A) Definition of a new project without project wizard......................................................................... B1.1) Offline configuration / Configuring a drive unit G150 / S150.................................................... Configuring a drive unit G150 / S150................................................................................................ B1.2) Offline configuration / Configuring a drive unit S120................................................................ Configuring a drive unit S120............................................................................................................ Configuring a drive unit S120............................................................................................................ Completing the project, storing, loading to the CU, copying RAM ROM........................................... B2) Online search (project wizard) and automatic configuration........................................................ First test with control panel and diagnostic monitor........................................................................... Volatile and Non-Volatile Memory.................................................................................................... Automatic request to save data........................................................................................................ Save and restore parameter sets.....................................................................................................
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
continued on page 3
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 6 - 2
SITRAIN Training for Automation and Drives
Commissioning with STARTER Content Page Structure of the Compact Flash Card (S120).................................................................................... 26 Saving and defaulting parameter sets............................................................................................... 27 Saving and defaulting parameter sets............................................................................................... 28 Saving and defaulting parameter sets............................................................................................... 29 Icons within the project navigator (ONLINE mode)............................................................................ 30 Expert functions 1(2)....................................................................................................................... 31 Expert functions 2(2)....................................................................................................................... 32 Parameter comparison..................................................................................................................... 33 “Comparative quality” of the components.......................................................................................... 34 Component replacement (series comm.) / Comparative-Q. “high“ .................................................... 35 BICO connections in STARTER....................................................................................................... 36 BICO signal sources........................................................................................................................ 37 Data sets.......................................................................................................................................... 38 Data sets.......................................................................................................................................... 39 Firmware update, keeping existing parameters................................................................................ 40 FW update via configuration mask.................................................................................................... 41 Boot Loader..................................................................................................................................... 42 FW update via expert list.................................................................................................................. 43 FW-update of the AOP30................................................................................................................. 44 Cycle times...................................................................................................................................... 45 Ordering data for the Compact Flash Card....................................................................................... 46 Product licence management........................................................................................................... 47 Licence entry without card reader..................................................................................................... 48 Parameterization via BOP20............................................................................................................ 49
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
06.03.2007 ABU DHABI: Page 6 - 3
SITRAIN Training for Automation and Drives
Required pre-conditions 1. 2.
The cabinet is wired up to line and motor
3. 4.
The PROFIBUS – connection is set up The most recent STARTER-release is installed The CU320 is equipped with the correct Compact Flash card and the matching FC-structure
5.
2
The DRIVE-CLiQ rules have been observed (factory wired for cabinets)
5
4
3
Line
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 6 - 4
1 SITRAIN Training for Automation and Drives
Wiring generalities • • • • • • • •
Example: CU320 with Active Line Module 2 motor modules with motors 2 motor sensors via SMC 1 external sensor via SMC
Main switch Line fuses for power unit / 24VDC 24VDC for components and Enable Pulse DRIVE-CLiQ wiring Line contactor with feedback Line reactor or filter-reactor combination
1
2
3
3
Motor and sensor cables Earthing and screening concept (large surface area, star-like to ground)
1 2
3
Leading auxiliary contact (>10ms) for Enable Pulse Enable Pulses on Active Line Module is mandatory (to protect other load from voltage peaks); 0V on terminal 3 effects “pulses disabled”. Enable Pulse on Motor Module active only in conjunction with Safe Standstill (is to be activated by password); without Safe Standstill no “disable pulses” at 0V/term.3
For further specifications concerning the wiring refer to the Installation Manuals
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 6 - 5
SITRAIN Training for Automation and Drives
DRIVE-CLiQ connection G150 / G130 Standard: G150
Option: G150
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 6 - 6
SITRAIN Training for Automation and Drives
Compliance with the DRIVE-CLiQ wiring rules CU 320
CU 320
Active Single Single Motor Motor Line Module Module Module
Active Single Double Motor Motor Line Module Module Module
X203
X2: motor 2 X1: motor 1 X500
X500
X500
X500
Encoder for motor 1
X500
X500
Encoder for motor 2
• Motor Modules may always be continued from port X201 to port X200 • Sensor Module or DRIVE-CLiQ motor should be on corresponding Motor Module port X202 • Double Motor Modules: Sensor Module or DRIVE-CLiQ motor assigned to corresponding Motor Module FW2.3: • Active Line Module and Motor Modules in operation type Servo can be operated in line topology (X201 – X200 / X201 – X200)
FW2.1 / 2.2: • Active Line Module and Motor Module on separate CU-Ports • On Active Line Module no further components
The compliance with the “can“ rules allows an automatic topology configuration SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
06.03.2007 ABU DHABI: Page 6 - 7
SITRAIN Training for Automation and Drives
Connection of the Line Module “Ready“-signal Line Modules with DRIVE-CLiQ
Line Modules without DRIVE-CLiQ
CU
“Infeed operation“ via DRIVE-CLiQ-connection (SW): ALM Æ CU320 Æ Motor Module
“Infeed operation“ via HW-connection (DO Æ DI): SLM X21:1 (DO) >> TB30 X481:1 (DI0)
ALM:r863.0 = drive:02.p864 drive:03.p864
TB30:r4022.0 = drive:02.p864 drive:03.p864
MM
ALM
p864
r863.0
SW
SINAMICS Siemens AG 2007. All rights reserved.
MM
CU / TB30
SLM ready to switch on
p864
r4022.0 DO Date: File:
HW
DI
06.03.2007 ABU DHABI: Page 6 - 8
SLM
ready to switch on
SW SITRAIN Training for Automation and Drives
Setting up the PROFIBUS communication Profibus connection and diagnostic LED • As tool the most recent STARTER is installed
• The communication from STARTER to the CU320 is set up via PROFIBUS observing the wiring rules.
• The PG/PC interface is set up with the system function “Set PG/PC Interface“
• The CU320 Profibus address is set Address setting via DIP switches or via parameter p0918 Diagnostic LEDs • RDY
•DP1 • OPT • MOD
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Date: File:
06.03.2007 ABU DHABI: Page 6 - 9
SITRAIN Training for Automation and Drives
Setting up the PG/PC interface
Interface used: PROFIBUS (not PROFIBUS-DP Slave)
SINAMICS Siemens AG 2007. All rights reserved.
• PG/PC is the only Master • 12 Mbit/s • DP (user-defined only with NetPro) Date: File:
06.03.2007 ABU DHABI: Page 6 - 10
• Test > O.K. • Bus nodes: i.e. 0 + 4
SITRAIN Training for Automation and Drives
SINAMICS firmware and STARTER software Current FW version
Current SW version
SINAMICS:
STARTER/SCOUT:
V2.4
V4.0
(Internal: V02.04.00.00)
(Internal: V41.00.00.30)
• The firmware is part of the Compact Flash Card • The validity of the Boot Loader is to be checked
Date: File:
Siemens AG 2007. All rights reserved.
STARTER V 3.2.1 (Servicepack 1)
FW 2.4 FW 2.5
V4 V5
(FW 2.3: 32 MB CFC, FW 2.4: 64 MB CFC)
• Firmware version V1.3 (only G150)
when updating FW by copying it to the CF-card (Loader 1: CU320, Loader 2: Compact Flash Card)
SINAMICS
SINAMICS FW 2.3
cannot be operated with STARTER.
06.03.2007 ABU DHABI: Page 6 - 11
SITRAIN Training for Automation and Drives
Software versions 04/03
10/03
04/04
04/05
07/05
04/06
04/07
04/08
Firmware SINAMICS S/G V2.1
V2.2
V2.3
V2.4
?
V2.5
STARTER
V3.2
V3.2.1
V4.0
?
V5.0
?
V2.5
V3.1 10/04
V2.2
SIZER
G150 V1.02
V1.03
V2.1
10/05
V2.3
V2.2
V2.4
V2.3
• new FW on • new CF-Card existing CF card with Loader 2 • new Parameterization old: *.SAV, new *.ACX
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
10/06
V2.5
V2.6
V2.4
04/06 V2.4 without BPOS / only Booksize 06/06 V2.4 with BPOS / also Large Drives
06.03.2007 ABU DHABI: Page 6 - 12
SITRAIN Training for Automation and Drives
Creating a project with STARTER A) Without Project Wizard by direct definition of a new project (STARTER / SCOUT)
B) With the Project Wizard (only STARTER) by: ¾ Configuring a drive unit (in offline), completing the configuration with the Configuration Wizard and loading the project into the device (Download). ¾ Performing an automatic search on PROFIBUS, an automatic configuration by the CU and uploading all data from the device into the project (Upload). ¾ Opening an existing project new Project Offline new Project Online existing Project
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SITRAIN Training for Automation and Drives
A) Definition of a new project without project wizard Creating Creating an an offline offline project project without without project wizard is possible project wizard is possible both both in in STARTER STARTER and and in in SCOUT. SCOUT.
1. New ...
The The configuration configuration of of aa drive drive unit unit is is then then continued continued ONLINE ONLINE or or OFFLINE. OFFLINE.
2. Insert drive unit OFFLINE ONLINE
OFFLINE ONLINE
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Date: File:
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SITRAIN Training for Automation and Drives
B1.1) Offline configuration / Configuring a drive unit G150, S150 > Configure drive unit
2
1
3
Without wizard direct access to > Configure drive unit
1. 1. Create Create aa new new project project and and configure configure aa drive drive unit unit offline offline 2. 2. Set Set up up PG PG interface interface 3. (menu prompted) prompted) 3. Configure Configure drive drive unit unit offline offline (menu
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Date: File:
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SITRAIN Training for Automation and Drives
Configuring a drive unit G150, S150
The type of telegram can be defined later and it can be redefined as well.
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Date: File:
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SITRAIN Training for Automation and Drives
B1.2) Offline configuration / Configuring a drive unit S120 > Configure drive unit
2
1
3
Without wizard direct access to > Configure drive unit
1. 1. Create Create aa new new project project and and configure configure aa drive drive unit unit offline offline 2. 2. Set Set up up PG PG interface interface 3. (menu prompted) prompted) 3. Configure Configure drive drive unit unit offline offline (menu
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 6 - 17
SITRAIN Training for Automation and Drives
Configuring a drive unit S120
SLM
MM
CU / TB30
p864
r4022.0 DO
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
HW
06.03.2007 ABU DHABI: Page 6 - 18
DI
SW
SITRAIN Training for Automation and Drives
Configuring a drive unit S120
The type of telegram can be defined or redefined at any time later as well.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 6 - 19
SITRAIN Training for Automation and Drives
Completing the project, storing, loading to the CU, copying RAMÆROM
5 6a
6b
4
4. 4. Complete Complete the the BICO-wiring BICO-wiring 5. 5. Store Store the the project project 6. 6. Load Load the the project project to to the the target target device, device, copy copy RAM RAM to to ROM ROM
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Date: File:
06.03.2007 ABU DHABI: Page 6 - 20
SITRAIN Training for Automation and Drives
B2) Online search (project wizard) and automatic configuration > configure drive unit
1
4
2
3
> automatic configuration
1. 1. Create Create aa new new project project and and search search drive drive units units online online 2. 2. Set Set up up PG PG interface interface 3. 3. Search Search for for accessible accessible nodes nodes 4. 4. Go Go online online Drive is already commissioned:
5a. 5a. Drive Drive is is already already commissioned: commissioned: load project load project data data into into PG PG (Upload) (Upload) 5b. 5b. Start Start Automatic Automatic configuration: configuration: load load to to PG PG (Upload) (Upload) 6. 6. Non Non DRIVE-CLiQ DRIVE-CLiQ objects: objects: complete complete motor motor and and sensor sensor etc. etc. offline with configuration configuration wizard wizard and and offline with store store the the project project 7. 7. Load Load the the drive drive unit unit to to the the target target device (online) and store device (online) and store into into ROM ROM
5a First commissioning required:
5b 6
7 SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
06.03.2007 ABU DHABI: Page 6 - 21
SITRAIN Training for Automation and Drives
First test with control panel and diagnostic monitor
To To reach reach the the control control panel: panel: 1. 1. Drive Drive >> Commissioning Commissioning >> Control Control panel panel 2. 2. Assume Assume control control authority authority 3. 3. Set Set the the Enables Enables 4. 4. Switch Switch on on 5. 5. Set Set speed speed with with setpoint setpoint and and scaling scaling
after ON
1
2 3
5
4
Control panel
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 6 - 22
SITRAIN Training for Automation and Drives
Volatile and Non-Volatile Memory
Offline
Online
Load to target
Open project
RAM
RAM
Save project
Load to PG
PG / PC
V02.02.03
HD
Copy RAM to ROM Save parameters
Reboot Parameter reset SINAMICS CU
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
06.03.2007 ABU DHABI: Page 6 - 23
SITRAIN Training for Automation and Drives
Automatic request to save data Request when Offline Æ Online
SERVO_02 (TODrive)
not available
SERVO_03 (TODrive)
not available
TB30_04 (TOTB30)
not available
Request when Online Æ Offline
with project matching the installation with drive already commissioned
Æ different data in VECTOR_02
SINAMICS Siemens AG 2007. All rights reserved.
Æ go online without upload/download: continue with “Close“ Date: File:
06.03.2007 ABU DHABI: Page 6 - 24
SITRAIN Training for Automation and Drives
Save and restore parameter sets PF1 (at restart / with RESET button) Target device > Copy RAM to ROM (all RAM data in PF1)
Data on CU320 CF-Card
PF1: PF1: User User data data
V02.02.03
Data in CU320 RAM
PF10, PF10, 11, 11, 12: 12: Customer Customer data data
Copy RAM to ROM P977 = 1, 10, 11, 12 (all RAM data in File 1..12) Drive Unit
Copy ROM to RAM: P009 = 30, parameter reset P976 = 1, 2, 10-12, (20-26) all parameters P976 = 100 only BICO
Drive Object Copy RAM to ROM P971 = 1 (RAM data of one Object in PF1 Drive Object DO x
PF20 PF20 .... 26: 26: factory: factory: reserved, reserved, read read only only access access
Copy ROM to RAM: P010 = 30, parameter reset P970 = 1 Object parameter P970 = 100 only BICO in Object
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
06.03.2007 ABU DHABI: Page 6 - 25
SITRAIN Training for Automation and Drives
Structure of the Compact Flash Card (S120) License key System data V02.02.03
CU Firmware
FW for components
GSD Data User data
1 user parameter file
Data on the Compact Flash Card are grouped as follows: • USER the user data • SIEMENS the system data
SINAMICS Siemens AG 2007. All rights reserved.
+
n back-up parameter files
For example: PS xx00= General PS xx01= Object 1: CU PS xx02= Object 2: Drive PS xx03= Object 3: TM31 PS xx99= General
Date: File:
06.03.2007 ABU DHABI: Page 6 - 26
SITRAIN Training for Automation and Drives
Saving and defaulting parameter sets Load project to target device • All project data to all target devices Æ drive unit 1 (i.e. addr. 4) Æ drive unit 2 (i.e. addr. 5) Æ SIMOTION • With / without copy RAM to ROM:
A) via icons A B C D
with / without copy RAM to ROM
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
Load project to target device • Drive unit of the project as marked Æ drive unit 1 A Load to PG B Load to target device C Restore factory settings (p976=1) D Copy RAM to ROM
06.03.2007 ABU DHABI: Page 6 - 27
SITRAIN Training for Automation and Drives
Saving and defaulting parameter sets B) via menu:
right mouse key
complete drive unit
right mouse key
only via expert list
right mouse key
individual drive objects
right mouse key
right mouse key
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Date: File:
06.03.2007 ABU DHABI: Page 6 - 28
SITRAIN Training for Automation and Drives
Reset on CU320
Saving and defaulting parameter sets C) via expert list of the Control Unit: • CU320 by itself • complete drive unit p09=30 p971 CU320 by itself p976,977 all objects
of the drive objects: • Infeed • In-/output units • Drives
SINAMICS Siemens AG 2007. All rights reserved.
p10=30
Date: File:
06.03.2007 ABU DHABI: Page 6 - 29
SITRAIN Training for Automation and Drives
Icons within the project navigator (ONLINE mode)
gn. - gn. rd. - rd. wt. - wt. rd. - gn.
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Date: File:
06.03.2007 ABU DHABI: Page 6 - 30
SITRAIN Training for Automation and Drives
Expert functions 1(2) add new list
create / open user defined list
SINAMICS Siemens AG 2007. All rights reserved.
save list
edit list
indication screen
Date: File:
access level
hex bin
generate DB for PLC
06.03.2007 ABU DHABI: Page 6 - 31
SITRAIN Training for Automation and Drives
Expert functions 2(2)
extended search
compare parameter files
parameter with data set assignment
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 6 - 32
SITRAIN Training for Automation and Drives
Parameter comparison
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 6 - 33
SITRAIN Training for Automation and Drives
“Comparative quality” of the components Project RAM CU RAM
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Date: File:
06.03.2007 ABU DHABI: Page 6 - 34
Hardware
SITRAIN Training for Automation and Drives
Component replacement (series comm.) / Comparative-Q. “high“
Hardware actual topology
CU 320 set topology automatic configuration
serial nr. A
serial nr. A
PG project project set topology upload
Æ OPERATION
serial nr. A
component change serial nr. B
serial nr. A p9909 = 1 power ON p9909 = 0 power ON
serial nr. B
Æ OPERATION
serial nr. A
Æ FAULT
upload
Series commissioning Independent of the parameter setting p9909 (=1/ =0) the serial number of the hardware (actual topology) is copied into the CU320 (set topology) after download.
p9905 = 1 serial nr. B
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
serial nr. B
Æ OPERATION
06.03.2007 ABU DHABI: Page 6 - 35
SITRAIN Training for Automation and Drives
BICO connections in STARTER
The The BICO BICO connection connection can can be be programmed programmed in in the the graphical graphical masks masks of of the the drive drive objects objects or or in in the the expert expert list list
Light blue: Binector Input Dark blue: Connector Input Yellow:
Con./Bin. Output
Green:
Parameter
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SITRAIN Training for Automation and Drives
BICO signal sources
drive objects
List List of of the the parameters parameters most most commonly commonly used used for for the the intended intended connection connection of of the the selected selected drive drive object object
drive objects
List List of of all all parameters parameters available available for for the the connection connection of of the the selected selected drive drive object object
SINAMICS
Date: File:
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06.03.2007 ABU DHABI: Page 6 - 37
SITRAIN Training for Automation and Drives
Data sets p0170: total nr. of DS p0810f: selection p0840: data p0844 p1070 ...
PROFIBUS Terminals
CDS G1
p0180: total nr. DS DDS EDS p0820f: selection p1080: data p11210 p1240 ... MDS
p0130: total nr. DS p0186: MDS nr. p0300: data M1 p0304 p0330 ...
SINAMICS Siemens AG 2007. All rights reserved.
M16
G2 G3 p0140: total nr. of DS p0187f: EDS number p0141: data p0142 p0400 ...
Date: File:
06.03.2007 ABU DHABI: Page 6 - 38
SITRAIN Training for Automation and Drives
Data sets
SINAMICS
Date: File:
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06.03.2007 ABU DHABI: Page 6 - 39
SITRAIN Training for Automation and Drives
Firmware update, keeping existing parameters STARTER V4.0
STARTER
Save V2.3-project and convert to V2.4 project
Load V2.4-project to target device; RAM to ROM
7. Netz.lnk
1. - 3.. 5.
8.
save
copy 9. V02.01.01
6. clear
V02.01.01
4.
10.
Bootloader valid for the new firmware available on CF card Bootloader not valid for the new firmware: - order new CF card with new FW - enter new key
11.
Officially suggested: order a new Flash-Card with the new firmware!
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SITRAIN Training for Automation and Drives
FW update via configuration mask Drive unit Æ Configuration Æ Version overview: Firmware Update
Selection of the components
Power ON Reset!
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06.03.2007 ABU DHABI: Page 6 - 41
SITRAIN Training for Automation and Drives
Boot Loader First First level level loader loader in in the the CU320 CU320
(Loader (Loader 1) 1)
• Loader 1 (boot FW for the CU320 processor) is an integral part the CU320 • Actual version of Bootloader 1 is for FW 2.1: 2000700 / 2002400 FW 2.2: 2002400 2200500 (for non-volatile fault buffer) FW 2.3 / 2.4: same as FW 2.2 • CU320 Version of Bootloader 1: see r197 • D435 Version of Bootloader 1: see SIMOTION
(Loader (Loader 2) 2)
V02.02.03
Second Second level level loader loader on on the the CF CF Card Card
• Loader 2 is an integral part of the CF Card • Current version of Bootloader 2 is 2002400 • Compact Flash Card Version of Bootloader 2: see r198 • A Compact Flash Card with Firmware V1.3 cannot be updated by copying the firmware V2.1.x to it, since the Bootloader of the CF Card has to be updated additionally.
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SITRAIN Training for Automation and Drives
FW update via expert list
Drive
component component number number
CU320
Firmware
1=Start
Advantage: STARTER can be used for other jobs while the component download is executed.
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06.03.2007 ABU DHABI: Page 6 - 43
SITRAIN Training for Automation and Drives
FW-update of the AOP30 V02.01.01
V2.4 V2.4
>> FW2.4 FW2.4
• The firmware update is executed automatically while the firmware and parameter-, fault- and alarmdatabanks are copied from the Compact Flash Card Æ independent of the FW version, always matching the CU-firmware • Availability of real-time information for the CU320 Æ real-time interrupt for fault- and alarm-messages • Features provided by new AOP with extended program- and databank / 6SL3055-0AA00-4CA3
55% to ≤ 100% > 100%
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06.03.2007 ABU DHABI: Page 6 - 46
necessary components (in addition to the Control Unit) Compact Flash Card without Performance Extension Compact Flash Card with Performance Extension 1 Additional Control Unit CU320 and Compact Flash Card necessary SITRAIN Training for Automation and Drives
Product licence management Certificate of Licence (Licence)
Licence and drive are ordered separately. Easy to do post licensing.
SP
second order 1 licence
Customer’s logistics licence-data bank at A&D MC OI
first order 1 Compact Flash 1 CU320
http://www.siemens.com/automation/license
SW-product certificate is filed
CF
example: PNCY-YBEB
SINAMICS Siemens AG 2007. All rights reserved.
SP
= Licence Key
Date: File:
Drive
Licence-key is generated for the FC-serial-Nr. Æ it is not transferable to other flash cards Æ with the original FC it can be used in any CU320
06.03.2007 ABU DHABI: Page 6 - 47
SITRAIN Training for Automation and Drives
Licence entry without card reader
example for licence entry: 17A6 2B6F value ASCII-Hex ASCII-Dec 1 31 49 7 37 55
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Date: File:
06.03.2007 ABU DHABI: Page 6 - 48
SITRAIN Training for Automation and Drives
Parameterization via BOP20 Changeover: operation ÅÆ Parameterization
Changing the currently active drive object
For For aa detailed detailed explanation explanation refer refer to: to: Commissioning Commissioning Manual, Manual, page page 8-356 8-356 … …
Changing parameter values
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
Changing BiCo-connections
06.03.2007 ABU DHABI: Page 6 - 49
SITRAIN Training for Automation and Drives
Diagnostics
Training objectives: You are informed about • Diagnosis via LEDs and AOP30 • Fault and alarm messages • Diagnosis via STARTER • Diagnostic functions
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SITRAIN Training for Automation and Drives
Diagnostics Content
Page
LED indications on the CU320 while booting.................................................................................... LED indications on the CU320 during operation............................................................................... LED indications on other components.............................................................................................. Diagnosis with the fault buffer [8060]............................................................................................... Diagnosis with the alarm buffer [8065]............................................................................................. Configuring faults / alarms [8075].................................................................................................... Diagnosis with the AOP30................................................................................................................ Diagnosis “of the power module“: current transformer offset............................................................. Diagnosis via “existing” and “missing” enables................................................................................. Diagnosis using parameters............................................................................................................. Drive navigator................................................................................................................................. Drive diagnosis................................................................................................................................ Diagnosis using measuring sockets.................................................................................................. Diagnosis using the trace function.................................................................................................... Recording encoder signals............................................................................................................... Function generator (control type “Vector” and “Servo“)..................................................................... Mathematical signal processing........................................................................................................ Measuring function (only for control type “Servo“)............................................................................. Power block diagnosis using the test box.........................................................................................
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3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
SITRAIN Training for Automation and Drives
LED indications on the CU320 while booting CU loader
FC loader
Cyclic Redundancy Check
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Date: File:
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SITRAIN Training for Automation and Drives
LED indications on the CU320 during operation
For Chassis units: LEDs on CIB
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Date: File:
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SITRAIN Training for Automation and Drives
LED indications on other components Active Line Module
Motor Module
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Date: File:
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SITRAIN Training for Automation and Drives
Diagnosis with the fault buffer [8060] r0945 Fault code
r0949 Fault value
NV-memory (non-volatile) in CU320 with: - 16 MB FC-memory from -0AA1 - new CU HW-release: 0AA0 >D 0AA1 - Bootloader 1 (r0197) 2200500 - from Firmware (r0018) V2.2
Real time stamp with new AOP30
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SITRAIN Training for Automation and Drives
Diagnosis with the alarm buffer [8065]
up to Alarm 64
Real time stamp with new AOP30
r2122 Alarm code
r2124 Alarm value
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
06.03.2007 ABU DHABI: Page 7 - 7
SITRAIN Training for Automation and Drives
Configuring faults / alarms [8075]
Fault response ?
Acknowledge mode ?
1 = acknowledgeable after Power ON if cause of the fault is removed 2 = always acknowledgeable if cause of the fault is removed
A06601 (F) Current offset measurement interrupted The alarm A06601 can be redefined as fault F06601
Fault or alarm ?
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SITRAIN Training for Automation and Drives
Diagnosis with the AOP30 Each Each object object has has its its own own faults faults and and alarms. alarms.
Both, Both, currently currently valid valid and and already already acknowledged acknowledged faults faults and and alarms alarms can can be be called called up. up.
Indication Indication of of the the called called up up fault fault or or alarm alarm with with identifier identifier and and clear clear text; text; Time Time stamp stamp in in system system time time or or in in real real time time (> V2.4 with with new new AOP). AOP). (> V2.4
Help Help menus menus with with possible possible causes causes and and remedies. remedies.
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SITRAIN Training for Automation and Drives
Diagnosis “of the power module“: current transformer offset
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SITRAIN Training for Automation and Drives
Diagnosis via “existing” and “missing” enables
after ON
SINAMICS
Date: File:
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SITRAIN Training for Automation and Drives
Diagnosis using parameters
r0046 HEX
1
4
0
F
BIN 0001 0100 0000 1111 Bit 12 8 4 0
r0002 r0002 r0046 r0046 r0050 r0050 r0051 r0051 r0721 r0721 r0747 r0747 r4022 r4022 r4047 r4047
drive drive status status missing missing enables enables active active CDS CDS active active DDS DDS status: status: CU320 CU320 DI/DO DI/DO status: status: CU320 CU320 DI DI status: status: TM31 TM31 DI DI status: status: TM31 TM31 DO DO
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SITRAIN Training for Automation and Drives
Drive navigator
only for operating types - Vector - Servo with setpoint channel
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Date: File:
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SITRAIN Training for Automation and Drives
Drive diagnosis Control and status words
Binector connections
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Date: File:
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SITRAIN Training for Automation and Drives
Diagnosis using measuring sockets
without limiting: 0.5 V/Hz 67 Hz Æ 33.5 V 33.5 – n*5 = 3.5 V
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
06.03.2007 ABU DHABI: Page 7 - 15
SITRAIN Training for Automation and Drives
Diagnosis using the trace function selection: trace 1 / trace 2
trigger: start / stop
axis: on, off 1 / function gen.: start, stop
Triggersignals recording duration
trigger conditions
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SITRAIN Training for Automation and Drives
Recording encoder signals 1. 1. Expert Expert list list Æ Æ selection selection encoder encoder diagnostic diagnostic signal signal 1: 1: p496[0] p496[0] == 00 .... 42 42 (access (access level level 4) 4)
1 3 2
2. 2. Assign Assign trace trace signal: signal: == r497[.] r497[.] ,, r498[.] r498[.] ,, r499[.] r499[.]
4
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SITRAIN Training for Automation and Drives
Function generator (control type “Vector” and “Servo“) • The function generator can be used to generate a number of different signal shapes.
Operating modes of the function generator:
• By selecting the operating mode the signal is connected to a predefined position within the control system.
1. Speed setpoint after filter (speed setpoint)
• The influence of superposed control loops is automatically eliminated.
1. Connector output (as setpoint source) ◘Vector ◘Servo
2. Speed setpoint before filter (speed setpoint)
◘Servo ◘Servo
3. Disturbing torque (after current setpoint)
◘Servo
4. Current setpoint after filter (current setpoint)
◘Servo
5. Current setpoint before filter (current setpoint)
◘Servo
Configurable signal shapes: • Rectangle • Step • Triangle • Sine • PRBS (pseudo random binary sequence, white noise)
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SITRAIN Training for Automation and Drives
Mathematical signal processing With mathematical processing, signals can be mathematically related and the result can be displayed as a curve by the trace recording: • Calculations according to an individually defined formula • Bode diagram output-signal to input-signal • Fast Fourier Transformation representation of the frequency content
FFT-diagram
1
Transfer($1;$2) Æ Bode diagram (n actual / n set)
Bode-diagram
amplitude /\
\/ phase
n.set n.actual
SINAMICS
Date: File:
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06.03.2007 ABU DHABI: Page 7 - 19
SITRAIN Training for Automation and Drives
Measuring function (only for control type “Servo“) • Controller optimization with automatic elimination of superposed control loops. • Easily configured • Automatically assigned: • Function generator • Trace channels
Pre-configured measuring functions:
2
– Speed controller setpoint frequency response (after speed setpoint filter) – Speed controlled system (signal injection after current setpoint filter) – Speed controller disturbance frequency response
(after current setpoint filter)
– Speed controller setpoint frequency response (before speed setpoint filter)
1
– Speed controller step of setpoint (after speed setpoint filter) – Speed controller step of disturbance variable (after current setpoint filter) – Current controller setpoint frequency response (after current setpoint filter) – Current controller step of setpoint (after current setpoint filter)
1
step of speed setpoint
2 frequency response
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SITRAIN Training for Automation and Drives
Power block diagnosis using the test box
The test box allows a quick and reliable diagnosis of the power block function. The test includes - the power semiconductors in rectifier and inverter - the interface boards for the power semiconductors - the current transformers Testbox Cables
6AG 1064 – 1AA04 – 0AA0 6AG 1065 – 1AA04 – 0AA0
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SITRAIN Training for Automation and Drives
Speed setpoint channel
Training objectives: • You are familiar with the possibilities of selecting and assigning speed setpoint values • You are able to parameterize the speed setpoint channel using the tool STARTER
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Date: File:
SITRAIN Training for
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Automation and Drives
Speed setpoint channel Content
Page
Overview of the speed setpoint channel........................................................................................... Fixed setpoints [3010]...................................................................................................................... Motor potentiometer [3020]............................................................................................................... Analog channels of TB30 [9104] or TM31 [9586].............................................................................. Main-, additional- and inching setpoints [3030, 3040]........................................................................ Limiters [3050].................................................................................................................................. Ramp function generator, basic and extended [3060, 3070]............................................................. Additional setpoints G150, S150 [3080]............................................................................................ Additional setpoints / S120 “Servo with setpoint”, Vector [3080]....................................................... Additional setpoints / S120 “Servo without setpoint“......................................................................... DSC changeover and setpoint filter / only for “Servo“....................................................................... Position controller without Dynamic Servo Control (DSC)................................................................. Reaction time of disturbance variables for position without DSC...................................................... Position controller with Dynamic Servo Control (DSC)..................................................................... Equivalent of “position controller with DSC after compensation........................................................ Position controller with Dynamic Servo Control (DSC) [3090]........................................................ Telegrams for DSC...........................................................................................................................
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3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
SITRAIN Training for Automation and Drives
Overview of the speed setpoint channel Fixed setpoint r1024 r1024 p1001 ... p1015 CO
[3010]
CO
scaling main SP Motorpot
Automatic setpoint
p1070 r1050 r1050
p1042
[3020]
limiting
RFG
additional setpoints
[3040]
[3050]
[3060] [3070]
[3080]
add. SP p1075
CI
cw/ccw [3030]
r1170 r1170
inching p1058
PROFIBUS
r1114 r1114
r1119 r1119
r1150 r1150
p1059 p1160
r2050 r2050
p1155
[2400]
CI Analog r4055 r4055
[9104] [9586]
SINAMICS
The The speed speed setpoint setpoint channel channel comprises comprises the the different different sources sources of of setpoints, setpoints, the the speed speed limits limits and and the the ramp ramp function function generator. generator.
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06/03/2007 ABU DHABI: Page 8 - 3
Automation and Drives
Fixed setpoints [3010] TM31: X520.2
DI 1
X520.3
DI 2
p1001 r4022.1
p1020
r4022.2
p1021
(i.e. p0700=6)
p1015
p1001 r1024 r1024
...
•• By p1020 By defining defining 44 control control bits bits p1020 .... p1023 p1023 15 p1001 15 fixed fixed setpoints setpoints p1001 .... p1015 p1015 and and “0 “0 ““ can can be be selected. selected. •• You r1024, You can can “wire” “wire” the the selected selected value value r1024, as as well well as as individual individual values. values. p1001 p1001 .... p1015 p1015 •• The The number number of of the the selected selected value value is is shown shown by by r1197 r1197
p1015
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Date: File:
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SITRAIN Training for Automation and Drives
Motor potentiometer [3020] DI 1 DI 2
r4022.1
p1035
r4022.2
p1036
TM31
MOP higher
(i.e. p0700=6)
r1050 r1050
(X)
p1042
(X) After an offline-configuration the assignment of values is initially blocked for a number of parameters. Online these values can be changed immediately, offline only after an initial Upload.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
SITRAIN Training for
06/03/2007 ABU DHABI: Page 8 - 5
Automation and Drives
Analog channels of TB30 [9104] or TM31 [9586]
TB30
r4055 r4055
TM31
p4071[0]
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Date: File:
06/03/2007 ABU DHABI: Page 8 - 6
AO 0
p4071[1]
AO 1
SITRAIN Training for Automation and Drives
Main-, additional- and inching setpoints [3030, 3040]
p1070
r1114 r1114
p1075
•• main main setpoint setpoint and and additionaladditionalsetpoint setpoint are are scaleable; scaleable; the the two two setpoints setpoints are are added added •• two two inching inching values values are are available available •• the the direction direction of of speed speed can can be be ininverted, a direction can be blocked verted, a direction can be blocked
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
06/03/2007 ABU DHABI: Page 8 - 7
SITRAIN Training for Automation and Drives
Limiters [3050]
r1114 r1114
p1080
r1119 r1119
p1083 p1082 r1112 r1112
p1091
p1094
p1086
p1101
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Date: File:
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SITRAIN Training for Automation and Drives
Ramp function generator, basic and extended [3060, 3070]
p1135 p1120
p1121
Basic ramp function generator
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
Extended ramp function generator
06/03/2007 ABU DHABI: Page 8 - 9
SITRAIN Training for Automation and Drives
Additional setpoints G150, S150 [3080]
p1155
p1160
r0062 r0062
p1430
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Date: File:
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SITRAIN Training for Automation and Drives
Additional setpoints / S120 “Servo with setpoint”, Vector [3080]
p1155
p1160
r0062 r0062
only for vector
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
p1430
SITRAIN Training for
06/03/2007 ABU DHABI: Page 8 - 11
Automation and Drives
Additional setpoints / S120 “Servo without setpoint“
p1155
p1160
p1135 p1121
Properties of “Servo without setpoint channel“ • setpoint is connected directly to p1155, p1160 • preferably in conjunction with Dynamic Servo Control • ramp-down times for OFF1 and OFF3 • CTW1, bit5 (freeze RFG) without function • not for Standard Telegram 1
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Date: File:
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SITRAIN Training for Automation and Drives
DSC changeover and setpoint filter / only for “Servo“ Proportional gain p1191>0 (connected) Position difference p1190>0 (connected)
1 = DSC active
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06/03/2007 ABU DHABI: Page 8 - 13
Automation and Drives
Position controller without Dynamic Servo Control (DSC)
speed-contr. drive
pos.-contr. master
n.set
ncmd : speed setpoint xcmd : position setpoint xerr : position error xact : actual position Tsc : sampling time speed-controller Tpc : sampling time position-controller Kpc : position controller gain
: not used !
When using the “position controller of the master controller” dead times at the speed setpoint interface result in a reduction of the controller dynamics.
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Date: File:
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SITRAIN Training for Automation and Drives
Reaction time of disturbance variables for position without DSC DP-cycle time Position controller-Interrupt
BG task
SIMOTION
GC
PROFIBUS
DP DP DP S1 S2 S3
PC PC PC A1 A2 A3
acyclic part
reserve
GC
DP DP DP S1 S2 S3
T dx T in SINAMICS
IW S1
T out SW S1
without DSC: T.in + T.DP + T.out with DSC: speed controller cycle time
actual values (position)
setpoints (speed) DP S T dx T in T out GC LR A
PROFIBUS-transmit time for one slave Overall transmit time for all slaves Time interval between availability of actual values and start of DP-cycle Time interval between Global Control and calculation of setpoints Global Control Telegram Position controller calculation time for one axis
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06/03/2007 ABU DHABI: Page 8 - 15
Automation and Drives
Position controller with Dynamic Servo Control (DSC) n.set
B
co s..d nt r
4
e riv
speed-contr. drive
3
2
po
pos.-contr. master
1
A : active !
Using the “position controller of the drive” allows a response to disturbance variables with cycle time of speed controller; setpoints remain delayed. Interpolation still requires the “master position controller”.
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Date: File:
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SITRAIN Training for Automation and Drives
Equivalent of “position controller with DSC after compensation
speed-contr. drive
po co s..d nt r e riv
Position actual value for axis interpolation
: active !
Using the “position controller of the drive” allows a response to disturbance variables with cycle time of speed controller; setpoints remain delayed. Interpolation still requires the “master position controller”.
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Date: File:
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Position controller with Dynamic Servo Control (DSC)
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Date: File:
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SITRAIN Training for Automation and Drives
[3090]
SITRAIN Training for Automation and Drives
Telegrams for DSC
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Date: File:
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SITRAIN Training for Automation and Drives
Open loop and Closed Loop Control
Training objectives: • You are familiar with the types of control of SINAMICS • You understand the principle of operation of the V/Hz control and of the closed loop speed control with and without encoder • You know where to find essential settings related to speed control and torque limiting
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Date: File:
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SITRAIN Training for Automation and Drives
Open loop and Closed Loop Control Content
Page
Comparison of available types of control.......................................................................................... 4 Available types of control for operating types Servo and Vector........................................................ 5 Equivalent circuit and vector diagram of an induction motor.............................................................. 6 Measurement at standstill................................................................................................................. 7 “Running measurement” and optimization of the speed controller..................................................... 8 Automatic optimization for operating type “Vector“............................................................................ 9 Equivalent circuit and vector diagram of a synchronous motor.......................................................... 10 Standstill- and running measurement (under preparation)................................................................. 11 V/Hz characteristic of the induction motor......................................................................................... 12 Operating type “Vector“, V/Hz control, characteristics [6300]......................................................... 13 Operating type “Vector“, V/Hz control............................................................................................... 14 IxR-comp. / flux current control / slip-comp. / current limiting............................................................. 15 Trace samples for V/Hz control........................................................................................................ 16 Operating type “Vector“: sensorless vector control (SLVC) / ASM.................................................... 17 Torque setpoint in open, closed loop control [710]........................................................................... 18 Operating type ”Vector”: sensorless vector control at 0 Hz / ASM..................................................... 19 Operating type ”Vector”: encoder-based vector control (VC) / ASM................................................. 20 continued on page 3
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Date: File:
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SITRAIN Training for Automation and Drives
Open loop and Closed Loop Control Content
Page
Encoder interface SMC30................................................................................................................ Trace samples for speed control....................................................................................................... Control scheme for AC-drives.......................................................................................................... Speed and current control................................................................................................................ Speed controller [6040]................................................................................................................... Torque setpoints [6060]................................................................................................................... Torque limits [1700]......................................................................................................................... Torque limits.................................................................................................................................... Torque limits [706].......................................................................................................................... Current controller.............................................................................................................................
SINAMICS
Date: File:
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21 22 23 24 25 26 27 28 29 30
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Automation and Drives
Comparison of available types of control Type of control
V/Hz characteristic
Type Vector without encoder ( SLVC )
Type Vector with encoder (speed control )
Type Servo with encoder (high resolution)
Dynamic
low
medium to high
high
very high
Rise time
high
medium
low
very low
Speed accuracy • low speed • high speed
low low
medium high
high high
high high
Position accuracy
---
---
limited
very high
manual
menu prompted
menu prompted
manual
not so suitable
very suitable
very suitable
suitable
Group drives
suitable
when mechanically coupled
when mechanically coupled
---
Applications
group drives, pumps, fans, compressors
pumps, fans, compressors, extruders, mixers, centrifuges
production machines
machine tools and production machines
S120 / S150 / G150
S120
Properties
Optimizing High power rating
S120 / S150 / G150 S120 / S150 / G150
The type of control required for a particular application is set by one parameter.
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Date: File:
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SITRAIN Training for Automation and Drives
Available types of control for operating types Servo and Vector Operating type
Servo / S120
Operating type
Type of closed loop control: Servo
P1300
Vector / S120, S150, G150
Type of close loop control: Vector
P1300
¾
Speed control without sensor
20
¾
Speed control without sensor
20
¾
Speed control with sensor
21
¾
Speed control with sensor
21
¾
Torque control without sensor
22
¾
Torque control with sensor
23
¾
Torque control with sensor
23
Open loop control: V/Hz ¾
P1317
V/Hz control for test operation
synchronoussynchronousservo servo motor motor (perm. (perm. excit.) excit.)
inductioninductionservo servo motor motor
1
torquetorquemotor motor
linearlinearmotor motor
Open loop control: V/Hz
P1300
¾
With linear characteristic
0
¾
With linear characteristic and FCC
1
¾
With parabolic characteristic
2
¾
With programmable characteristic
3
¾
For frequency synchronous drives (“textile”)
5
¾
For frequency synchronous drives with FCC
6
¾
With independent voltage setpoint
19
starting with V2.2: limited mixed operation of Servo / Vector Servo / P1300 = 20
inductioninductionmotor motor
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P1317 = 1 Vector / P1300 = 5, 6 Date: File:
sensorless induction motor (simple applications) permanently excited SYN (for n>0.2 n.rated) only induction motors for reluctance motors
inductioninductionmotor motor SITRAIN Training for
06/03/2007 ABU DHABI: Page 9 - 5
Automation and Drives
Equivalent circuit and vector diagram of an induction motor j X.σS
i.S
R.S i.S
u.S
EMF EMK
ϕ .S
i.S i'.R
i.Sq
i.μ i.Sd Φ.H
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SITRAIN Training for Automation and Drives
Measurement at standstill
Selection of the measurement at standstill (motor – ident.) with p1910 During During the the standstill standstill measurement measurement the the values values mentioned mentioned under under “... “... motor motor identification...“ identification...“ are are measured; measured; the the cable cable resistance resistance R.cable R.cable has has to to be be entered entered before before starting starting the the standstill standstill measurement. measurement.
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“Running measurement” and optimization of the speed controller Selection of the “running measurement” (speed controller optimization) with p1960 Data identified during the “running measurement”: Possible with decoupled load as well - magnetizing current (p0320) - magnetizing characteristic (p0362 – p0369) Possible only with “inert masses“ coupled - moment of inertia of the motor / overall (p0342) - pre-control acceleration (p1496) - speed controller settings (p1470, p1472)
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Automatic optimization for operating type “Vector“ Motor Motor identification identification and and speed speed controller controller optimization optimization p1900 p1900 == 00 :: inhibited inhibited p1900 p1900 == 11 :: sets sets p1910 p1910 == 11 and and p1960 p1960 == 0, 0, 1, 1, 22 (according (according to to p1300) p1300) (1. (1. identification identification of of motor motor data, data, 2. 2. controller controller optimization optimization with with rotating rotating motor) motor) p1900 p1900 == 22 :: sets sets p1910 p1910 == 11 (autom. (autom. ident. ident. of of p0350, p0350, p0354, p0354, p0356, p0356, p0358, p0358, p0360, p0360, p1825, p1825, p1828) p1828) Selection of the motor data identification with p1910:
0: Inhibited 1: Complete identification and acceptance of motor data 2: Complete identification of motor data without acceptance 3: Identification of the saturation characteristic and acceptance 4: Identification of the saturation characteristic without acceptance 5: Identification of dynamic leakage inductance Lsig (r1920) without acceptance 6: Identification of lockout time (r1926) without acceptance 7: Identification of stator resistance Rs (r1912) without acceptance 8: Identification of stator inductance Ls (r1915) without acceptance 9: Identification of rotor time constant Tr (r1913) without acceptance 10: Identification of static leakage inductance Lsig (r1914) without acceptance 20: Voltage vector input
Selection of the speed controller optimization with p1960:
0: Inhibited 1: Speed controller optimization for sensorless operation: p1400.0,p1458/1459,p1470/1472,p1496 2: Speed controller optimization with encoder: p1458,p1459,p1460,p1461,p1462,p1463,p1496
SINAMICS Siemens AG 2007. All rights reserved.
Speed controller optimization configuration with 00 Enc test active 01 Saturation characteristic identification 02 Moment of inertia identification 03 Recalculates the speed controller parameters 04 Speed controller vibration test Speed controller optimization speed Speed controller optimization dynamic factor Date: File:
p1959 p0320, p0360, p0362 ... p0369 p0341, p0342 p1400.0, ... p1965 = 50% p1967 = 100%
(10 .. 75%) (1 .. 400%) SITRAIN Training for
06/03/2007 ABU DHABI: Page 9 - 9
Automation and Drives
Equivalent circuit and vector diagram of a synchronous motor
ΔU U.P
U.1
i.sq
i.1
Φ i.sd
ΔU
U.P U.1 i.sq = i.1
Φ
Φ i.sd = 0
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SITRAIN Training for Automation and Drives
Standstill- and running measurement (under preparation)
SINAMICS
Date: File:
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Automation and Drives
V/Hz characteristic of the induction motor i.S
R.S
X.σS
X '.σR
R '.R / s
i '.R
U/V 400
i.μ u.S
EMF EMK
in general allgemein
X.H
Feldfield weakening schwächung
i.S
R.S
X.σS i.μ
u.S
Φ ( i.μ )
EMF EMK
X.H
idealized ideeller Leerlauf no-load operation (Schlupf s = 0) (slip = 0)
i.μ = i.S
f / Hz
50
100%
u.S = R.S i.S + j X.σS i.S + j X.H i.S Feldfield weakening schwächung 50
f / Hz
mit (zunächst) Vernachlässigung if R.S is (initially) disregarded: von R.S folgt
u.S = j 2 π f ( L.σS + L.H ) i.S i.S = i.μ = u.S / f 2 π ( L.σS + L.H )
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SITRAIN Training for Automation and Drives
Operating type “Vector“, V/Hz control, characteristics [6300]
SINAMICS
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Automation and Drives
Operating type “Vector“, V/Hz control
V/Hz voltage V
U +
f nset
+ +
-
RFG f
frequency
f n
+
+ -
+
Imax current limit - Iact
FCC / I * R compensation Ix(RS;LσS)
slip compensation
IxRCable
slip
current actual value sensing M
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SITRAIN Training for Automation and Drives
IxR-comp. / flux current control / slip-comp. / current limiting IxR-comp.
FCC
380V 405V
380V 400V
i=0 : i=iN :
M prop. n 2
380V / 50Hz 380V / 50Hz
M
P prop. n 3
i.Last i.load i.max i.max
Pumpen pumps fans Lüfter centrifuges Zentrifugen
n;f
M = konstant constant
M
f.slip f.Schlupf
P prop. n hoisting Hebezeuge conveyer belts Fließbänder “steel mills” "Walzwerke"
i.Last i.load i.max i.max
n;f
SINAMICS
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SITRAIN Training for Automation and Drives
Trace samples for V/Hz control
step of reference speed
step of load / without slip compensation
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step of load / with slip compensation
06/03/2007 ABU DHABI: Page 9 - 16
SITRAIN Training for Automation and Drives
Operating type “Vector“: sensorless vector control (SLVC) / ASM Torque generating current in the rotor
j X.σS
speed controller
i.S
torque current controller Iset, q
nset
coordinate transformation
- Iact, q
- nact
Uset
P field current controller
field controller
θset
R.S i.S
K
u.S
Phi
Iset, d
- θact
EMF EMK
ϕ .S
- Iact,d
motor model
IUVW i.S i'.R
i.Sq
M
Field generating current in the stator Stator current Torque gener. current Field gener. current
i.μ
is iq id
i.Sd Φ.H
Sensorless Vector Control ¾ for standalone induction motors of high power ratings and medium to high dynamic performance. ¾ for a speed range up to 1:20. (> 2.5 % fn)
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Automation and Drives
Torque setpoint in open, closed loop control [710]
Is set to zero in open loop control
current controller
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SITRAIN Training for Automation and Drives
Operating type ”Vector”: sensorless vector control at 0 Hz / ASM zero crossing
¾The position of the flux-vector and the actual speed are only determined via motor model. ¾The model bases its calculation on the accessible currents and voltages. ¾At low frequencies (around 0 Hz), the model is not able to determine flux and speed with sufficient accuracy. For longer than very temorary operation in this range, a changeover from closed-loop control to open-loop control is inevitable.
Unique features of the sensorless vector control of SINAMICS: ¾ Transition through the range of low frequencies (around 0 Hz) in closedloop control ¾ Open-loop control operation after parameterizable delay time (max 2 sec.) at low frequencies (min. 1 Hz).
The high-performance sensorless vector control allows to keep the range of open loop control at low frequencies very small; thus many applications do not require an encoder.
SINAMICS
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Automation and Drives
Operating type ”Vector”: encoder-based vector control (VC) / ASM speed controller
torque current controller Iset, q
nset
coordinate transformation
- Iact, q
- nact
Uset
P field current controller
field controller
θset
K
Phi
Iset, d
- θact
- Iact,d
motor model
IUVW
M G
Closed-loop vector control with encoder is required for ¾ very high accuracy of the speed ¾ very dynamic applications (step of reference, step of load) ¾ torque control of a control range beyond than 1:20 ¾ operation below approximately 5 % of the rated motor frequency p0310 if a high dynamic or static accuracy of torque or speed are required
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SITRAIN Training for Automation and Drives
Encoder interface SMC30
• • •
The SMC30 evaluates TTL / HTL encoder signals and a KTY sensor. In case of signal loss, an automatic changeover to “sensorless” operation can be requested (p0491 / fault is monitored, drive maintains operation). The sequence of “running measurement / encoder test” can be influenced via p1959.
SINAMICS
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Automation and Drives
Trace samples for speed control
step of reference (low dynamic)
step of reference (medium dynamic)
step of load (low dynamic)
step of load (medium dynamic)
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SITRAIN Training for Automation and Drives
Control scheme for AC-drives
torque pre-control speed pre-control position xset
nset
power unit
current
speed
motor
PWM
Iset
encoder G
M - xact
- nact
- Iact Iq Id
position KV...gain
motor model
KP…gain TN…int.time
Siemens AG 2007. All rights reserved.
Iβ
2 3
IV
ωM
IW
ϕM
rotor position
speed
SINAMICS
IU
Iα
KP…gain TN...int.time
Date: File:
encoder evaluation
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Automation and Drives
Speed and current control speed controller
torque setpoint
torque limit
DRIVE CLiQ
current setpoint filter
current controller power unit
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SITRAIN Training for Automation and Drives
Speed controller [6040]
SLVC
VC
p1470
p1460
p1472
p1462
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SITRAIN Training for Automation and Drives
Torque setpoints [6060]
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Torque limits [1700]
r0079
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SITRAIN Training for Automation and Drives
Torque limits
A negative value at the output of the positive torque limit results in an acceleration of the drive in negative direction!
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SITRAIN Training for Automation and Drives
Torque limits [706]
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SITRAIN Training for Automation and Drives
Current controller
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SITRAIN Training for Automation and Drives
Optimization
Training objectives: • You are able to optimize the current- and speed controller - in the time range - in the frequency range
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Automation and Drives
Optimization Content
Page
Scheme of closed loop control (example: feed drive) ....................................................................... Structure of a speed control loop...................................................................................................... Main objectives of (speed-)controller optimization............................................................................. Cascade control and its evaluation................................................................................................... Quick-optimization of a PI controller................................................................................................. Transient function / step response.................................................................................................... Application-specific optimization schemes........................................................................................ Current controller optimization.......................................................................................................... Optimization of a speed controller with PI-characteristic................................................................... Transfer function and frequency response........................................................................................ Amplitude- and phase-response....................................................................................................... Bode diagram of the setpoint value frequency response................................................................... Recording the transfer function of the open control loop.................................................................... Phase- and Amplitude-reserve (open control loop)........................................................................... Evaluation of the control property (closed control loop)..................................................................... Step response in the frequency and time range................................................................................ Bode diagram of a 2-mass system (ONLY controlled system)..........................................................
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
continued on page 3
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SITRAIN Training for Automation and Drives
Optimization Content Page Frequency response (multi-mass system / ONLY controlled system)................................................ 21 Multi-mass system / closed control loop........................................................................................... 22 Multi-mass system / closed control loop........................................................................................... 23 Multi-mass system / closed control loop........................................................................................... 24 Multi-mass system / closed control loop........................................................................................... 25 Characteristics of low pass and band stop filters.............................................................................. 26 Evaluation of the filter criteria........................................................................................................... 27 Multi-mass system / closed control loop........................................................................................... 28 Multi-mass system / closed control loop........................................................................................... 29 Current setpoint filter / at resonance of the speed control loop.......................................................... 30 Setpoint frequency response in the speed control loop..................................................................... 31 Speed setpoint filter / at resonance of the position control loop......................................................... 32 Measuring functions......................................................................................................................... 33 Modes of application of measuring functions.................................................................................... 34 Current controller optimization.......................................................................................................... 35 Speed controller optimization........................................................................................................... 36 Reference model for the speed control loop (Servo + Vector)........................................................... 37 Settings for the reference model....................................................................................................... 38 Reference model and symmetry filter............................................................................................... 39
SINAMICS
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Automation and Drives
Scheme of closed loop control (example: feed drive) Torque pre control Speed pre control Position xset
Speed nset
Power unit
Current
Motor Encoder
PWM
Iset
G
M - xact
- Iact
- nact
Current actual value Iq
Motormodel
Id
KV...Gain
– Xact
2 3
IV
ωM
IW
ϕM
Encoder evaluation
KP... Gain KP... Gain TN... Integral time TN... Integral time
Position
Xset
Iβ
Rotor position
Speed
Position
IU
Iα
Speed
Current
nv
Iv
nset
Iset – nact
Current 1/L uA
–
Siemens AG 2007. All rights reserved.
Angle
ϕM
– EMF
Iact ϕM
SINAMICS
iR
Torque Speed (Motor + Load) cM, KT ML 1/GGes MM ωM
Date: File:
IR ωM
06.03.2007 ABU DHABI: Page 10 - 4
KE
SITRAIN Training for Automation and Drives
Structure of a speed control loop Controller
Controlled system Disturbance
Setpoint value n.set
Speed controller
Manipulated value
I.set Power unit
Current controller
n.act Measuring transducer
Control loop
Measuring transducer
Controlled value T
Motor
Load
Feedback
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SITRAIN Training for Automation and Drives
Main objectives of (speed-)controller optimization Dynamics
is defined by • short rise time in time range • large bandwidth in frequency range is obtained by • large controller gain k.P • short cycle time t.cycle
Stability
is defined by • small overshoot in time range • large phase reserve in frequency range is obtained by • small controller gain k.P • large rise time T.N
Accuracy
is defined by • small following error in time range • large controller gain at low frequencies in frequency range is obtained by • large controller gain k.P • dynamically acting integral action controller property; small rise time T.N
Robustness
Is the ability to provide both stability and dynamic response despite changes of the controlled system (aging, change of temperature). Robustness requires to compromise dynamic performance, stability and accuracy.
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SITRAIN Training for Automation and Drives
Cascade control and its evaluation Advantages of cascade control:
• Step by step commissioning of the control loops from the inside to the outside (Current Æ Speed Æ Position) ; independent settings. • Lower-level controllers act as substitute delay time for the superposed system and in this way affect the dynamic properties of the whole system in respect to setpoint response. This disadvantage can be compensated by implementing pre control on the lower-level control loops. • Easy to do limiting of the lower-level controlled value by limiting the superposed control setpoint value. • Effects of non-linearity are limited. The superposed controller features reduced non-linearity. • Reduction of delay times via compensation of the lower-level control loop. • In the lower-level controller disturbances are immediately corrected and compensated very quickly.
There are many possibilities to evaluate the control response of a control system: Methods to describe the dynamic response characteristic Time range
Frequency range
Description by means of differential equation
Description by means of frequency response
Description by means of step response
Frequency response equation (formulas)
SINAMICS
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Bode diagram (graphical)
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Automation and Drives
Quick-optimization of a PI controller
Input (Setpoint)
Output (Actual value) PI controller Setpoint
Manip. value System
Actual value
Oscillation
KP... Gain TN... Integral time t
Set the integral time to a very large value (i.e. 1000ms) Input a constant input signal (1..5% of maximum value) to optimize at a friction-optimal operating point
t
Increase KP until controller oscillates (evaluate the manipulated value)
Reduce KP to half of that value Now reduce TN until the controller oscillates again
Set TN to the double of that value
VERY rough procedure
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SITRAIN Training for Automation and Drives
Transient function / step response x Overshoot
speed Tolerance band
Trise
torque
t
Trecovery
Output (actual value) too
Increase the gain KP and repeat measurement
slow
Output (actual value) t Output (actual value)
1 Set integral time TN to a large value, i.e. 1000ms (or define P-controller) 2 Input a step of reference 3 The manipulated value must not go into limit
Kp
1) KP is optimal 2) Now decrease TN (TN ≈ rise time) to allow only one undershoot
Tn t Output (actual value)
only one undershoot; in consequence an overshoot of 20–50 %
t
Tan
too
Decrease the gain KP and repeat measurement
dynamic example speed controller
t
SINAMICS
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SITRAIN Training for Automation and Drives
Application-specific optimization schemes X [%]
Symmetrical optimum (SO) 43,4% 4,3%
Value optimum (BO, Betragsoptimum)
100%
Linear optimum, LO
SO: preferred for speed control loops BO: preferred for current control loops LO: preferred for position control loops 3,1
SINAMICS Siemens AG 2007. All rights reserved.
4,7
X ... Controlled value [%] σ ... Sum of small delays
Date: File:
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σ
SITRAIN Training for Automation and Drives
Current controller optimization
Siemens drives If the motor was selected via the menu “motor selection..." and once the motor data have been downloaded to the drive, you can do without the current controller optimization. Along with the actual motor data the motor selection sets optimized controller settings. A recording of the current actual value step response in the time range allows a reliable evaluation of these standard settings. In the operating mode Vector, the commissioning tool STARTER offers an automatic motor identification for the self-optimization of induction motors. In a number of test runs relevant electrical data of the induction motor are determined automatically. Based on these values the current controller is optimized automatically. Third party drives For third party drives, the operating mode Servo requires an individual optimization of the current controller. To do this a small step of setpoint is programmed (to initially maintain the standard parameter settings is a good start condition) and the step response of the current actual value is analyzed. Aim to get the shortest possible rise time combined with a good damping, i.e. the overshoot should not be larger than max. 10% (the step response should come close to the Value Optimum).
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Optimization of a speed controller with PI-characteristic
speed
torque
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Transfer function and frequency response Linear measuring system (direct MS) Encoder
Table (Load)
Coupling
Motor Ball screw
“infinitely large mass“ (not affected by the movement of the load)
Machine base
Spring Response to the noise signal
Noise signal
mLoad Damper
Numerical control
xMotor Transfer function = Frequency response =
xLoad
Response to the noise signal Noise signal
The processing of this transient function within a large frequency band results in the amplitude and phase response of the BODE diagram.
SINAMICS
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Automation and Drives
Amplitude- and phase-response Amplitude response
Input value e
A =
Spring
e System
a
aˆ eˆ
eˆ aˆ
Damper
Phase delay
Mass
ϕ = 360° ⋅
Δt
Output value a
Eingang
f1 low
The output can follow the input
f2 middle
The output oscillates with large amplitude ⇒ resonance
Ausgang
f3 high
The output hardly moves. The damper operates optimally ⇒ shock absorber
A( f1 ) = 1
A( f 2 ) >> 1
A( f 3 ) 12 dB
-45
-
-90 -135
600 > Phase reserve > 300
Phase reserve
-180 -225 -270 -315 -360 1
10
SINAMICS Siemens AG 2007. All rights reserved.
100 Date: File:
Frequency [ Hz ]
06.03.2007 ABU DHABI: Page 10 - 17
SITRAIN Training for Automation and Drives
Evaluation of the control property (closed control loop) Amplitude [ dB ]
The gain peak (max. 5 dB) defines the overshoot
0 - 3dB
-20
Amplitudemargin
Natural frequency as high as possible Gain peak to a maximum of +5dB
-40
At a phase more negative than -180 degree Æ amplitude < 0 dB (amplitude reserve required)
Phase [ Grad ]
0
-90 resonance frequency (at gain peak) -180 The natural frequency (-3 dB) defines the rise time
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 10 - 18
SITRAIN Training for Automation and Drives
Step response in the frequency and time range Natural frequency: 40 Hz
Natural frequency: 40 Hz
Gain peak: + 6dB
Gain peak: + 12dB
The natural frequency defines the rise time The gain peak defines the overshoot
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
06.03.2007 ABU DHABI: Page 10 - 19
SITRAIN Training for Automation and Drives
Bode diagram of a 2-mass system (ONLY controlled system) Spring
mLoad
mMotor Damper
xMotor
xLoad
Pole position
Pole position = Resonance frequency Æ critical if control loop is closed via motor encoder
Zero position Zero position = Natural frequency Æ possibly critical if control loop is closed via machine encoder
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 10 - 20
SITRAIN Training for Automation and Drives
Frequency response (multi-mass system / ONLY controlled system)
n.act m.set
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
SITRAIN Training for
06.03.2007 ABU DHABI: Page 10 - 21
Automation and Drives
Multi-mass system / closed control loop
Amplitudemargin
For a phase more negative than -180 degree, the Amplitude has to be < 0 dB! Æ the large amplitudemargin allows to increase the gain k.P
n.act n.set
An increase of the gain k.P reduces the amplitude margin
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 10 - 22
SITRAIN Training for Automation and Drives
Multi-mass system / closed control loop Danger !
Pole position is no longer damped (positive dB) Requirement of amplitude reserve is violated !
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 10 - 23
SITRAIN Training for Automation and Drives
Multi-mass system / closed control loop Filter not yet activated
Filter as band stop to compensate the pole position
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 10 - 24
SITRAIN Training for Automation and Drives
Multi-mass system / closed control loop Filter activated Result
Amplitude < 0 dB Æ sufficient Amplitude reserve Æ gain k.P can again be increased
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 10 - 25
SITRAIN Training for Automation and Drives
Characteristics of low pass and band stop filters
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 10 - 26
SITRAIN Training for Automation and Drives
Evaluation of the filter criteria Notch frequency
Notch depth 50%
Bandwidth 50%
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
SITRAIN Training for
06.03.2007 ABU DHABI: Page 10 - 27
Automation and Drives
Multi-mass system / closed control loop k.P is set to its optimum value as the resonance peak starts to show up
To achieve a higher natural frequency (shorter rise time) T.N is reduced
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 10 - 28
SITRAIN Training for Automation and Drives
Multi-mass system / closed control loop
As the natural frequency increases (shorter rise time) the gain peak increases as well (speed overshoot) If this rise time is required (dynamic response), but no speed overshoot can be accepted, the reference model has to be activated and optimized
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06.03.2007 ABU DHABI: Page 10 - 29
Automation and Drives
Current setpoint filter / at resonance of the speed control loop Speed controller
Filter 1
Filter 2
Filter 3
Current controller Iset
nset
nact
Filter 4
KP... Gain TN... Integral time
Low pass Natural frequency damping
Band stop Lock frequency Band width
Iact
KPi... Gain TNi... Integral time
Filter 1: preset for Motor ÅÆ Encoder coupling
Amplitude response without band stop
Current setpoint filter
Amplitude response with band stop
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 10 - 30
SITRAIN Training for Automation and Drives
Setpoint frequency response in the speed control loop By analyzing the setpoint frequency response, the gain and integral time can be set to values that ensure a high natural frequency with sufficient stability reserve. For the optimization and frequency response measurements in the speed control loop, the speed setpoint filters have to be “switched off“. They have no effect on the speed control loop stability, but they substantially affect the result of the measurement.
kp=0.3
kp=0.03 Tn=50,0
Tn=5,0
The “more dynamic“ settings of Kp and Tn result in Æ higher natural frequency / Æ shorter rise time Æ larger gain peak / Æ larger speed overshoot
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 10 - 31
SITRAIN Training for Automation and Drives
Speed setpoint filter / at resonance of the position control loop
Without influence on the dynamics of the speed control loop To dampen resonance in the in the position control loop To avoid the static following error when using setpoint ramps
For interpolating axes, the axis-specific system delay has to be considered as it will differ with differently set speed setpoint filters!
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 10 - 32
SITRAIN Training for Automation and Drives
Measuring functions • Controller optimization with automatic suppression of superposed control loops. • Easy to do parameterization • Immediately ready to run: • function generator • trace channels
Pre-configured measuring functions: 1 2 3
Speed controller setpoint frequency response (after speed setpoint filter) Speed controlled system (signal injection after current setpoint filter) Speed controller disturbance frequency response (after current setpoint filter) Speed controller setpoint frequency response (before speed setpoint filter)
5 6 7 8
Speed controller step of setpoint (after speed setpoint filter) Speed controller step of disturbance variable (after current setpoint filter) Current controller setpoint frequency response (after current setpoint filter) Current controller step of setpoint (after current setpoint filter)
step of speed setpoint
frequency response
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06.03.2007 ABU DHABI: Page 10 - 33
Automation and Drives
Modes of application of measuring functions 1
5
2
3
Current
7
8
6
Identification
current control loop
frequency range
mode 7
Verification
response current controller - setpoint
time range
mode 8
Identification
speed control loop
frequency range
mode 2
Verification
response speed controller – setoint value
frequency range
mode 1
response speed controller – setpoint value
time range
mode 5
response speed controller – disturbance value
frequency range
mode 3
response speed controller – disturbance value
time range
mode 6
control loop
Speed control loop
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 10 - 34
SITRAIN Training for Automation and Drives
Current controller optimization
1
2
Signals to be recorded:
SINAMICS
1. 2.
Date: File:
Siemens AG 2007. All rights reserved.
r77: torque generating current setpoint r78: torque generating current actual value
SITRAIN Training for
06.03.2007 ABU DHABI: Page 10 - 35
Automation and Drives
Speed controller optimization
1
2
Signals to be recorded:
SINAMICS Siemens AG 2007. All rights reserved.
3
1. 2. 3.
Date: File:
r62: speed setpoint after the filter r61: speed actual value (motor encoder) r80: torque actual value
06.03.2007 ABU DHABI: Page 10 - 36
SITRAIN Training for Automation and Drives
Reference model for the speed control loop (Servo + Vector) r62[D]
n.set
P
m.set Kp
speedcontroller
I Tn
r1436[D]
n.act p1433[D]
r61[D]
p1434[D] p1435[D] reference model off Vm on
r61
The reference model delays the set-actual-deviation for the integral component of the speed controller. In consequence, transient overshoot is noticeably reduced.
r62
Steps of load are controlled with the high dynamic property set via proportional gain.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
t Trise
SITRAIN Training for
06.03.2007 ABU DHABI: Page 10 - 37
Automation and Drives
Settings for the reference model
1)
Set the damping in respect to the currently valid response criteria of the speed control loop (refer to diagrams below)
2)
Experimentally identify the natural frequency to have the transfer function of the reference model (*) match the transfer function of the closed speed control loop as good as possible
3)
Evaluate the dead time from the step response (see diagram)
(*) (*) trace of: input = r0062 ; output = r1436
Tt
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Date: File:
06.03.2007 ABU DHABI: Page 10 - 38
SITRAIN Training for Automation and Drives
Reference model and symmetry filter setpoint control
m.set
n.set k.P
Reference model
referencemodel
speedcontroller
k.P T.N
control of disturbance variable
n.act
setpoint control
n.set
x.set
Symmetry filter
symmetryfilter
positioncontroller
k.V
control of disturbance variable
x.act
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 10 - 39
SITRAIN Training for Automation and Drives
Basics of communication with PROFIBUS-DP
Training objectives: SIMATIC
• You are informed about some of the possibilities of PROFIBUS communication according to PROFIdrive V4 with cyclic and acyclic data exchange
SIMATIC
S7 M7
1
?
PROCESS FIELD BUS
• You know how to integrate a SINAMICS slave into the S7 Hardware Configuration • You know how to use Standard Telegrams and how to adapt the interface “wiring” • You are familiar with the particularities of internal and external control and status words
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
SITRAIN Training for
06/03/2007 ABU DHABI: Page 11 - 1
Automation and Drives
Basics of communication with PROFIBUS-DP Content
Page
Communication within the SINAMICS-family.................................................................................... Application of selected PROFIdrive V4 functions.............................................................................. Net data........................................................................................................................................... SINAMICS slave on PROFIBUS....................................................................................................... Configuration with STARTER or SCOUT.......................................................................................... Standard telegrams / i.e. S120 V2.2................................................................................................. Standard telegrams / i.e. S120 V2.4 [2420]...................................................................................... Standard telegrams / i.e. G150 V2.4 [2420]..................................................................................... Receive and send signals................................................................................................................. PZD receive signals / drive objects “LM, CU, TB, TM“ [2481]........................................................... PZD receive signals / drive object “Servo, Vector“ [2460]................................................................. Control word 1 (PROFIdrive-Profile / Standard Telegram) [2442]...................................................... Assignment of control words............................................................................................................ Control word sequence control / Motor Module [2501]...................................................................... Control word sequence control / Active Line Module [8920].............................................................. Control word and Status word / external and internal........................................................................ Status word 1 (PROFIdrive-Profil / Standard Telegram) [2452]......................................................... PZD send signals / drive object “Servo, Vector“ [2470]..................................................................... PZD send signals / drive object “LM, CU, TB, TM“ [2483]................................................................ Extension of the telegram length of a Standard Telegram.................................................................
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 11 - 2
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
SITRAIN Training for Automation and Drives
Communication within the SINAMICS-family SINUMERIK
OP
SIMOTION SIMATIC
COMM-PC OP direct access
1. PROFIBUS/PROFIdrive 2. PROFIBUS
clock-synchronous (Servo only)
CAN-Bus (CANopen)
cross talking
PROFINET (IRTE)
CBxx slave
CBC10 CBP10 DRIVE-CLiQ
slave
CU320
Line Module
Motor Module
TMxx TMxx further drive systems
RS232 external measuring system
SINAMICS Siemens AG 2007. All rights reserved.
SMExx
speed position temperature
SMCxx
SMIxx factory-PC
Date: File:
SITRAIN Training for
06/03/2007 ABU DHABI: Page 11 - 3
Automation and Drives
Application of selected PROFIdrive V4 functions SIMATIC S7
Functionality
SIMATIC M7
1
Automation (Master Class 1) S7, S5, others
Cyclic communication (SFC14/15)
Engineering (Master Class 2) STARTER
Operation (Master Class 2) SIMATIC HMI
Acyclic communication (SFC58/59 and DS47) Clock synchronous operation (only “Servo“) Cross-talking Routing
cross traffic (slave) drive. ET200
OP Direct Access Teleservice
drive, ET200
cyclic channels
acyclic channels
PROFIBUS-communication-board
SINAMICS
Direct access to parameters
Routing
Cross-talking
PROCESS FIELD BUS
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 11 - 4
SITRAIN Training for Automation and Drives
Net data Main tasks of the Master-Slave-Communication: 1. • •
Writing and reading of parameters: reading faults and diagnostics signals reading and changing function values i.e. in set-up mode
2. • •
Controlling the operating process: permanent assignment of control bits and setpoint values permanent reading of status and actual values
parameter data range (PKW)
process data range (PZD)
source of main setpoint
value of main setpoint
source of control bits
logic state of control bits The data are transferred:
• •
on request only if necessary with free access to any parameter
• •
fast and permanently with assigned (fixed) “wiring” to the process
acyclic
cyclic
via DS47 telegrams SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
via Standard Telegrams SITRAIN Training for
06/03/2007 ABU DHABI: Page 11 - 5
Automation and Drives
SINAMICS slave on PROFIBUS STARTER also allows an easy and comfortable integration of a SINAMICS drive unit into a SIMATIC automation project: GSD-file from CFC
HW Config
The SINAMICS drive unit as a PROFIBUS slave supports: ¾ the integration into SIMATIC/STARTER and SIMOTION for easy engineering ¾ the cyclic communication with (without) Standard Telegrams / clock synchronous operation for Servo ¾ the acyclic communication for drive parameterization
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 11 - 6
SITRAIN Training for Automation and Drives
Configuration with STARTER or SCOUT with S7 HW config PLC-side
Slave-configuration
initially select any kind of Standard Telegram
with STARTER
Drive-side
Drive-configuration
The drive tool (STARTER) is opened from the programming tool (STEP 7). Common data management is provided by using only one project. By selecting a Standard Telegram, the “interface-wiring“ on the drive is automatically configured (BICO). By aligning the communication data (via STARTER) data consistency is guaranteed.
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06/03/2007 ABU DHABI: Page 11 - 7
Automation and Drives
Standard telegrams / i.e. S120 V2.2 Standard Telegrams of the S7 HW Configuration Type Function VECTOR VECTOR
SERVO SERVO
SERVO+ SERVO+ VECTOR VECTOR
PZD: S/R
1
Speed control
2/2
20
Speed control
2/6
2
Speed control
4/4
3
Speed, 1 position sensor
5/9
4
Speed, 2 position sensors
6 / 14
5
DSC, 1 position sensor
9/9
6
DSC, 2 position sensors
10 / 14
102
Speed, T-Red., 1 pos. sensor
6 / 10
103
Speed, T-Red., 2 pos. sensors
7 / 15
105
DSC, T-Red., 1 pos. sensor
10 / 10
106
DSC, T-Red., 2 pos. sensors
11 / 15
116
DSC, T-Red., 2 pos. sens. + act.val 11 / 19
352
PCS7
6/6
370
Active Infeed
1/1
390
CU320: Digital I/O
2/2
391
CU320: Digital I/O
3/7
999
Free BICO
-/-
automatic BICO-“wiring“ with STARTER
p0922 = 1
p0922 = 106
p0922 = 999
In the S7 HW Configuration all Standard Telegrams according to PROFIdrive - Profile V4 are available. On the drive the automatic BICO-configuration is limited to the telegrams relevant for the selected operating type (Servo, Vector).
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 11 - 8
SITRAIN Training for Automation and Drives
Standard telegrams / i.e. S120 V2.4 [2420]
Telegrams 1 to 20 Telegrams 102 to 391 Telegram 999
SINAMICS Siemens AG 2007. All rights reserved.
manufacturer independent Standard Tel. Siemens-specific Standard Telegrams free telegram
Date: File:
automatic configuration in SINAMICS automatic configuration in SINAMICS manual configuration required
SITRAIN Training for
06/03/2007 ABU DHABI: Page 11 - 9
Automation and Drives
Standard telegrams / i.e. G150 V2.4 [2420]
Telegrams 1, 20 Telegrams 352 to 391 Telegram 999
SINAMICS Siemens AG 2007. All rights reserved.
manufacturer independent Standard Tel. Siemens-specific Standard Telegrams free telegram
Date: File:
06/03/2007 ABU DHABI: Page 11 - 10
automatic configuration in SINAMICS automatic configuration in SINAMICS manual configuration required
SITRAIN Training for Automation and Drives
Receive and send signals
Process data
Drive object 1
axis disconnector
Process data
Drive object 2
Process data Process data
type actual
type setpoint
SIMATIC S7
SIMATIC S7
Drive object 1 Drive object 2 Drive object 3 Drive object n
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
SITRAIN Training for
06/03/2007 ABU DHABI: Page 11 - 11
Automation and Drives
PZD receive signals / drive objects “LM, CU, TB, TM“ [2481]
PROFIBUS PROFIBUS receive receive word word
Co-Bi-converter Co-Bi-converter
Internal Internal bits bits r2091.0 r2091.1
r2050[0] r2050[1]
maximum 5 words
i.e. without standard telegram
starting starting with with V2.3 V2.3 aa limited limited selection selection of of standard standard teletelegrams grams is is available available
Offline Offline screen screen shots shots
SINAMICS Siemens AG 2007. All rights reserved.
i.e. individually wired
Date: File:
06/03/2007 ABU DHABI: Page 11 - 12
SITRAIN Training for Automation and Drives
PZD receive signals / drive object “Servo, Vector“ [2460] CTW1
N-set
PROFIBUS PROFIBUS receive receive word word
PROFIBUS PROFIBUS control control word word
Internal Internal control control bits bits
i.e. Standard Telegram 2 r2050[0] r2060[1]
r2090.0 r2090.1
maximum 16 words
SINAMICS Siemens AG 2007. All rights reserved.
“wiring” of receive words and process data automatically ASSIGNED ! Date: File:
06/03/2007 ABU DHABI: Page 11 - 13
SITRAIN Training for Automation and Drives
Control word 1 (PROFIdrive-Profile / Standard Telegram) [2442]
E
7
internal internal control control words words
4
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 11 - 14
SITRAIN Training for Automation and Drives
Assignment of control words PZD 1 (PLC)
Control word sequence control
r 2090.0
p0840
bit 0 / On, Off 1
r 2090.1
p0844
bit 1 / no Off 2
r 2090.2
p0848
bit 2 / no Off 3
r 2090.3
p0852
bit 3 / INV enable
r 0898
r 2090
Control word setpoint channel
SINAMICS Siemens AG 2007. All rights reserved.
r 2090.13
p1035
bit 13 / MOP up
r 2090.14
p1036
bit 14 / MOP down
Date: File:
06/03/2007 ABU DHABI: Page 11 - 15
r 1198
SITRAIN Training for Automation and Drives
Control word sequence control / Motor Module [2501]
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 11 - 16
SITRAIN Training for Automation and Drives
Control word sequence control / Active Line Module [8920]
B = 1011
0 = 0000
4 = 0100
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06/03/2007 ABU DHABI: Page 11 - 17
Automation and Drives
Control word and Status word / external and internal Control Control word word CTW1 CTW1 all Standard Telegrams all Standard Telegrams
Control Control word word CTW2 CTW2 Standard Telegrams Standard Telegrams 22 to to 116 116
MASTERDRIVE-compatible
SIMODRIVE-compatible
Internal Control and Status words: sequence control CTW setpoint channel CTW speed controller CTW monitoring faults / alarms 1, 2 faults / alarms CTW command data set CTW
Status Status word word STW1 STW1 all all Standard Standard Telegrams Telegrams
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
STW STW STW STW
Status Status word word STW2 STW2 Standard Telegrams Standard Telegrams 22 to to 116 116
06/03/2007 ABU DHABI: Page 11 - 18
SITRAIN Training for Automation and Drives
Status word 1 (PROFIdrive-Profil / Standard Telegram) [2452]
internal internal status status words words
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
SITRAIN Training for
06/03/2007 ABU DHABI: Page 11 - 19
Automation and Drives
PZD send signals / drive object “Servo, Vector“ [2470]
STW1
N-act
Internal Internal status status bits bits
PROFIBUS PROFIBUS status status word word
PROFIBUS PROFIBUS send send word word r2089[0]
p2080[0] p2080[1]
p2051[0] p2061[1]
“wiring” of send words and process data automatically ASSIGNED !
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 11 - 20
maximum 19 words SITRAIN Training for Automation and Drives
PZD send signals / drive object “LM, CU, TB, TM“ [2483]
Internal Internal bits bits
Bi-Co-converter Bi-Co-converter
PROFIBUS PROFIBUS send send word word
r2089[0] p2080[0]
p2051[0]
i.e. individually wired
p2051[1]
without assignment / max. 5 (CU: 7) words >> V2.3 V2.3 aa limited limited selection selection of of stand.tel. stand.tel. is is available available
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
SITRAIN Training for
06/03/2007 ABU DHABI: Page 11 - 21
Automation and Drives
Extension of the telegram length of a Standard Telegram PLC-side
Drive-side
Add the signal assignments for the additional telegram word
The The choice choice of of aa free free telegram telegram length length up up to to the the object object dependent dependent maximum maximum length length is is always always possible possible (drive (drive objects: objects: 16 16 words, words, other other objects: objects: 55 words). words). To To extend extend the the length length of of aa Standard Standard telegram, telegram, itit must must be be redefined redefined to to “free “free telegram telegram configuration configuration with with BICO“. BICO“. Already Already existing existing assignments assignments are are maintained, maintained, changes changes are are possible. possible. In In the the HW HW Config Config the the “Standard “Standard Telegram“ Telegram“ is is renamed renamed to to “User “User defined“. defined“.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 11 - 22
SITRAIN Training for Automation and Drives
Options and “functions” Training objectives: You are informed about • cabinet options • safety and protective functions • other functions
SINAMICS Siemens AG 2007. All rights reserved.
SITRAIN Training for
Date: 06.03.2007 File: ABU DHABI: Page 12 - 1
Automation and Drives
Cabinet options and “functions” Content
Page
Basic design and electrical options / S150........................................................................................ Options on the line side.................................................................................................................... Option “line reactor“......................................................................................................................... Option “operation in isolated networks“............................................................................................. DC-link option “Braking Module & Braking Resistor“......................................................................... Options on the motor-side................................................................................................................ Converter-protection in case of long motor cables............................................................................ Options within the Line Connection Module...................................................................................... Protection function “emergency-off, category 0“................................................................................ Protection function “emergency-off, category 1“................................................................................ Protection function “thermistor motor protection“.............................................................................. Protection function “PT100 evaluation unit“...................................................................................... Insulation monitoring for isolated networks....................................................................................... Starting function “automatic restart“.................................................................................................. Main contactor control...................................................................................................................... Brake control.................................................................................................................................... Starting function “restart on the fly“...................................................................................................
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
continued on page 3
SINAMICS Siemens AG 2007. All rights reserved.
Date: 06.03.2007 File: ABU DHABI: Page 12 - 2
SITRAIN Training for Automation and Drives
Cabinet options and “functions” Content
Page
Energy function “V.DC-max-limiting controller“................................................................................. Energy function “power ride through“................................................................................................ Safety Integrated.............................................................................................................................. Safety – function “Safe Torque Off (Safe Standstill)“........................................................................ Safety – function “Safe Torque Off (Safe Standstill)“........................................................................ Parallel operation of power blocks.................................................................................................... Redundant operation of power blocks............................................................................................... Initialization with partial topology...................................................................................................... Simulated operation......................................................................................................................... Synchronization and Bypass............................................................................................................ Operation with different motors......................................................................................................... Technology function “free PID-controller“.......................................................................................... Technology......................................................................................................................................
SINAMICS
SITRAIN Training for
Date: 06.03.2007 File: ABU DHABI: Page 12 - 3
Siemens AG 2007. All rights reserved.
21 22 23 24 25 26 27 28 29 30 31 32 33
Automation and Drives
Basic design and electrical options / S150
S150
Line supply connection Line isolator with input fuses 800A Active Line Module Motor Module Sensor interface Customer’s options Motor supply connection LC-filter, reactor Line Connection Module
Active Interface Module
Active Motor Line Module Module
Standard
Option
¾ SINAMICS S150 features a wide range of peripheral equipment as a standard. ¾ Options allow adaptations to special applications.
SINAMICS Siemens AG 2007. All rights reserved.
Date: 06.03.2007 File: ABU DHABI: Page 12 - 4
SITRAIN Training for Automation and Drives
Options on the line side Netz
L26 load break switch up to 800A • to isolate the unit from the line • for cable and converter protection L26 circuit breaker >800A up to 1600A line isolation, cable- and converter protection
M
bis 800A
L00 EMC radio interference suppression filter (class A1) to reduce radio interference voltage / in addition to the line reactor
800 -1600 A
L13 main contactor (one rsp. 3 in parallel up to 800 A) to isolate the converter from the line supply L22 option “no line reactor” for P 500kW (up to 500kW the reactor comes as a standard) to reduce harmonics feed-back to the line
SINAMICS
SITRAIN Training for
Date: 06.03.2007 File: ABU DHABI: Page 12 - 5
Siemens AG 2007. All rights reserved.
Automation and Drives
Option “line reactor“ • Up to 500 kW with line reactor as a standard. Without line reactor: option L22 - for low short circuit power of the line supply - when using a transformer which is adapted to the system power rating converter connection point
other load
Sk"line
converter
line line supply inductance
line reactor
• Beyond 500 kW without line reactor as a standard (to reduce line side harmonics most drives are supplied by individual transformer) • option L23: with line reactor for high short circuit power of the line supply converter connection point
transformer connection point
Sk "line
Sk1"
line
converter line supply inductance
output
line reactor can be omitted
option code, line reactor omitted
line reactor required
option code, line reactor
RSC < 43
L22
RSC > 43
--
200 ... 500 kW
RSC < 33
L22
RSC > 33
--
>500 kW
RSC < 20
--
RSC > 20
L23
20 Æ Sk“line > 20 PUmrichter reactor for high short circuit power of the line supply SITRAIN Training for Automation and Drives
Option “operation in isolated networks“
ISO (1) (1)
TN-C grounded network
IT
isolated network
In addition to the options line filter and line reactor converters feature an integrated basic interference suppression circuit. In a grounded network harmonics dissipate to the common PE. In isolated networks the converters are operated with insulation monitor. To avoid tripping of the converter by the basic interference suppression circuit it has to be deactivated: remove the metal clip fixed by two screws in the upper end of the power section!
SINAMICS Siemens AG 2007. All rights reserved.
SITRAIN Training for
Date: 06.03.2007 File: ABU DHABI: Page 12 - 7
Automation and Drives
DC-link option “Braking Module & Braking Resistor“ S150: ¾ in regular operation regenerative energy (i.e. when decelerating) is fed back to the line by the active infeed ¾ if controlled deceleration is requested in case of line supply failure as well, an additional braking unit is required G150, G130 ¾ mandatory in case of high regenerative load
¾ the braking unit is available in two power ratings: 100 / 200kW. ¾ the braking unit comprises two units:
- braking chopper - braking resistor
braking unit P20=100 kW
for: 75 - 132 kW
braking unit P20=200 kW
for:
SINAMICS Siemens AG 2007. All rights reserved.
> 132 kW
Date: 06.03.2007 File: ABU DHABI: Page 12 - 8
L61 L62 SITRAIN Training for Automation and Drives
Options on the motor-side L10 dv/dt-filter U
dv/dt= 5 ... 10kV/µs
t
The dv/dt-filter reduces voltage peaks on the motor by limiting the voltage gradient of the inverter output.
L15 LC-output-filter The sine-filter provides a sinusoidal voltage at the motor (voltage peaks are eliminated all together); additionally the converter-typical noise is nearly eliminated. Requirements and consequences: • available only for 380..480 V, up to 200 kW • pulse frequency: 2 kHz Æ 4 kHz • current derating about. 15% (increased losses) • voltage derating (only space vector modulation)
M
SINAMICS
SITRAIN Training for
Date: 06.03.2007 File: ABU DHABI: Page 12 - 9
Siemens AG 2007. All rights reserved.
Automation and Drives
Converter-protection in case of long motor cables Converter output voltage: substitute circuit diagram of a cable with parasitic resistors and capacitors
U M t Converter output current:
shielded cable
unshielded cable on tray
I t
maximum length of cable type of cable
shielded (NYCWY)
unshielded (NYY)
all units *1
300m
450m
note *1: for longer cables two reactors in series
Motor voltage: U t
¾ The cable capacity increases proportional to the length of the cable. ¾ The switching operations of the pulse width modulation result in charging currents of the cable capacity; these are superposed on the motor current and cause additional strain on the inverter. ¾ The parasitic capacity of shielded cables can be up to 50% more than that of an unshielded cable. ¾ To avoid overcurrent tripping of the inverter caused by the charging-/discharging currents maximum cable lengths have to be observed.
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Date: 06.03.2007 File: ABU DHABI: Page 12 - 10
SITRAIN Training for Automation and Drives
Options within the Line Connection Module Extended customer terminal interface (2.TM31)
G61
Sensor Module SMC30
K50
Thermistor motor protection Alarm
L83
Thermistor motor protection Fault
L84
PT100-evaluation unit
L86
Emergency Stop Category 0
L57
Emergency Stop Category 1
L59
Insulation monitor
L87
A variety of options supplements both the protective functions already provided by the software as well as the interfaces for the operative control of the drive.
SINAMICS Siemens AG 2007. All rights reserved.
SITRAIN Training for
Date: 06.03.2007 File: ABU DHABI: Page 12 - 11
Automation and Drives
Protection function “emergency-off, category 0“
L45
Emergency-Off pushbutton
The emergency-off pushbutton is installed in the cabinet door; its contacts are wired to a terminal strip. In conjunction with options L57, L59 and L60 emergency-off functions of category 0 or category 1 can be activated.
emergency-off combination OFF 2 OFF2 = safe stop safe stop, pulses inhibited
main breaker opened power supply disconnected
motor coasts
Emergency-Off, category 0
L57
Emergency-off, category 0 for uncontrolled shutdown according to EN 60 204. The function provides the isolation of the motor from the inverter supply by opening the line contactor; the controller is bypassed by a safety combination unit according to EN60204-1: the motor coasts to standstill. Jumpers offer an operation with AC230V or DC24V.
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Date: 06.03.2007 File: ABU DHABI: Page 12 - 12
SITRAIN Training for Automation and Drives
Protection function “emergency-off, category 1“ emergency-off combination
Δt = 0,5..30s
OFF 3
emergency-off timer
OFF 2
OFF2 = safe stop OFF3 = fast stop safe stop, pulses inhibited
motor decelerates with fast stop ramp
safe stop, pulses inhibited
main breaker opened power supply disconnected
motor is shut down with delay Δt
Emergency-Off, category 1 (AC 230 V)
L59
Emergency-Off, category 1 (DC 24 V)
L60
Emergency-off, category 1 for controlled shutdown according to EN 60 204. The function provides the deceleration of the drive via fast stop (the fast stop ramp can be set as required). In a second step the power supply is disconnected as explained for emergency-off, category 0.
SINAMICS Siemens AG 2007. All rights reserved.
SITRAIN Training for
Date: 06.03.2007 File: ABU DHABI: Page 12 - 13
Automation and Drives
Protection function “thermistor motor protection“ External alarm 1 PTC thermistor for alarm (installed within the windings)
PTC thermistor for fault (installed within the windings)
resistance
temperature
External fault 1
Thermistor-motor protection (alarm)
L83
Thermistor motor protection with PTB-approval for PTC-temperature sensor type A for alarm. Auxiliary supply and evaluation within the converter.
Thermistor-motor protection (fault / trip)
L84
in series with ”PT100”
Thermistor motor protection with PTB-approval for PTC-temperature sensor type A for fault / trip. Auxiliary supply and evaluation within the converter.
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Date: 06.03.2007 File: ABU DHABI: Page 12 - 14
SITRAIN Training for Automation and Drives
Protection function “PT100 evaluation unit“ External alarm 1 External fault 1
in series with ”Thermistor”
L86 Evaluation unit for PT100 - resistors ¾ Monitoring of up to six sensors. ¾ Limit values can be programmed for each channel. ¾ Measuring channels in two groups with three channels each (i.e. three PT100 in the stator windings and two PT100 in the motor bearings). ¾ The output relays are integrated in the internal fault and shutdown circuit of the converter. ¾ The customer can additionally access the signals by two separate fault signalling relays. ¾ Two programmable analog outputs (0/4-20 mA rsp. 0/2-10 V) are available for integration into a higher level control system.
SINAMICS Siemens AG 2007. All rights reserved.
SITRAIN Training for
Date: 06.03.2007 File: ABU DHABI: Page 12 - 15
Automation and Drives
Insulation monitoring for isolated networks Ground fault monitoring on the output side as a standard for TN line supplies A ground fault in the output resulting in fault currents (i.e. insulation fault) is identified via overall current monitoring (vector-addition of three phase currents) and results in a shutdown. In an isolated network the first ground fault triggers no response. insulation monitoring for isolated networks:
ground fault monitoring for grounded networks: 3-phase current actual value measurement
insulation monitor
M
insulation fault
L87
Insulation monitoring
If the drive is operated on an isolated line supply an insulation monitor is required. The device monitors the entire electrical circuit for an insulation fault. Both the insulation resistance and insulation faults on the DC-link and on the motor side of the converter are detected. The two response values can be set from 1 kΩ to 10 MΩ. On reaching the set response values an alarm is output to terminals of the insulation monitoring device (further processing of the alarm by customer specific control). Please note: the EMC-Filter has to be deactivated by removing the metal clip on the power block!
SINAMICS Siemens AG 2007. All rights reserved.
Date: 06.03.2007 File: ABU DHABI: Page 12 - 16
SITRAIN Training for Automation and Drives
Starting function “automatic restart“
SINAMICS Siemens AG 2007. All rights reserved.
Date: 06.03.2007 File: ABU DHABI: Page 12 - 17
SITRAIN Training for Automation and Drives
Main contactor control
With the BiCo-signal wiring as defaulted the main contactor control serves identically as main contactor feedback.
SINAMICS Siemens AG 2007. All rights reserved.
Date: 06.03.2007 File: ABU DHABI: Page 12 - 18
SITRAIN Training for Automation and Drives
Brake control
Basic brake control - for holding brakes only Extended brake control - start of the drive against closed brake - possible use as emergency brake (brake closes with OFF3)
SINAMICS Siemens AG 2007. All rights reserved.
Date: 06.03.2007 File: ABU DHABI: Page 12 - 19
SITRAIN Training for Automation and Drives
Starting function “restart on the fly“
“restart on the fly“ enables the converter to be switched on while the motor is running - because it is still coasting - because of external mechanical power acting on the motor (i.e. fan in piping network). As response to the on command a frequency matching the actual speed is set; after synchronizing the torque is enabled and the drive accelerates to the speed setpoint. In sensorless operation (SLVC) the actual speed is identified automatically by forcing a search current.
SINAMICS Siemens AG 2007. All rights reserved.
Date: 06.03.2007 File: ABU DHABI: Page 12 - 20
SITRAIN Training for Automation and Drives
Energy function “V.DC-max-limiting controller“
An automatic adaptation of the deceleration ramp provides regenerative energy only to the extent of maintaining a factory set level of DC-link voltage.
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Date: 06.03.2007 File: ABU DHABI: Page 12 - 21
SITRAIN Training for Automation and Drives
Energy function “power ride through“
The function power ride through forces the drive to regenerative operation. Using the kinetic energy of the rotating masses the energy fed to the DC-link covers up for internal losses and keeps the drive in operation (short time loss of line supply).
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Date: 06.03.2007 File: ABU DHABI: Page 12 - 22
SITRAIN Training for Automation and Drives
Safety Integrated two-channel scheme SW
SW HW simultaneousness
HW
safety scheme
Safety scheme
two-channel activation and deactivation of safety-functions
Two-channel scheme two independent switch-off channels; one in hardware, one in software Simultaneousness
both switch-off channels have to activate within a specified time
SINAMICS
SITRAIN Training for
Date: 06.03.2007 File: ABU DHABI: Page 12 - 23
Siemens AG 2007. All rights reserved.
Automation and Drives
Safety – function “Safe Torque Off (Safe Standstill)“ P24 Safe standstill on power section P24 Safe standstill on CU320
HW
no torque generating energy
SW
Safe Standstill (SH)
(one terminal for one or for several drives)
Feedback signal
digital-input / password protected parameterization P24
CU320
2 independent trip circuits
μP
Motor Module control within ASIC
internal control NO Safe standstill M P24 = safety-relevant signals
SINAMICS Siemens AG 2007. All rights reserved.
Date: 06.03.2007 File: ABU DHABI: Page 12 - 24
SITRAIN Training for Automation and Drives
Safety – function “Safe Torque Off (Safe Standstill)“ Monitoring and tripping channels of the function “Safety Integrated“ operate in “two-channel” mode. “Safe stop“ makes sure that no torque generating energy will be available on the motor terminals. Once the “safe stop” has been activated, the on command is interlocked.
Monitoring channel Control unit Monitoring channel Motor module
SINAMICS
Date: 06.03.2007 File: ABU DHABI: Page 12 - 25
Siemens AG 2007. All rights reserved.
SITRAIN Training for Automation and Drives
Parallel operation of power blocks
690V / 5600 kW
SINAMICS Siemens AG 2007. All rights reserved.
Date: 06.03.2007 File: ABU DHABI: Page 12 - 26
SITRAIN Training for Automation and Drives
Redundant operation of power blocks CU320
Active Line Module
Active Interface Module
DMC20 (HUB)
Motor Module “A“
Motor Module “B“
VSM
SMC30
Object “A“ Object “B“
If power blocks are operated “in parallel”, operation can be continued with even one of them available only. Requirement: the DRIVE CLiQ wirings of the respective power blocks are star connected.
SINAMICS Siemens AG 2007. All rights reserved.
Date: 06.03.2007 File: ABU DHABI: Page 12 - 27
SITRAIN Training for Automation and Drives
Initialization with partial topology
Settopology
Partialtopology
DRIVE CLiQ encoder power
REMOVAL
In de-energized condition physically remove “drive 1“ and adapt the DRIVE-CLiQ wiring accordingly After Power ON “drive 1“ is specified as “not ready for operation“ Alarm messages: “component missing“ and “BiCo-connections to deactivated objects“ Save the BiCo-connections mentioned via p9495=1 Deactivate drive object “drive 1” via p0105=0 / copy RAM Æ ROM
INSTALLATION
In de-energized condition physically install “drive 1“ and adapt the DRIVE-CLiQ wiring accordingly After Power ON the new serial number of “drive 1“ is copied to the set-topology (if p9909=1) Alarm messages: “Object inactive, ready for operation“ and “interrupted BiCo-connection available“ Activate drive object “drive 1” with p0105=1 Recreate the BiCo-connections with p9496=1 / copy RAM Æ ROM
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Date: 06.03.2007 File: ABU DHABI: Page 12 - 28
SITRAIN Training for Automation and Drives
Simulated operation
Line contactor control is deactivated
24 VDC
CU320
Active Line Module
Motor Module
By providing a small DC-link voltage externally (i.e. 24 VDC) and enabling the inverter any output frequency can be set to run the inverter transistors in V/Hz-control (p1300=0)
Simulated operation of drive functions without motor, without DC-link voltage
SINAMICS
SITRAIN Training for
Date: 06.03.2007 File: ABU DHABI: Page 12 - 29
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Automation and Drives
Synchronization and Bypass
VSM Active Line Module
CU320
Motor Module VSM
DO TM31 DI Selection p1260 = 2 or 3 only in conjunction with function “on the fly” (p1200)
Bypass
Synchronization and Bypass only in SLVC (p1300=20) or V/Hz (p1300=0...19)
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Date: 06.03.2007 File: ABU DHABI: Page 12 - 30
SITRAIN Training for Automation and Drives
Operation with different motors DDS2
selection DDS
DDS0
MDS1 MDS4
- disable pulses - deselect DDS0 enable pulses activate DDS 2
MDS4
SEQUENCE
The request of a new drive data set disables the pulses (p0820, 0821) The internal deselection of the current drive data set de-energizes motor contactor K4 (r0830) The feedback “contactor de-energized“ activates the requested data set and energizes K1 (r0830) After the feedback “contactor K1 energized“ pulses are enabled For a changeover onto a running motor the function “on the fly“ has to be activated (p1200)
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Date: 06.03.2007 File: ABU DHABI: Page 12 - 31
SITRAIN Training for Automation and Drives
Technology function “free PID-controller“
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Date: 06.03.2007 File: ABU DHABI: Page 12 - 32
SITRAIN Training for Automation and Drives
Technology Basic Position motion control (incl. Basic MC)
Actual value Position controlled evaluation positioning Speed setpoint Cam functions
Programmed motion control
Gear (incl. Position)
Master axis functions Electronic gear Synchronization/ desynchronization
Homing
Temperature Control
Electronic cam Temperature controller Table operation or polynominal Controller equations up to optimization 6th degree Motion acc. to VDI 2143
Measuring sensor
basic functions
Cam (incl. Gear)
Scalable curve
optional technology packages
D425 SINAMICS Siemens AG 2007. All rights reserved.
Date: 06.03.2007 File: ABU DHABI: Page 12 - 33
SITRAIN Training for Automation and Drives
EMC / Electromagnetic compatibility
Training objectives: You are informed about causes of electromagnetic interference. You know the general principle of emc-compatible design
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 13 - 1
SITRAIN Training for Automation and Drives
EMC / Electromagnetic compatibility Content
Page
EMC-model...................................................................................................................................... 3 Definition of compartments within a drive system............................................................................. 4 Low frequency noise emissions (< 9kHz).......................................................................................... 5 High frequency noise emissions (> 9kHz)......................................................................................... 6 Earth connection of conductive enclosures ...................................................................................... 7 Earth connection of conductive enclosures....................................................................................... 8 Capacitive coupling.......................................................................................................................... 9 Converters within a cabinet.............................................................................................................. 10 Cables / installation of cables......................................................................................................... 11 Shielding and potential compensation.............................................................................................. 12
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Date: File:
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SITRAIN Training for Automation and Drives
EMC-model
SINAMICS
Date: File:
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06.03.2007 ABU DHABI: Page 13 - 3
SITRAIN Training for Automation and Drives
Definition of compartments within a drive system
interference receiver
interference receiver interference source
interference receiver
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Date: File:
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SITRAIN Training for Automation and Drives
Low frequency noise emissions (< 9kHz) ¾ Voltage distortions ¾ Voltage dips (voltage fluctuations)
¾ Small line impedance of the incoming feeder (Sinv. / SK.line < 0.01) ¾ Line reactor
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Date: File:
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SITRAIN Training for Automation and Drives
High frequency noise emissions (> 9kHz) interference source
noise current IS due to charging effects of the parasitic capacity CP ; causes noise voltage on ZE and ZN
backflow of the noise current IS via shielded motor cable; impedance is reduced by EMC-filter
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Date: File:
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SITRAIN Training for Automation and Drives
Earth connection of conductive enclosures
PLC
converter
noise voltage
motor - in long earth connections of small cross section the noise current generates high noise voltages
noise voltage
PLC
converter
motor
+ star shaped short connections of large cross section considerably reduce inevitable noise voltages
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Date: File:
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SITRAIN Training for Automation and Drives
Earth connection of conductive enclosures Solid bus bar of large cross section for common earth connections Earth connection of metallic subassemblies preferably by flexible lead Use multi strand cable of large cross section to substitute for flexible lead
Earth connection of movable doors by short flexible lead
Solid bus bar of large cross section continued through several cabinets for common earth connections
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 13 - 8
SITRAIN Training for Automation and Drives
Capacitive coupling
interference source
the potential difference between insulated wires causes a noise current IS ; consequently generating noise voltage on Z
using shielded signal cables the noise current IS leaks off via the housing
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
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SITRAIN Training for Automation and Drives
Converters within a cabinet
+ screened line- and motor cables
+ large, conductive base mounting plate + screened PROFUBUS cable crossing the power cable at an angle of 90 degrees + line filter mounted on the large conductive base mounting plate providing effective earth connection - mixed wiring of power- and control cables
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
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SITRAIN Training for Automation and Drives
Cables / installation of cables
¾ Shielded motor cables, as short as possible, of small capacitance per unit length ¾ Install motor cables and the group of temperature sensor-, signal- and data-cables separately (Æ not in parallel to the motor cable / with grounded metal sheets / close to the grounded conduct) ¾ Ground the shield of temperature sensor-, signal- and data-cables on both ends ¾ Ground analog signal cables on one end via capacitor (0.1μF) ¾ Install signal cables “in one piece” (Æ uninterrupted shield) ¾ Ground spare wires on both ends ¾ Twist unshielded wires of the same current circuit with each other
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
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SITRAIN Training for Automation and Drives
Shielding and potential compensation ¾ Ground shields on both ends on a large area (not by separate wire) ¾ Ground the shield directly after entry to the cubicle; continue shielded from here on ¾ Use conductive connector housings to connect shielded cables with each other ¾ Use cables of sufficient cross section (> 10mm2) for the potential compensation between associating parts of the drive assembly ¾ Connect potential compensation cables to one common ground
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 13 - 12
SITRAIN Training for Automation and Drives
Power section components / Component replacement / Test box
Training objectives: You are informed about • the constructional design of power section components of SINAMICS-cabinet-units • Constructional design and wiring of the power block You are familiar with the particularities of the replacement of the main components You can test the functions of the power block with the test box
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
SITRAIN Training for
06/03/2007 ABU DHABI: Page 14 - 1
Automation and Drives
Power section components / component replacement / test box Content
Page
Principle of operation / S150............................................................................................................ Pulse width modulation..................................................................................................................... Principle of operation of an inverter.................................................................................................. Space vector modulation.................................................................................................................. Trace-samples of the inverter output voltage.................................................................................... Active Line Module: rectifying and voltage step up mode.................................................................. Active Line Module: regenerating operation...................................................................................... Rectifying and regenerating operation / Reactive power compensation............................................. ”Elimination“ of voltage harmonics by Clean Power Filter................................................................. ”Elimination“ of voltage harmonics by Clean Power Filter................................................................. Forming of DC-link capacitors.......................................................................................................... Design of a power block................................................................................................................... Combining power modules to create different frame sizes................................................................ Power modules as part of power units.............................................................................................. Power block for ALM (AC DC), MM (DC AC)................................................................................ Electronic sub assembly................................................................................................................... Replacement of spare parts..............................................................................................................
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
continued on page 3
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Date: File:
06/03/2007 ABU DHABI: Page 14 - 2
SITRAIN Training for Automation and Drives
Power section components / component replacement / test box Content
Page
Verifying the de-energized condition................................................................................................. Frame size F, G, H and J................................................................................................................ Fan / Installation and voltage supply................................................................................................. Installation of the Control Interface Board (CIB) / i.e. G150............................................................... Installation of the power block / i.e. G150.......................................................................................... Power block support for safe replacement of the power block........................................................... Shipping device for the power block................................................................................................. Test box and power block................................................................................................................. Circuit diagram................................................................................................................................. Auxiliary supply 24VDC ................................................................................................................... 1. Testing the rectifier function......................................................................................................... 2. Testing the inverter function......................................................................................................... 3. Testing the current transformers................................................................................................... Test of the semiconductors............................................................................................................... Inverter test by applying ohmic load ................................................................................................. Rectifier and inverter analysis by current measurement....................................................................
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
SITRAIN Training for
06/03/2007 ABU DHABI: Page 14 - 3
Automation and Drives
Principle of operation / S150 U, f = constant
U, f = variable
U AC - DC i.e. 3AC, 400V, 50 Hz
Pre-charging
U
Udc
DC - AC
controlled to setpoint voltage
Rectifier
DC-link
U1 V1 W1
Inverter
U2 V2 W2
M
Motor
Line DC-link
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
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SITRAIN Training for Automation and Drives
Pulse width modulation
2 kHz --> 500 µs
Pulse width modulation / Active Line Module
Pulse width modulation / Motor Module
Framesize
Switching frequency Active Line Module
Switching frequency Motor Module
Current contr. sample time
F, G (400V)
4.0 kHz
2.0 kHz (.... 8.0 kHz)
250 μs
F, G (690V)
4.0 kHz
1.25 kHz (.... 5.0 kHz)
400 μs
H, J (400V)
2.0 / 4.0 kHz
1.25 kHz (.... 5.0 kHz)
400 μs
s losse
hing Switc
form c per i m a Dyn
ance
1,25 pulse frequency (kHz) Booksize
8.0 kHz
2.5 / 4.0 kHz (.... 16 kHz)
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
8
400 / 250 μs
SITRAIN Training for
06/03/2007 ABU DHABI: Page 14 - 5
Automation and Drives
Principle of operation of an inverter + U.ZK
U.L1L2
switching state 1
1
2
2
3
4
5
L1 L2 L3
DC-link
- U.ZK U.L2L3
+ U.ZK
motor
4
1
6
3
5
switching state
6 1
2
3
4
5
1
6
- U.ZK switching state
potential condition on motor terminals
transistor nr. (X = closed) 1
2
3
4
X
X
X
5
resulting voltage pointer
6
- L1 1
Z1 Z1
L2 +
+ L3
Z2
2
X
X
Z6
X
Z2
-
+
Z3
+ 3
X
X
X
special state
X
X
X X
Siemens AG 2007. All rights reserved.
Z0
X +
SINAMICS
Z4
+
+ X
Z5
Z3
+
Date: File:
06/03/2007 ABU DHABI: Page 14 - 6
SITRAIN Training for Automation and Drives
Space vector modulation u(t) Z1
Z1
Z2
Z2
Z6
t
Z3
Z5
Z4
t.P
t.P
t.P Z1
Z1
t
t
resulting pointer position : 45 degrees resulting voltage : i.e. 40%
Z2 t
t
resulting pointer position: 30 degrees resulting voltage : i.e. 50%
Date: File:
Siemens AG 2007. All rights reserved.
t
Z2
Z2
SINAMICS
Z1
t
resulting pointer position : 15 degrees resulting voltage : i.e. 60% SITRAIN Training for
06/03/2007 ABU DHABI: Page 14 - 7
Automation and Drives
Trace-samples of the inverter output voltage
0.5 ms
0.5 ms
0.5 ms
0.5 ms
SINAMICS Siemens AG 2007. All rights reserved.
0.5 ms
0.5 ms
0.5 ms
Date: File:
0.5 ms
0.5 ms
0.5 ms
06/03/2007 ABU DHABI: Page 14 - 8
0.5 ms
0.5 ms
0.5 ms
0.5 ms
0.5 ms
SITRAIN Training for Automation and Drives
Active Line Module: rectifying and voltage step up mode VDC=1,5 Vn
S150
Simplified principle of operation: 1. Two line phases are short circuited. 2. The short circuit current is limited by the step up reactors. 3. At the same time the magnetic field of the reactor acts as energy buffer.
VU-V
4. The short circuit current is interrupted. 5. The large current gradient results in a high self induction voltage on the reactor. 6. The self induction voltage is added to the currently valid line voltage. The resulting voltage exceeds the DC-link voltage. 7. Current flows to the DC-link. 8. After 250 μs the discussed cycle restarts (for a pulse frequency of 4 kHz).
Vind= di/dt VU-V
In rectifying operation the Active Line Module operates basically like the Motor Module in regenerative operation. The line supply takes the position of the motor. In rectifying operation current flow through the free wheeling diodes dominates.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 14 - 9
SITRAIN Training for Automation and Drives
S150
Active Line Module: regenerating operation VDC=1,5 Vn VU-V
Simplified principle of operation: 1. At any moment the DC-link voltage is higher than the line voltage. 2. By switching on two transistors the positive and negative DC-link bus bar are connected to a matching line phase. 3. Energy is fed back to the line.
4. To control regeneration one transistor is switched off. 5. The step up reactor maintains the current flow through a matched free wheeling diode. 6. After 250 μs the discussed cycle restarts (for a pulse frequency of 4 kHz). In regenerating operation the Active Line Module operates basically like the Motor Module in motor operation. In regenerating operation current flow through the transistors dominates.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 14 - 10
SITRAIN Training for Automation and Drives
Rectifying and regenerating operation / Reactive power compensation i.line Z i.line
u.line u.ALM
u.line u.ALM
u.ALM
u.line
u.line
u.ALM
u.line u.ALM
Z i.line
u.line
u.ALM
u.line
i.reactive = +20% (inductive reactive load) u.ALM
i.reactive u.line
ϕ ind.
i.line
i.line
i.active
ϕ ind.
i.apparent i.reactive = 20% (of i.ALM.rated)
u.line i.line
u.line i.line
i.active = function (load) ϕ ind.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 14 - 11
SITRAIN Training for Automation and Drives
”Elimination“ of voltage harmonics by Clean Power Filter
Clean Power Filter
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 14 - 12
SITRAIN Training for Automation and Drives
”Elimination“ of voltage harmonics by Clean Power Filter New Clean Power Filter
Considerably more compact design The filter is designed for the drive not to exceed the tolerance-limits up to the 50th harmonic and in the low-frequency range of 2...9 kHz in rated operation. On the line connection point the values of disturbance voltage read a maximum of 1%.
0,12%
Clean Power Technology 0,08%
0,04%
0,00% 5, 7
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
11, 13
17, 19
23, 25
SITRAIN Training for
06/03/2007 ABU DHABI: Page 14 - 13
Automation and Drives
Forming of DC-link capacitors Frame sizes C to F voltage %
ON
ON
ON
storage time less than 1 year
no measure required
storage time 1 to 2 years
energize the DC-link for one hour prior to switching on the inverter
storage time 2 to 3 years
form up the DC-link capacitors according to the characteristic
storage time more than 3 years
form up the DC-link capacitors according to the characteristic
time t [h]
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 14 - 14
SITRAIN Training for Automation and Drives
G150 / G130
Design of a power block
Rectifier • B6-thyristor-bridge, fully controlled
size F, G
2 INV
RECT + 3 INV
• B6-diode-precharging • thyristor firing pulses • basic interferance suppression
RECT + 1 INV
Pre-charging
size H
DC-link
• IGBT+ FW-diodes • IGD: controls IGBTs • heat sink • balancing • current transformers
INV
INV
Inverter
INV
RECT
• capacitors • braking chopper
size J
High efficiency IGBTs / DC-link bus bar with low inductance / very compact design
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06/03/2007 ABU DHABI: Page 14 - 15
Automation and Drives
Combining power modules to create different frame sizes frame sizes of power modules
components of power modules
F
G
H
J
nic tro le c ele odu m
po
rb we su
loc
k
te pla t r o pp
fan
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 14 - 16
SITRAIN Training for Automation and Drives
Power modules as part of power units
components of power modules nic tro le c ele odu m
1 power block
k loc rb e e w lat po rt p o pp su n fa
FS: F 110KW
power module
4 power blocks FS: J 560KW/480V 800kW/690V
The power section (Power Unit) of SINAMICS G150/G130 is an AC-AC unit called Power Module (PM). Its design is basically identical to the power modules of SINAMICS S150 (G150/G130 with thyristor rectifier, however).
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
SITRAIN Training for
06/03/2007 ABU DHABI: Page 14 - 17
Automation and Drives
Power block for ALM (ACÆDC), MM (DCÆAC) IGD-board, IGBT current transformer
Features: ¾ state of art IGBT technology ¾ DC-link bus bar with low inductance ¾ very compact in design ¾ thermal model for high reliability
heat sink
Fro nt
Rectifier / Inverter: ¾IGBT+ FW-diodes ¾IGD: controls IGBTs ¾heat sink ¾current transformers
S150
DC-link:
DC-link bus bars
¾capacitors ¾braking chopper (option)
capacitor battery Power block serves as: ¾ Active Line Module (ALM) as AC/DC-power-block ¾ Motor Module (MM) as DC/AC-power-block Both power blocks are identical in hardware; they differ in: ¾ MLFB, terminal assignments and data of the power-block. The required difference in functionality is provided by software.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 14 - 18
SITRAIN Training for Automation and Drives
Electronic sub assembly Fib re-o ptic
3a 2
Powersupply
3 3b
3 DRIVE-CLiQ sockets
1
3 Communication Interface board 3a Adaptation Interface board 3b Power Stack Adapter
CIB AIBO PSA
Base plate
(shunts, limit value monitoring) (generation of the inverter pulse pattern)
Extended functionality of the CIB-FW starting with V2.3 and CIB-MLFB ...-3 (starting with HW-version M): edge triggered modulation / safe stop / parallel operation of power sections up to 4xLM and 4xMM per CU320
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 14 - 19
SITRAIN Training for Automation and Drives
Replacement of spare parts Adapted to the converter-cabinet as ordered an individual spare parts list is generated for the customer. Spare parts of SINAMICS G150/S150 basic unit (respectively of MM4 PX) are: Power Blocks Electronic module with CU320 Fan, fan transformer and terminal strip X9 Further spare parts of SINAMICS-cabinets are: Terminal Module TM31 Operator Panel AOP30 Power supply 24V SITOP Mechanical and electrical components depending on selected options
Fan replacement: after max. 35 000 operating hours at 40 °C ambient temperature. Collected dust has to be removed every year.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 14 - 20
SITRAIN Training for Automation and Drives
Verifying the de-energized condition
Measuring points up to 690 VAC fan supply example frame size G
Measuring points motor connection frame size F
Measuring points up to 1200 VDC DC-link voltage example frame size F
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06/03/2007 ABU DHABI: Page 14 - 21
Automation and Drives
Frame size F, G, H and J
1 DC-link 2 DC-coupling 3 Motor Module
SINAMICS Siemens AG 2007. All rights reserved.
4 Control Unit 5 Unit fan 6 Terminal strip Date: File:
06/03/2007 ABU DHABI: Page 14 - 22
7 Sensor Module 8 Motor connection 9 Auxiliary voltage
10 PE-bus bar 11 EMC-screenbus bar SITRAIN Training for Automation and Drives
Fan / Installation and voltage supply
The fan is supplied with voltage via contactor; control is provided via module CIB.
After taking out two screws and after removing the single phase supply the fan slides out towards the front.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 14 - 23
SITRAIN Training for Automation and Drives
Installation of the Control Interface Board (CIB) / i.e. G150
PSB
After removal of the CU320 and after sliding out the power supply board (PSB) towards the front module CIB can be removed from the PSB.
SINAMICS Siemens AG 2007. All rights reserved.
1 support of CU 2 optical and signal cables 3 DRIVE-CLiQ cables 4 mounting screws PSB Date: File:
06/03/2007 ABU DHABI: Page 14 - 24
Module CIB is a spare part as such. The parameterization of the power stack data via BINfiles may only be done in factory and in authorized service centers. SITRAIN Training for Automation and Drives
Installation of the power block / i.e. G150
1 line-, motor connection 2 DC-link connection 3 upper mounting screws 4 lower mounting screws 5 support PSB / 5 plug 6 plugs for optical cables 7 plug of thermistor 8 fan mounting screws
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
06/03/2007 ABU DHABI: Page 14 - 25
SITRAIN Training for Automation and Drives
Power block support for safe replacement of the power block 1 Mounting screws 2 Hight adjustment 1
2 A
B
SINAMICS Siemens AG 2007. All rights reserved.
Watch out for horizontal (A) respectively vertical (B) position; make sure the vertical supports cannot slip; carefully tighten the screw handles! (weight of power blocks up to 100 kg) Date: File:
06/03/2007 ABU DHABI: Page 14 - 26
SITRAIN Training for Automation and Drives
Shipping device for the power block 1
4
1. 1. Remove Remove the the power power block block following the guideline following the guideline 2. 2. Pull Pull itit out out onto onto the the power power block support block support 3. 3. Put Put the the power power block block on on the ground (2 persons!) the ground (2 persons!) 4. 4. Mount Mount the the bottom bottom of of the the shipping shipping device device on on the the side side of of the the power power block block 5. 5. Tilt Tilt the the assembly assembly to to the the side side 6. 6. Put Put the the ESD ESD cover cover in in place place and and close close the the cover cover
5 2
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 14 - 27
SITRAIN Training for Automation and Drives
Test box and power block
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 14 - 28
SITRAIN Training for Automation and Drives
Circuit diagram Basic Basic Line Line Module Module Motor Motor Module Module
nicht bei BLM S120 Cabinet
(Pre-charging), (Pre-charging), thyristor thyristor drive drive board board TDB, TDB, thyristors thyristors Testbox 6AG 1064 – 1AA04 – 0AA0
Cables 6AG 1065 – 1AA04 – 0AA0
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
Inverter: Inverter: IGD, IGD, IGBT, IGBT, UCE UCE
Current Current transformers transformers SITRAIN Training for
06/03/2007 ABU DHABI: Page 14 - 29
Automation and Drives
Auxiliary supply 24VDC TDB -X244: 1.. 6
-A20
-X204: 1.. 6
+24V
-A24
AIBO
-A29
IGD -X291: 1.. 2
+24V
+24V
-X208: 1.. 15
-G27
-X278: 1 .. 15
1
PSB
+24V
-X9: 2
-X271: 2 .. 1
-X9: 1
SITOP
2
24V, 3A
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 14 - 30
SITRAIN Training for Automation and Drives
TDB X244
1. Testing the rectifier function
L1, L1, L2, L2, ... ... L+
L+, L+, L+, L+, ... ...
RVL
L1 L2 L3
RVL
Lpre-charging rectifier (diodes)
operation rectifier (thyristors) with TDB
24VDC
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
SITRAIN Training for
06/03/2007 ABU DHABI: Page 14 - 31
Automation and Drives
2. Testing the inverter function T1
T2
T3
L+ US T1 T2 T3 IGD X291
L+ L+ T1 T1 // T2 T2 /T3 /T3
UCE LS
U1 1
U2 1
LIGBTs and control
LL-
24VD C
SINAMICS Siemens AG 2007. All rights reserved.
U3 1
press the key EXECUTE for a maximum of 2 seconds only!
Date: File:
06/03/2007 ABU DHABI: Page 14 - 32
SITRAIN Training for Automation and Drives
CT X23
3. Testing the current transformers
T1
T2
T3
L+
T1 T2 T3
M IGD X291
CT U1 1
L+ L+
L-
U2 1 LLU3 1
24VDC
press the key EXECUTE for a maximum of 2 seconds only!
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
SITRAIN Training for
06/03/2007 ABU DHABI: Page 14 - 33
Automation and Drives
Test of the semiconductors 2999
DC +
This This test test identifies identifies the the function function of of the the rectifierand of the free-wheelingrectifier- and of the free-wheelingdiodes; diodes; itit reveals reveals short-circuited short-circuited IGBTs. IGBTs. In In the the rectifier rectifier of of units units of of larger larger U power are power ratings ratings shorted shorted thyristors thyristors are V indicated by R = “0 Ohm“, shorted indicated by R = “0 Ohm“, W shorted diodes diodes by by R R == “R.pre-charge“. “R.pre-charge“.
L1 L2 L3
DC 2999
DC +
L1 L2 L3
U V W
DC -
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 14 - 34
SITRAIN Training for Automation and Drives
Inverter test by applying ohmic load
L1 L2 L3
In In V/Hz-operation V/Hz-operation the the output output current current is is limited limited to to aa maximum maximum but but not not monitored monitored any any other other way. way.
U
f
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
Consequently Consequently an an inverter inverter can can be be operated operated without without load load respectively respectively at at very very low low load load which which allows allows aa functional functional test test of of the the inverter. inverter.
06/03/2007 ABU DHABI: Page 14 - 35
SITRAIN Training for Automation and Drives
Rectifier and inverter analysis by current measurement At At low low load load the the current current peaks peaks of of the the line line current are unsymmetrical. current are unsymmetrical. The The measurement, measurement, however, however, shows shows that that all all diodes diodes become become conductive. conductive.
High High frequency frequency noise noise and and ripple ripple superposed superposed on on the the sinusoidal sinusoidal output output current current are are consequences consequences of of the the pulse pulse width width modulated modulated output output voltage. voltage.
The The output output current current has has to to be be fairly fairly symmetrical symmetrical for for all all three three phases; phases; pre-condition: pre-condition: ii >> 0.1 0.1 i.rated. i.rated. Missing Missing half half cycles cycles indicate indicate aa faulty faulty inverter. inverter. A A missing missing output output phase phase or or aa phase phase current current considerably considerably smaller smaller than than the the others others indicates indicates unsymmetrical unsymmetrical load load or or aa faulty faulty inverter inverter
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06/03/2007 ABU DHABI: Page 14 - 36
SITRAIN Training for Automation and Drives
Power block / power circuit, interface boards and repair Training objectives: • You are familiar with the circuit diagrams of the cabinet SINAMICS S150 • You are familiar with the circuit diagrams of power blocks • You are familiar with the replacement of the spare part components of the power block
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 15 - 1
SITRAIN Training for Automation and Drives
Power block / Design, diagnosis and repair Content
Page
S150 / FS G [sheet 1 of 11]............................................................................................................. S150 / FS G [sheet 2 of 11]............................................................................................................. S150 / FS G [sheet 3 of 11]............................................................................................................. S150 / FS G [sheet 4 of 11]............................................................................................................. S150 / FS G [sheet 5 of 11]............................................................................................................. S150 / FS G [sheet 6 of 11]............................................................................................................. S150 / FS G [sheet 7 of 11]............................................................................................................. S150 / FS G [sheet 8 of 11]............................................................................................................. S150 / FS G [sheet 9 of 11]............................................................................................................. S150 / FS G [sheet 10 of 11]........................................................................................................... S150 / FS G [sheet 11 of 11]........................................................................................................... Design of a power block................................................................................................................... Connections of the power block (FS F)............................................................................................ Thyristor Rectifier / TDB (FS F) ...................................................................................................... IGBT Inverter / IGD (FS F) .............................................................................................................. CTs and Interface Board / AIBO (FS F) .......................................................................................... Power Supply Board / PSB................................................................................................................
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
continued on page 3
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 15 - 2
SITRAIN Training for Automation and Drives
Power block / Design, diagnosis and repair Content
Page
Thyristor Rectifier / TDB (FS H)...................................................................................................... IGBT Inverter / IGD (FS H).............................................................................................................. IGBT Inverter / IGD (FS H) ............................................................................................................. Current transformers and Interface board AIBO (FS H).................................................................... Power Supply Board / PSB (FS H).................................................................................................. DRIVE CLiQ connection of CIBs (FS H).......................................................................................... Repair work on the power block........................................................................................................ Replacement of an IGBT assembly / Example FS F (1)................................................................. Replacement of an IGBT assembly / Example FS F (2)................................................................. Replacement of an IGBT assembly / Example FS F (3)................................................................. Replacement of an IGBT assembly / Example FS G (1)................................................................. Replacement of an IGBT assembly / Example FS G (2)................................................................. Re-installation of an IGBT assembly................................................................................................. Heat sink compound / Sequence to tighten the screws..................................................................... Table of torque to tighten screws...................................................................................................... Replacement of a power block / Example FS J (1)......................................................................... Replacement of a power block / Example FS J (2)......................................................................... Disassembly of the DC-link capacitor connections............................................................................ Replacement of the IGBTs...............................................................................................................
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
06.03.2007 ABU DHABI: Page 15 - 3
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39
SITRAIN Training for Automation and Drives
S150 / FS G [sheet 1 of 11]
main circuit breaker
230VAC UES (PSB)
fan contactor
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 15 - 4
SITRAIN Training for Automation and Drives
S150 / FS G [sheet 2 of 11] pre charging contactor pre charging resistors
line reactor
UES (PSB) line noise filter
VL (PSB)
clean power filter
230VAC voltage sensing module
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
06.03.2007 ABU DHABI: Page 15 - 5
SITRAIN Training for Automation and Drives
S150 / FS G [sheet 3 of 11]
230V
power block: active line module
SINAMICS Siemens AG 2007. All rights reserved.
to precharging contactor to undervoltage coil and fan contactor Date: File:
06.03.2007 ABU DHABI: Page 15 - 6
SITRAIN Training for Automation and Drives
S150 / FS G [sheet 4 of 11] power block: motor module
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 15 - 7
SITRAIN Training for Automation and Drives
S150 / FS G [sheet 5 of 11]
circuit breaker
auxiliary supply transformer
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 15 - 8
SITRAIN Training for Automation and Drives
S150 / FS G [sheet 6 of 11]
main contactor
230VAC auxiliary voltage
24 V power supply emerg.-off relais 24V to PSB
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
SITRAIN Training for
06.03.2007 ABU DHABI: Page 15 - 9
Automation and Drives
S150 / FS G [sheet 7 of 11]
control unit CU320 DRIVE CLiQ emerg.-off relais
operating panel AOP30
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 15 - 10
SITRAIN Training for Automation and Drives
S150 / FS G [sheet 8 of 11]
terminal board TM31
DRIVE CLiQ
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
SITRAIN Training for
06.03.2007 ABU DHABI: Page 15 - 11
Automation and Drives
S150 / FS G [sheet 9 of 11]
emergency off key 230VAC CU: DO CU: DI 230 V emergency off circuit
main contactor phases 1, 2, 3
230VAC HS (PSB) main contactor
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 15 - 12
SITRAIN Training for Automation and Drives
S150 / FS G [sheet 10 of 11]
cabinet illumination with socket
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 15 - 13
SITRAIN Training for Automation and Drives
S150 / FS G [sheet 11 of 11]
anti condensation heating
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 15 - 14
SITRAIN Training for Automation and Drives
Design of a power block
Rectifier • B6-thyristor-bridge, fully controlled
size F, G
2 INV
RECT + 3 INV
• B6-diode-precharging • thyristor firing pulses • basic interferance suppression
RECT + 1 INV
Pre-charging
size H
DC-link
• IGBT+ FW-diodes • IGD: controls IGBTs • heat sink • balancing • current transformers
INV
INV
INV
Inverter
RECT
• capacitors • braking chopper
size J
High efficiency IGBTs / DC-link bus bar with low inductance / very compact design
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
06.03.2007 ABU DHABI: Page 15 - 15
Connections of the power block (FS F)
SITRAIN Training for Automation and Drives
G150
(1)
PSB
CIB
(1) the transformer tapping has to be selected to match the local line voltage: - for the supply of the fan of the motor module (active line module) - for the internal 230VAC supply of the line connection module
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 15 - 16
SITRAIN Training for Automation and Drives
G150
Thyristor Rectifier / TDB (FS F) AIBO
The firing angle as calculated by CU320 is signalled to module PSA via DRIVE-CLiQ; from module PSA to module AIBO and on to module TDB and to the thyristors.
line
TDB operating rectifier
TDB
pre charging rectifier MIVI
CIB
LWL
CLiQ
PSA
to CT
to INV
AIBO
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
PSB
Automation and Drives
IGBT Inverter / IGD (FS F)
upper switch
AIBO
SITRAIN Training for
06.03.2007 ABU DHABI: Page 15 - 17
lower switch
G150 S150
upper switch
lower switch
AIBO U.CE
IGD
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 15 - 18
SITRAIN Training for Automation and Drives
CTs and Interface Board / AIBO (FS F)
IGD
G150 S150
AIBO (2) connection to
PSB
PSA (1)
TDB
(1) The values of f.set and v.set as calculated by the CU320 are signalled to the PSA via DRIVE-CLiQ; module PSA generates the pulse sequence. (2) Optical cables are controlled via AIBO; from there on to module IGD and to the transistors.
SINAMICS
Date: File:
Siemens AG 2007. All rights reserved.
06.03.2007 ABU DHABI: Page 15 - 19
Power Supply Board / PSB
SITRAIN Training for Automation and Drives
G150 S150
24V ext.
PSB IGD
V.DC / RECT
AIBO
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 15 - 20
SITRAIN Training for Automation and Drives
Thyristor Rectifier / TDB (FS H)
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 15 - 21
IGBT Inverter / IGD (FS H)
G150
SITRAIN Training for Automation and Drives
G150 S150
phase 1
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 15 - 22
SITRAIN Training for Automation and Drives
IGBT Inverter / IGD (FS H)
G150 S150
phase 2
phase 3
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 15 - 23
SITRAIN Training for Automation and Drives
Current transformers and Interface board AIBO (FS H)
G150 S150
wiring see next page
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 15 - 24
SITRAIN Training for Automation and Drives
Power Supply Board / PSB (FS H)
G150 S150
IGD INV 1
SINAMICS Siemens AG 2007. All rights reserved.
IGD INV 2 IGD INV 3 Date: File:
SITRAIN Training for
06.03.2007 ABU DHABI: Page 15 - 25
Automation and Drives
DRIVE CLiQ connection of CIBs (FS H)
G150 S150
PSB 1 / CIB
for power block 1
Additional DRIVE CLiQ connection if two power blocks are paralleled
PSB 2 / CIB
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 15 - 26
for power block 2
SITRAIN Training for Automation and Drives
Repair work on the power block
On the power block following parts may be replaced: • IGBT/IGD-assembly • Thyristors (only G150) • Pre-charging resistors (only G150) • Thyristor control board (only G150) • Current transformers
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SITRAIN Training for Automation and Drives
Replacement of an IGBT assembly / Example FS F (1)
Disconnect the plugs with the optical cable (numbered from bottom up; verify!) Disconnect the auxiliary supply (press the release catch)
Undo the top IGBT-connections (Torx 30)
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Remove the 6 screws of the bus bars (screws are self tapping in the plastic support; be careful in re-assembling) 06.03.2007 ABU DHABI: Page 15 - 28
SITRAIN Training for Automation and Drives
Replacement of an IGBT assembly / Example FS F (2)
Remove the fixing screws of the PCB (Torx 10)
Lift the copper bus bars free of the IGBTs; slacken the four screws of the transformer assembly to gain clearance between the copper bus bars and the IGBTs
Undo the bottom IGBT connections (Torx 30)
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Current transformers are held in place by a large clip.
To replace one of the current transformers it is suggested to remove the entire transformer assembly prior to exchanging an individual current transformer.
SITRAIN Training for Automation and Drives
Replacement of an IGBT assembly / Example FS F (3)
Undo the eight IGBT fixing screws Note the PCB support spacers of the IGBT-module! Lift the IGBT assembly clear
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Replacement of an IGBT assembly / Example FS G (1)
Disconnect the plugs with the optical cable (numbered from left to right; verify!) Disconnect the auxiliary supply (press the release catch)
Undo the 6 self tapping bus bar fixing screws
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Undo 24 IGBT connections (Torx 25)
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SITRAIN Training for Automation and Drives
Replacement of an IGBT assembly / Example FS G (2)
The bus bars are now loose. In order to lift them, slacken, but do not remove the CT assembly (seven screws) to create space between the copper bus bars and the IGBTs.
Now lift each bus bar individually and temporarily hang it onto the plastic assembly using a spare screw. Bus bars are now clear of the IGBTs; the IGBT assembly can now be removed.
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Re-installation of an IGBT assembly
Install the new IGBT assembly noting the following (as discussed in detail on previous occasions): • Clean the heat sink • Apply new compound in thin layers • Put the IGBT module in place directly after applying the compound • Note the sequence of tightening the screws • Apply jointing compound between IGBT and copper bus bars • Following the right sequence, tighten all screws using the advised torque
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SITRAIN Training for Automation and Drives
Heat sink compound / Sequence to tighten the screws Application of the heat sink compound • Clean the heat sink with alcohol and a cloth free of lint • Apply new compound with a rubber roller in thin layers intersecting at 90 degrees covering the entire base-plate of the module (thickness of compound 0.1 – 0.2 mm; transparent) • Put the the thyristor module in place immediately after applying the compound. • Be careful to place the module in its correct position right away; it must not be relocated after it has been placed in position.
Fixing semiconductor modules • Semiconductor modules and resistors on support plates are extremely sensitive to mechanical stress Æ risk of breaking the ceramic insulation • Place the module onto the heat sink in correct position • Note the sequence of tightening the screws according to the type of module; initially use 0.8 Nm to fix the module • Again observing the sequence of tightening the screws tighten them using the advised torque (refer to the table next page)
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SITRAIN Training for Automation and Drives
Table of torque to tighten screws
Component
Torque
Note
IGBT-module on heat sink
3.0 Nm (+15% / -15%)
pre-tighten with 0.8 Nm
IGD-board on IGBT
2.0 Nm (+5% / -10%)
pre-tighten with 0.8 Nm
Resistors on heat sink
1.8 Nm
pre-tighten with 0.8 Nm
Thermosensors on heat sink
3.0 Nm
PCB-support bolts on heat sink
6.0 Nm
Nuts on PCB-support bolts
6.0 Nm
Power connections on bus bars
13 Nm
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Automation and Drives
Replacement of a power block / Example FS J (1) Remove connection to the DC-link (8 screws)
Disconnect the signal connectors
After taking out 2x4 screws (at the top and on the bottom) remove the motor side copper bus bars Remove the upper fixing bolt (set back)
(the power block in the center has been removed already)
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SITRAIN Training for Automation and Drives
Replacement of a power block / Example FS J (2)
Disconnect the screen of the CT-wiring and remove the plug Remove the lower mechanical fixing on the right hand side of the unit and lift out the complete power block. Please be careful: HEAVY!
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SITRAIN Training for Automation and Drives
Disassembly of the DC-link capacitor connections
Remove the plastic cover Unplug the connections to the symmetrising resistors Remove the assembly of copper and insulating plates. Note: the plates are not fixed together; take care the spacers and plates do not come loose!
Remove all fixing screws and connections (on the side as well)
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SITRAIN Training for Automation and Drives
Replacement of the IGBTs
6 fixing screws to be removed 2 temperature sensors to unplug 3 plastic spacers to watch out for Remove the IGBT drive board
Replace any damaged IGBTs Note the following when putting in new IGBTs: • Wipe off old compound and clean the heat sink • Apply new compound in thin layers • Apply jointing compound between IGBT and bus bar • Observe sequence and advised torque when fixing the screws
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SITRAIN Training for Automation and Drives
Troubleshooting Methodology Training objectives: On the basis of both general and drive-specific steps you will become familiar with troubleshooting processes .
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Troubleshooting Methodology Content
Page
Thought Processes between Error Detection and Removal.............................................................. 3 Professional Troubleshooting Methods............................................................................................. 4 Professional Troubleshooting Methods............................................................................................. 5 Procedures Depending on Complexity of Step Sequence................................................................. 6 Basic Concepts of Logic Analysis..................................................................................................... 7 Principles of Logic Analysis to Determine the Focus Area................................................................. 8 Determining the Focus Area............................................................................................................. 9 Determining the Focus Area / Example for Application..................................................................... 10 The "Split-Half Search" Technique................................................................................................... 11 The "Chess Problem"....................................................................................................................... 12 The "Nine Point Problem"................................................................................................................. 13 What do Experts differently during Troubleshooting?........................................................................ 14 Safety Measures and Initial Diagnosis.............................................................................................. 15 Steps Prior to Troubleshooting/Repair.............................................................................................. 16 Initial Steps when Starting Troubleshooting...................................................................................... 17 Measures for Troubleshooting.......................................................................................................... 18 First Conclusions.............................................................................................................................. 19 Sources of faults and (plausible) consequences............................................................................. 20 Sources of faults and (plausible) consequences ........................................................................ 21 Concluding Tests............................................................................................................................. 22 Solutions .................................................................................................................................. 23 - 27
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SITRAIN Training for Automation and Drives
Thought Processes between Error Detection and Removal Visual check and rough diagnosis Detection of obvious error indications
Problem solver has pre-knowledge about - Failure probabilities - Component functions - Similar fault diagnoses
Setting up a hypothesis about the number of probably probably possible impossible error causes (determination of search area)
Symptoms are defines more precisely via - Measurement - Use of documentation - Asking probing questions - Direct impressions - Making indicative changes
Selection of preferred hypothesis by - Minimizing the checking time - Maximizing the success probability
Check of hypothesis
The first loop pass is rarely successful, but each subsequent pass increases the extend and depth of information.
Cause of error is diagnosed
SINAMICS
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SITRAIN Training for Automation and Drives
Professional Troubleshooting Methods Minimization of amount of trouble or checking time + The checking steps are assessed with regard to the amount of trouble or time they take Æ Steps with take less trouble or time to do have priority i.e. routine checks such as visual inspection of fuse, temperature check by feeling with hand General: visual inspection of plant for anomalies Use of documentation + Definitely neccessary in situations where the technical system is unknown or insufficient knowledge of the system is available i.e. function block diagrams, description of parameters and error messages Checking direct impressions + Direct impressions (i.e. smells, vibrations, noise, heat, visible destruction) can be detected in a very short time Æ They contribute right at the beginning of the troubleshooting process to locate the fault Failure probabilities (historical information) + Accessing information that goes beyond the currently available information maximizes the effectiveness of the diagnosis i.e. your own experience (previously recorded), reports from colleagues, error statistics
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SITRAIN Training for Automation and Drives
Professional Troubleshooting Methods Determine focus of the search (process of elimination) + With the process of elimination, the objective is to select a sequence of steps that allows you to eliminate as many components as possible to quickly narrow down the search focus In a sum of linked components, each component can be assigned to a current error probability; components are assigned to the following groups: - Possibly defective or - Being intact with a high probability (and therefore "not in the focus area") Topographical search + Procedure based on the functional structure of the system Æ Successive checking of system functions until a deviation from the expected setpoint state is detected Generally very time-consuming; typically necessary for diagnosing new types of faults Symptomatic search + Comparison of the sum of the pattern of symptoms of already known faults with the current fault Æ Very effective method when experienced with a technical system Search forwards and backwards + Topographical search with/against the signal or energy flow
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SITRAIN Training for Automation and Drives
Procedures Depending on Complexity of Step Sequence
Level
Description
Diagnostics strategy
Using a sequence of different techniques or checking steps with integrated overall target i.e. topographical/symptomatic strategy
Diagnostic technique
Checking step sequence with partial target tracking i.e. make indicative changes, ask the plant operator probing questions, principle of reducing amount of trouble or time
Checking step
i.e. measure signal level, evaluate error messages, determine “signal wiring” from circuit diagram or from programming
Target Diagnosis of cause of error
Acquisition and evaluation of a system constellation
Acquisition and evaluation of a specific symptom
Checking step To select the diagnostic technique, it is necessary to master specific checking operations (measuring i.e. using tracer / using technical support systems, i.e. motor identification / assigning error messages / reading circuit diagrams) Diagnostic technique To think strategically, you need to master typical diagnostic techniques Symptom = defective fuse / System constellation = at Power ON / Error cause = short circuit in rectifier
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SITRAIN Training for Automation and Drives
Basic Concepts of Logic Analysis Intact input signals are a prerequisite to execute the defined function.
INPUT Each component in the system has a specific function
FUNCTION A functioning component that receives the correct input signals will generate the correct output signals.
OUTPUT
VI VC
T
Input voltage 220 V
Control voltage VC
Output Voltage
Ground
Input A
&
AND gated input conditions dominate
VA F Input B
Output
Æ Function
1
1
1
Intact
Æ Function
1
1
0
Defective
Intact ( 1 )
1
0
0
Undetermined
Defective ( 0 ) Defective ( 0 )
0
1
0
Undetermined
Defective ( 0 ) Defective ( 0 ) Undetermined
0
0
0
Undetermined
Input
Output
Intact ( 1 )
Intact ( 1 )
Intact ( 1 )
SINAMICS
Date: File:
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Automation and Drives
Principles of Logic Analysis to Determine the Focus Area Technical system with six function elements Input A
& F3 & F1
FAILED
& F5
According to the principles of logical analysis which elements are in the focus area?
Input B & F2
& F4
& F6
OK
Input C
Certain conclusion Components linked with intact upstream function units (direction of source of signals) are always considered intact Probable conclusion Components linked with defective upstream function units are considered possibly defective A combination of the certain conclusion and the probable conclusion gives the following result: Components are only in the relevant focus area if they are linked with defective function units upstream and at the same time do not provide the conditions for intact function units.
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SITRAIN Training for Automation and Drives
Determining the Focus Area Technical system with 22 function elements
According to the principles of logical analysis which elements are in the focus area?
& F6
Input A & F1
& F12 & F7
Input B & F2
& F19 & F13
& F8
Input C & F3
& F17 & F14
& F20
& F9
Input D & F4
& F22
FAILED
& F18 & F15
& F10
Input E
OK
& F5
& F21 & F16
& F11
Input F
SINAMICS
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Automation and Drives
Determining the Focus Area / Example for Application Which components are in the focus area according to the principles of logical analysis, and therefore probably in part responsible for the diagnosed error functions?
External 24 VDC TM31 FAILED
Command MC ON
CU320 RECT
MC = main contactor
Mains voltage available
PSB 24 V source
PSB voltage detection
AOP
FAILED
Voltmeter
OK
MC Voltage converter
Fuse
Ground
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SITRAIN Training for Automation and Drives
The "Split-Half Search" Technique Systematic separation of a system Into separate areas to check
A
B
C
D
E
Define areas according to error probability i.e. cable is a fixed installation between A and C, between C and E it is trailing A
B
C
D
E
Cable 10m from A to E Trailing cable
Fixed cable
Select the half-way point preferably so that areas for simple and complex checking are created. I.e. modules that can quickly be exchanged / thyristor that is integrated in the heatsink A
B
C
D
Modules that can be exchanged
E
Thyristor
With complex systems it is hard to find the half-way point. I.e. areas: sensors / control / actuators or mechanical system / electrical system with further subdivision A
B Sensors
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C
D
Control
E Actuators SITRAIN Training for
06.03.2007 ABU DHABI: Page 16 - 11
Automation and Drives
The "Chess Problem"
An imagined mark is positioned on one of the 64 fields. How many questions need to be asked to find the position of the mark?
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SITRAIN Training for Automation and Drives
The "Nine Point Problem"
Join all nine points together with one line without taking the pen off the paper
If you select a search focus that is too small, often no solutions are visible; if the issue seems unsolvable, broaden the search focus accordingly. Example: A main fuse protects two inverters Æ Troubleshooting only one of the inverters (the one that is not defective) will remain unsuccessful.
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SITRAIN Training for Automation and Drives
What do Experts differently during Troubleshooting? Experts have more experience, i.e. specific knowledge about assigning typical error symptoms to possible causes. Experts mainly use depth structure that is not directly visible of the technical system for orientation, i.e. the signal flows and energy flows. Experts spend proportionally more time on analysing the initial situation before starting the search process. Experts do not necessarily have more fundamental knowledge. Their knowledge, however, is better structured, i.e. they can establish and understand relationships, and have in-depth specialist knowledge. Experts draw upon a broader range of diagnostic and checking techniques. Experts use facts as the basis to construct hypotheses that can be tested by experimental investigation. Beginners on the other hand mainly use general hypotheses as the basis and search for confirmation. Experts are more flexible in changing their hypotheses. They recognize early just when it is necessary to change an approach and do not suppress relevant information that would change the thought process. Experts communicate more and more effectively with their colleagues. This provides them with an excellent source to expand their expertise. Experts have participated in courses at the Training Center.
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SITRAIN Training for Automation and Drives
Safety Measures and Initial Diagnosis ¾ Ensure that the inverter is safely disconnected from the mains and that it can only reconnected after you have authorized reconnection.
¾ Ensure that the only way the drive can be switched on is if you activate it (locally).
¾ Ensure that the DC link is discharged before starting any work in the power section (and that no voltage is applied via the mains)
¾ Open the cabinet doors, remove the housing and inspect for visible damage Æ especially in the areas of rectifier, DC link and inverter
¾ If several modules and/or semiconductors in the power block are visibly damaged (signs of burning), exchanging the power block is generally the most economic solution.
¾ Modules themselves are not repaired (no detailed circuit diagrams, no spare parts)
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SITRAIN Training for Automation and Drives
Steps Prior to Troubleshooting/Repair ¾ Let the plant operator explain the fault profile – but check functioning and facts yourself (to a meaningful extent) ¾ Most inverters operate without errors – does this one have any anomalies? ¾ Check the environmental conditions. + High temperature of cooling air + High temperature in cabinetÆ Blocked filter, cooling air short-circuit + Dust (possibly conducting?)Æ Cooling air throughput, blocked filter mats + Condensation water or external fluid ¾ Check the motor and connecting cable for anomalies – old motor, long cables ¾ Inspect the system from the point of view of EMC + Missing or inadequate grounding + Unshielded or incorrectly shielded cables + Contactors that are not connected ¾ Are there any indications for exchange or manipulation of components?
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SITRAIN Training for Automation and Drives
Initial Steps when Starting Troubleshooting ¾ First check the basic requirements + Three-phase power supply available and in tolerance range? + Control commands and setpoints available? Æ Inverter can be operated via AOP? + Motor type and connection correct? Æ Star / Delta + Parameters set correctly in core areas? Æ Motor data, control type
¾ Read out the error and warning log messages to determine the error history
¾ Backup the current parameter settings to a free user file (PF10, 11, 12) ¾ Backup the entire contents of the Flash card to PG
¾ Compare the current parameter settings with the "installation and start-up settings" (if available)
¾ Reset parameters to factory settings and carry out quick commissioning; test the function via the AOP
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SITRAIN Training for Automation and Drives
Measures for Troubleshooting ¾ Changing the inverter (possible with units of small power rating) indicates immediately whether there is an error in the inverter or in the plant ¾ Operate the inverter with another motor if available; ensure correct motor current is used!
¾ Replacing or exchanging a component identifies faulty components (CU, TM, TB, SMC)
¾ Typically, with inverters that have already been commissioned, the errors do not lie in the parameter settings but in the hardware ¾ Check the inverter's functioning + Without motor in V/Hz operation + With motor in V/Hz operation + With motor in SLVC (sensorless vector control)
¾ If a hardware error is present on the inverter, try to find the cause of the error before repairing and testing.
¾ If the inverter can be activated, check the DC voltage, mains voltage and motor currents
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SITRAIN Training for Automation and Drives
First Conclusions ¾ The error is located in the inverter itself Æ Additional troubleshooting in the inverter (rectifier, int. 24V, inverter, modules) ¾ The error only occurs when the motor is connected or with a load Æ Additional troubleshooting in the motor loop, in the "mechanical system" Æ if applicable, in parameter settings that are not adapted to current operating conditions ¾ The error is infrequent Æ The error occurs in connection with external conditions + Supply fault (through brown-out, phase failure) + Switching operations of other load (via mains supply or signal interference) + After a specific time or rise in temperature + Vibrations (loose connections, insulation error) Æ The error occurs sporadically + Component or module error (often related to temperature) + Faults caused by EMC ¾ The error is caused by exceeding the designed capacity of the drive Æ i.e. full torque with synchronous speed in space vector modulation Æ i.e. higher overload than available by currently used inverter Æ i.e. greater dynamic performance than possible with the current motor
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SITRAIN Training for Automation and Drives
Sources of faults and (plausible) consequences ¾ Pre-charging rectifier, pre-charging resistors + No DC voltage, no int. 24V supply + Fuse blown when mains was applied (circuit breaker, main contactor) ¾ Operating rectifier, rectifier control TDB (CU320) + Reduced DC link voltage, significant loss with active-power load on motor Æ Possible follow-up faults: Overloading of pre-charging resistors ¾ Internal power supply PSB + No int. 24V supply (DC link voltage present, only displayed with ext. 24V) + No fan control ¾ DC link voltage detection PSB + DC link voltage present, but not displayed ¾ IGBT inverter, inverter control CIB, IGD (CU320) + U.CE message with ON command + Missing phase in motor current Æ Motor "sputters" or message "Drive blocked" with ON command
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SITRAIN Training for Automation and Drives
Sources of faults and (plausible) consequences ¾ Actual current value acquisition + Overcurrent deactivation + Ground-leakage message + (Considerably) asymmetrical offset adjustment ¾ CU320 closed-loop control module + Possible cause for faulty function - of the operational rectifier - of the I/O modules - of the encoder acquisition - of the PROFIBUS communication ¾ Inverter interface module CIB + Possible cause for faulty function - of the inverter - of the actual current value acquisition ¾ I/O modules TM31, TB30 + No gating via digital inputs, no reaction to analog setpoint values + No status messages via digital outputs, no analog output signals + Incorrect or missing motor temperature messages
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SITRAIN Training for Automation and Drives
Concluding Tests ¾ After the repair work has been completed, the inverter must undergo a functional test: + Motor operation with maximum load in entire (permitted) speed range in the plant-specific open-loop control/closed-loop control type + Operation in "Local" operating mode with AOP and "Remote" according to system ¾ All function areas that were repaired must be explicitly tested ¾ Functions implemented via the program and that were operating correctly before the repair work cannot be faulty (the processor either computes correctly or not at all!) and therefore do not need testing + Speed, torque, current limits + Temperature thresholds + Controller settings + BICO connections + PROFIBUS parameter settings, etc.
¾ If an inverter fails repeatedly (with the same or a similar error), the cause typically is located in the plant environment + Mains supply or EMC problems + Non-compliant operation (i.e. constant ON/OFF, contactor in motor cable)
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SITRAIN Training for Automation and Drives
Solution to “Determine the Focus Area” (1) Technical system with six function elements Input A
& F3
FAILED
& F5
& F1
According to the principles of logical analysis which elements are in the focus area?
Input B & F4
& F2
& F6
OK
Input C
Certain conclusion Components linked with intact upstream function units (direction of source of signals) are always considered intact Probable conclusion Components linked with defective upstream function units are considered possibly defective A combination of the certain conclusion and the probable conclusion gives the following result: Components are only in the relevant focus area if they are linked with defective function units upstream and at the same time do not provide the conditions for intact function units.
SINAMICS
Date: File:
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Automation and Drives
Solution to “Determine the Focus Area” (2) Technical system with 22 function elements
& F6
Input A & F1
& F12 & F7
Input B & F2
& F13
& F3
& F14
& F4
& F20
OK
& F22
FAILED
& F18 & F15
& F10
Input E & F5
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& F17
& F9
Input D
SINAMICS
& F19
& F8
Input C
Input F
According to the principles of logical analysis which elements are in the focus area?
& F21 & F16
& F11
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SITRAIN Training for Automation and Drives
Solution to “Determine the Focus Area” (3) Which components are in the focus area according to the principles of logical analysis, and therefore probably in part responsible for the diagnosed error functions?
External 24 VDC TM31 FAILED
Command MC ON
CU320
PSB voltage detection
RECT
MC = main contactor
Mains voltage available
PSB 24 V source
AOP
FAILED
Voltmeter
OK
MC Voltage converter
Fuse
Ground
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Automation and Drives
Solution to the “Chess Problem” (1)
To solve the problem, the chess board is mentally divided into quadrants. Six questions are required: i.e. 1. 2. 3. 4. 5. 6.
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Columns E – H ? No Æ Columns A – D Rows 1 – 4 ? Yes Æ lower left Quadrant Columns C – D ? No Æ Left half of the quadrant Rows 1 – 2 ? No Æ Upper left area Column B ? Yes Æ B3 or B4 Row 3 ? No Æ Solution: B4
SITRAIN Training for Automation and Drives
Solution to the “Nine Point Problem” (1)
Join all nine points together with one line without taking the pen off the paper
If you select a search focus that is too small, often no solutions are visible; if the issue seems unsolvable, broaden the search focus accordingly. Example: A main fuse protects two inverters Æ Troubleshooting only one of the inverters (the one that is not defective) will remain unsuccessful.
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SITRAIN Training for Automation and Drives
Technical support and Access to spare parts
Training objectives: You know how to access general and specific spare parts lists
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SITRAIN Training for Automation and Drives
Technical support and Access to spare parts Content
Page
Internet access to documentation, firmware, software....................................................................... Support for trouble-shooting via “Support request“............................................................................ Service & Support at Automation and Drives.................................................................................... Your access to ordering spare parts................................................................................................. Your access to ordering spare parts................................................................................................. Deliverable spare parts for SINAMICS............................................................................................. Access to “Spares On Web“............................................................................................................. Specific spare part list via “Spares On Web“..................................................................................... Spare parts for SINAMICS S150...................................................................................................... Contact to order spare parts: Select country and location................................................................. Spare parts via Repair Center.......................................................................................................... Product information via “WebLogX“.................................................................................................. Product information via “WebLogX“.................................................................................................. Spare parts: Registry.......................................................................................................................
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 17 - 2
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SITRAIN Training for Automation and Drives
Internet access to documentation, firmware, software
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 17 - 3
SITRAIN Training for Automation and Drives
Support for trouble-shooting via “Support request“
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 17 - 4
SITRAIN Training for Automation and Drives
Service & Support at Automation and Drives http://support.automation.siemens.com
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 17 - 5
SITRAIN Training for Automation and Drives
Your access to ordering spare parts
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 17 - 6
SITRAIN Training for Automation and Drives
Your access to ordering spare parts
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 17 - 7
SITRAIN Training for Automation and Drives
Deliverable spare parts for SINAMICS
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 17 - 8
SITRAIN Training for Automation and Drives
Access to “Spares On Web“ http://intra1.nbgm.siemens.de/ld-intranet/html_76/ersatzteilkat.html
Intranet offers access to general spare parts available also for customers (PreSales SINAMICS). After definition of order- and serialnumber the specific spare parts list is generated (SINAMICS).
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 17 - 9
SITRAIN Training for Automation and Drives
Specific spare part list via “Spares On Web“
After definition of the serial-number a specific spare parts list is generated for the particular cabinet.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 17 - 10
SITRAIN Training for Automation and Drives
Spare parts for SINAMICS S150
For each cabinet a specific spare parts list containing following information is generated: - order number - quantity - description
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 17 - 11
SITRAIN Training for Automation and Drives
Contact to order spare parts: Select country and location
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 17 - 12
SITRAIN Training for Automation and Drives
Spare parts via Repair Center
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 17 - 13
SITRAIN Training for Automation and Drives
Product information via “WebLogX“ https://www.weblogxparts.industry.siemens.com/WebLogX/Esprit/Internet/Kundenauskunft/Home/Home.aspx
Product numbers and order numbers not listed in WebLogX are handled by other locations. Î For detailed information refer to FDB
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 17 - 14
SITRAIN Training for Automation and Drives
Product information via “WebLogX“
For each product number following information will be provided: • material information • price • contact • number of units on stock
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
SITRAIN Training for
06.03.2007 ABU DHABI: Page 17 - 15
Automation and Drives
Spare parts: Registry
serial-no. order-no.
SINAMICS Siemens AG 2007. All rights reserved.
Date: File:
06.03.2007 ABU DHABI: Page 17 - 16
SITRAIN Training for Automation and Drives