SINAMICS drives SINAMICS DCM DC Converter Migration Guide Reference Manual Edition 06/2015 Answers for industry. SINAMICS SINAMICS DC MASTER Migration Guide Reference Manual 06/2015 A5E35776390A/RS-AA/001;1 Introduction 1 SINAMICS DC MASTER - an overview of the highlights 2 Comparison of the functions 3 Terminal assignment SIMOREG DC-MASTER SINAMICS DC MASTER 4 Commissioning SINAMICS DC MASTER using the BOP20 operator panel 5 Legal information Warning notice system This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger. DANGER indicates that death or severe personal injury will result if proper precautions are not taken. WARNING indicates that death or severe personal injury may result if proper precautions are not taken. CAUTION indicates that minor personal injury can result if proper precautions are not taken. NOTICE indicates that property damage can result if proper precautions are not taken. If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage. Qualified Personnel The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems. Proper use of Siemens products Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed. Trademarks All names identified by (R) are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner. Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions. Siemens AG Division Process Industries and Drives Postfach 48 48 90026 NURNBERG GERMANY A5E35776390A/RS-AA/001;1 06/2015 Subject to change Copyright (c) Siemens AG 2015. All rights reserved Table of contents 1 Introduction ............................................................................................................................................. 7 2 SINAMICS DC MASTER - an overview of the highlights ....................................................................... 11 3 Comparison of the functions .................................................................................................................. 13 4 Terminal assignment SIMOREG DC-MASTER - SINAMICS DC MASTER ............................................ 23 5 4.1 Digital inputs ...........................................................................................................................23 4.2 Digital outputs .........................................................................................................................24 4.3 Analog inputs ..........................................................................................................................25 4.4 Analog outputs ........................................................................................................................25 4.5 Pulse encoder .........................................................................................................................26 4.6 Interfaces ................................................................................................................................27 Commissioning SINAMICS DC MASTER using the BOP20 operator panel ........................................... 29 5.1 Preconditions ..........................................................................................................................29 5.2 Commissioning steps ..............................................................................................................30 SINAMICS DC MASTER Migration Guide Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 5 Table of contents SINAMICS DC MASTER Migration Guide 6 Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 1 Introduction As a result of its functionality, range of power ratings and flexibility, for many years now SIMOREG DC-MASTER has been an extremely successful product series. It has been used for single and multi-motor applications for production machines, in general machinery construction and in all industrial sectors. After the discontinuation of SIMOREG DC-MASTER in February 2014, with our SINAMICS DC MASTER as successor we are continuing the Siemens success story as global market leader for DC converters. Since 2010, with SINAMICS DCM 6RA80 we have a product series completely integrated in the SINAMICS platform with extended modularity and functionality. For example, Drive Control Chart (DCC) for graphically configuring and extending the device functionality using freely available closed-loop control, arithmetic and logic blocks. Motivation Frequently, DC drives are being replaced by AC drives; however, many customers have high regard for the advantages of DC technology SINAMICS DC MASTER has been developed for this group of customers, and in turn the proven technology of SIMOREG DC-MASTER integrated in the SINAMICS platform. This modernization sends a clear signal to our customers: "Also in the future, Siemens will place a lot of emphasis on DC technology!" This document is intended to help customers better understand SINAMICS DC MASTER - and especially its new functions, therefore providing valuable support when transitioning to our new generation of devices. Figure 1-1 SINAMICS DC MASTER product family SINAMICS DC MASTER Migration Guide Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 7 Introduction Figure 1-2 SIMOREG DC-MASTER product family Additional documentation on SINAMICS DC MASTER SINAMICS DC MASTER in the Internet (https://www.industry.siemens.com/drives/global/de/umrichter/dc-stromrichter/sinamicsdcm) SINAMICS DC MASTER operating instructions (http://support.industry.siemens.com/WW/view/en/55622945) Accessories SICROWBAR AC overvoltage protection SICROWBAR DC overvoltage protection SIMOREG DC-MASTER CCP Commutating reactors Radio interference suppression filters Advanced Operator Panel AOP30 and more You can obtain more information about all of the accessories in Catalog D23.1: (https://www.industry.siemens.com/mcms/infocenter/content/de/Seiten/order_form.aspx?nod eKey=key_9181486&InfoType=catalogs) SINAMICS DC MASTER Migration Guide 8 Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 Introduction Additional information in the Internet FAQ (http://support.industry.siemens.com/WW/view/de/38157755/133000) Selecting replacement DC converters (http://support.industry.siemens.com/WW/view/de/26117006) Service and support Our specialist support and product management are more than willing to provide you with information about reference projects and respond to any questions that you might have (DC-migration-support.industry@siemens.com) You can find information about our services and regional contact persons in the Internet (www.siemens.de/industry/csi_de/service). SINAMICS DC MASTER Migration Guide Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 9 Introduction SINAMICS DC MASTER Migration Guide 10 Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 SINAMICS DC MASTER - an overview of the highlights 2 SINAMICS DC MASTER devices address all industrial applications involving low-voltage DC drive technology. The open-design closed-loop control structure offers allows users to optimally adapt the drive control to their particular requirements. SINAMICS DC MASTER offers the following highlights: UL certification (for all devices up to 575 V) Marine certification 6 devices can be connected in parallel to increase the power rating and achieve redundancy (n + m operation) If a power unit fails, then the remaining functional SINAMICS DC MASTER devices continue to operate without any interruption. The power rating can be extended with engineered solutions, up to 60 kA and more in a cabinet design (12 pulse) Control Modules for retrofit drive projects and for high current rectifiers in electrochemical applications up to 100 kA Rated input voltages from 3 AC 50 V up to 950 V Single-phase connection (110 V to 575 V AC) for devices up to 125 A Extended temperature range for transport and storage (-40 C up to +70 C) The DC motor insulation resistance can be measured without having to disconnect the motor from the DC converter SIMOREG CCP to protect against inverter commutation faults Optimized cooling and service concept (optional, single-phase, quieter, integrated operating hours counter) The memory card can be used to save the project, update the firmware and for series commissioning Offline and online long-term traces Field power supply that complies with requirements - Without field (for devices from 60 A rated armature current, with price reduction) - With 1Q field (up to 85 A rated field current) - With 2Q field and active current reduction, including field overvoltage protection (for devices with 60 A rated armature current and above) DCC for demanding closed-loop control tasks Free function blocks the standard (no option S00) Onboard encoder interfaces Integrated electronics power supply for 24 V DC (option L05) SINAMICS DC MASTER Migration Guide Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 11 SINAMICS DC MASTER - an overview of the highlights Integrated in the SINAMICS drive family therefore, the same commissioning tools, same look & feel, parameterization supported by graphic screen forms, same components used for expansion Optional coated modules Optional nickel-plated busbars PROFIBUS on board/ PROFINET optional The Control Units can be variably configured - and therefore optimally adapted to address a wide range of requirements, from a technical and cost perspective Optional armature circuit supply with low voltage SINAMICS DC MASTER can be re-equipped for operation with line input voltages from 10 up to 50 V. Optional Ethernet-IP communication with CBE20 SIMOLINK replaced by other communication standards: - SINAMICS Link - Parallel interface - CU-Link (controller-controller direct data exchange) - OA link Position actual value sensing rms phase current sensing Password protection and know-how protection Commissioning engineers are supported by graphic screens SINAMICS DC MASTER Migration Guide 12 Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 3 Comparison of the functions The following comparison of the functions provides a factual comparison between SINAMICS DC MASTER with its predecessor, the SIMOREG DC-MASTER. The comparison includes all of the usual evaluation criteria. Reading notes The symbols in the table columns of the following chapter have the following significance: + Advantage = Neutral - Disadvantage Ambient conditions SINAMICS DC MASTER SIMOREG DC-MASTER + - IP00, IP20 possible up to 850 A IP00 Ambient temperature + - Storage -40 C ... +70 C -25 C ... +70 C Ambient temperature = = Operation 0 C ... +55 C 0 C ... +50 C or +60 C (devices < 125 A) above 40 C derating above 40 C derating = = up to 5000 m above sea level up to 5000 m above sea level + - Degree of protection Max. installation altitude Current derating from 1000 m above sea level, temperature- from 1000 m above sea level, temperaturedependent current derating max. 70 % dependent current derating max. 67 % Voltage derating Rated frequency Field power supply Power semiconductors = = were relevant, from 4000 m above sea level from 4000 m above sea level = = 45 - 65 Hz (extended range on request) 45 - 65 Hz (extended range on request) + - integrated (up to 85 A field current) for all types 1500 A integrated (up to 85 A field current) for 8 specific types 1500 A = = thyristor bridges thyristor bridges SINAMICS DC MASTER Migration Guide Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 13 Comparison of the functions SINAMICS DC MASTER SIMOREG DC-MASTER Closed-loop control stability = (operation with a pulse encoder n = 0.006 % and digital setpoint and/or rated speed) = Closed-loop control accuracy without encoder (EMF control, dependent on the motor temperature) = = approx. 5 %, field weakening not possible approx. 5 %, field weakening not possible SINAMICS DC MASTER SIMOREG DC-MASTER = = Electronics power supply AC 380 (-25 %) to 480 (+10 %) Electronics power supply AC 380 (-25 %) to 480 (+10 %) = = 15-3000 A 15-3000 A = = 6 6 n = 0.006 % Power units Permissible line fluctuations Power range Number of devices that can be connected in parallel Compact size Noise when installed in a cabinet Overload capability = = for devices with high and average currents; 1200 A devices 268 mm wide for devices with high and average currents; 1200 A devices 410 wide = = no fan noise up to and including 125 A devices no fan noise up to and including 125 A devices = = 180% 180% Discharge resistance from the very high (> 100 M) power unit isolated voltage sensing (armature and field with respect to ground) Armature 575 V = 0.91 M Armature 830 V = 1.3 M Armature 1000 V = 1.6 M Field 460 V = 1.8 M SINAMICS DC MASTER Migration Guide 14 Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 Comparison of the functions Control Unit (CU/CUD) Memory card Power-up time (up to o7.0) SINAMICS DC MASTER SIMOREG DC-MASTER + - for a firmware update (the drive automatically powers up with the new firmware), offline trace or series commissioning no memory card, internal flash memory -- + 40 s 3s ++ - onboard Option 2 x 32 PZDs (IF1 and IF2) 10 PZDs Data interfaces PROFIBUS RS232 or RS485 / USS Peer-to-peer Isochronous PROFIBUS No isochronous PROFIBUS Slave-to-slave communication Slave-to-slave communication = = onboard onboard = = onboard onboard Ethernet / PROFINET ++ - via CBE20 + Advanced CUD no SIMOLINK = = functionally replaced by SINAMICS Link to CU320-2 and using OA-Link yes ++ - yes no - + yes, via external bus coupler CANopen on request (option CBC) - + yes, via external bus coupler yes ++ - 4 inputs + 4 inputs or outputs 4 EtherNet/IP CAN Device Net Inputs and outputs Digital inputs on board per CUD Digital outputs on board ++ - 4 2 per CUD Analog inputs on board ++ - 7 (+/-10 V) 2 per CUD Resolution, analog outputs with sign = = 3x with 14 bit 4x with 14 bit 4x with 11 bit SINAMICS DC MASTER Migration Guide Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 15 Comparison of the functions Analog outputs on board SINAMICS DC MASTER SIMOREG DC-MASTER = = 2 2 per CUD + fixed current actual value output Resolution, analog outputs with sign + - 15 bit 11 bit Onboard encoder interfaces = = 1 x pulse encoder (15 V) (analog tachometer connected to the basic device) 1x pulse encoder (analog tachometer connected to the basic device) + - 1 (PTC / KTY84, PT100 and PT1000) 1 (PTC or KTY84-130) Electronics power supply + - 24 V yes no Temperature evaluation onboard Others Accessories and supplementary components Commutating reactor single and three-phase Line-side overvoltage protection to protect the power semiconductors Recommendation for overvoltage protection at the output when supplying high inductances Protection against the effects of inverter commutation faults Radio interference suppression filter for field and armature circuit SINAMICS DC MASTER SIMOREG DC-MASTER = = as accessory as accessory = = Overvoltage protection SICROWBAR AC Overvoltage protection SICROWBAR AC = = SICROWBAR DC overvoltage protection and special thyristor control "reliable triggering" SICROWBAR DC overvoltage protection and special thyristor control "reliable triggering" = = CCP optional up to 2000 A rated current up to 690 V CCP optional up to 2000 A rated current up to 690 V = = Optional Optional Integrated semiconductor protection fuses (arm fuse) = = existing devices for 900 A existing devices for 900 A Optional encoder interfaces SMC 30 SBP HTL / TTL encoder = = yes yes + - yes no SSI encoder Expanded interfaces SINAMICS DC MASTER Migration Guide 16 Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 Comparison of the functions SINAMICS DC MASTER SIMOREG DC-MASTER + - Terminal Module TM15 Terminal expansion board EB1 24 digital inputs/digital outputs 3 digital inputs 4 digital inputs/digital outputs 3 analog inputs Terminal Module TM31 Terminal expansion board EB2 2 analog inputs 2 digital inputs 2 analog outputs 4 relay contacts 4 digital inputs 2 analog outputs 4 digital outputs or 4 digital inputs/digital outputs fiber optic cable modules SCI1, SCI2 2 relay contacts Terminal Module TM150 T100, T300, T400 Up to 9 temperature sensors can be conmax. 2 EB modules possible per CUD nected (2, 3 or 4-wire connection) including short-circuit and wire breakage monitoring * PT100 * PT1000 * KTY84 * PTC Bimetallic NC contact (without monitoring) Max. 3 TM per CUD possible * Second CUD for performance and terminal expansion CUD2 to expand terminals Optional panel Advanced Operator Panel AOP30 Operator Panel OP1S Control panel = = yes yes Fault diagnostics in plain text + - yes no Fully graphic capable + - yes no SINAMICS DC MASTER Migration Guide Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 17 Comparison of the functions Multilingual SINAMICS DC MASTER SIMOREG DC-MASTER + = German no Russian, Chinese with special software English French Spanish Italian Chinese Russian Polish Numerical keypad = = yes yes SINAMICS DC MASTER SIMOREG DC-MASTER + = SIZER LD web SIZER (free load cycles) DT Configurator SIMOREG Pro Engineering tools Engineering support SINAMICS DCM Pro SIZER WEB engineering Engineering software STARTER commissioning tool DriveMonitor Connection = = via PROFIBUS, PROFINET via RS232 / RS485 also routing from a higher-level control system Graphic function diagram screen forms + - available not available Trace + - 2 x 8 channels 10 channels Longer-term trace with memory card Trace 1/2 Arithmetic functions (several y scales) Function generator Scripting Prompted commissioning Wizard + - available not available = = yes yes + - yes only user-defined list SINAMICS DC MASTER Migration Guide 18 Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 Comparison of the functions Functions 12-pulse series SINAMICS DC MASTER SIMOREG DC-MASTER = = possible possible 12-pulse parallel = = possible possible Topology switchover series/parallel + - yes (option S50) no Single-phase connection (armature circuit) + - possible not possible = = Redundant operation armature circuit Redundant operation field circuit optimized for SINAMICS DC MASTER possible without interruption possible without interruption = = possible possible Data sets BICO data sets = = 2 (CDS - command the data set) 2 = = 4 drive data sets (DDS) 4 function data sets with 4 encoder data sets each Automatic optimization runs Current controller = yes yes Speed controller including precontrol (frictional torque and moment of inertia) = = yes yes Plotting the field characteristic = = yes yes EMF controller optimization Optimization run for mechanical systems that are prone to oscillation = = = yes yes + - yes no = - Free function blocks 52 function blocks for basic logic interconnections with standard performance available at no additional price + - DCC (license cost for each PC) Option S00 (license cost for each device) for high requirements, graphic editor, simulation mode, as many block instances as required (only restricted by the arithmetic and storage capacity) no graphic editor, no simulation mode, a maximum of 300 blocks available SINAMICS DC MASTER Migration Guide Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 19 Comparison of the functions SINAMICS DC MASTER SIMOREG DC-MASTER = = Expanded by CUD inserted in the righthand slot CFC in technology modules T300 and T400 + - SINAMICS Link SIMOLINK Peer-to-peer Peer-to-peer Additional functions Communication between 2 devices CU-Link Control Module Know-how protection Same speed controller reference model as for the SINAMICS S120 = = available available = = yes yes + - SINAMICS DC MASTER SIMOREG DC-MASTER Fan replacement (if a fan is available) Fan replacement (if a fan is available) - - only with higher-level control only with higher-level control Services Maintenance See also maintenance concept Remote access Fault diagnostics Detailed documentation in several languages Range of training courses + + Faults and recommendations for resolving faults are output in plain text (on the AOP30 or the STARTER commissioning tool) Faults and recommendations for resolving faults are output in plain text (in DriveMonitor) + - 7-languages including Russian. Operating instructions and List Manual including function diagrams 5 languages + - Service & commissioning- DR-DCM-SI Diagnostics & maintenance- DR-DCM-DG Repair (only for Siemens personnel) - DRDCM-REP 5-day training course SINAMICS DC MASTER Migration Guide 20 Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 Comparison of the functions Certificates/tests/standards SINAMICS DC MASTER SIMOREG DC-MASTER UL approval = = yes yes Marine + - yes, in the standard version yes, with EMC envelope/covering + + yes yes + - PROFIdrive certified according to PNO no + - PROFIdrive certified according to PNO no SINAMICS DC MASTER SIMOREG DC-MASTER + - EAC (GOST) PROFIBUS PROFINET Quality Ruggedness of the devices The ruggedness of the devices has been decisively improved as a result of continuous improvement, internal quality standards and the more stringent situation regarding standards. SINAMICS DC MASTER Migration Guide Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 21 Comparison of the functions SINAMICS DC MASTER Migration Guide 22 Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 Terminal assignment SIMOREG DC-MASTER SINAMICS DC MASTER 4.1 4 Digital inputs Table 4- 1 Digital inputs Terminal number SIMOREG DC-MASTER Terminal number SINAMICS DC MASTER Comment X171.34 X177.9, X177.10 24 V DC short-circuit proof X171.35 X177.23, X177.24 Digital ground X171.36 X177.11 Binary select input 1 X171.37 X177.12 Binary select input 2 X171.38 X177.13 Binary select input 3 X171.39 X177.14 Binary select input 4 X163.40 X177.15 Binary select input/output 1 X163.41 X177.16 Binary select input/output 2 X163.42 X177.17 Binary select input/output 3 X163.43 X177.18 Binary select input/output 4 X163.44 X177.9 24 V DC short-circuit proof If CUD2 is inserted Replaced by Terminal Module TM31 X161.210 X540.1 24 V DC short-circuit proof X161.211 X520.1 Binary select input X161.212 X520.2 Binary select input X161.213 X520.3 Binary select input X161.214 X520.4 Binary select input X161.215 Ground for binary inputs X161.216 X520.5 Ground for binary inputs X161.217 X520.6 Ground SINAMICS DC MASTER Migration Guide Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 23 Terminal assignment SIMOREG DC-MASTER - SINAMICS DC MASTER 4.2 Digital outputs 4.2 Digital outputs Table 4- 2 Digital outputs Terminal number SIMOREG DC-MASTER Terminal number SINAMICS DC MASTER Comment X171.46 X177.19 Binary select output 1 X171.47 X177.23 Ground, digital X171.48 X177.20 Binary select output 2 X171.54 X177.23 Ground, digital X163.50 X177.21 Binary select output 3 X163.51 X177.24 Ground, digital X163.52 X177.22 Binary select output 4 X163.53 X177.24 Ground, digital If CUD2 is inserted SINAMICS DC MASTER Migration Guide 24 Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 Terminal assignment SIMOREG DC-MASTER - SINAMICS DC MASTER 4.3 Analog inputs 4.3 Analog inputs Table 4- 3 Analog inputs Terminal number SIMOREG DC-MASTER Terminal number SINAMICS DC MASTER Comment X174.1 X177.33, X177.34 Ground, analog X174.2 X177.31 P10 X174.3 X177.32 N10 X174.4 X177.25 Main setpoint + X174.5 X177.26 Main setpoint - X174.6 X177.27 Analog select input 1 + X174.7 X177.28 Analog select input 1 - X174.22 X177.53 Motor temperature + X174.23 X177.55 Motor temperature- X174.24 X177.33 Ground, analog X164.8 X177.29 Analog select input 2 X164.9 X177.30 Ground, analog X164.10 X177.1 Analog select input 3 X164.11 X177.2 Ground, analog X164.204 X522.7 Motor temperature 2 + (on TM31) X164.205 X522.8 Motor temperature 2 - (on TM31) Terminal number SINAMICS DC MASTER Comment If CUD2 is inserted 4.4 Analog outputs Table 4- 4 Analog outputs Terminal number SIMOREG DC-MASTER X175.12 Current actual value X175.13 Ground, analog X175.14 X177.49 Analog output 1 X175.15 X177.50 Ground, analog X175.16 X177.51 Analog output 2 X175.17 X177.52 Ground, analog X164.18 X522.1 Analog output 3 (on TM31) X164.19 X522.2 Ground, analog X164.20 X522.4 Analog output 4 (on TM31) X164.21 X522.5 Ground, analog If CUD2 is inserted SINAMICS DC MASTER Migration Guide Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 25 Terminal assignment SIMOREG DC-MASTER - SINAMICS DC MASTER 4.5 Pulse encoder 4.5 Pulse encoder Table 4- 5 Pulse encoder Terminal number SIMOREG DC-MASTER Terminal number SINAMICS DC MASTER Comment X173.26 X177.41 P15 for supply in the pulse encoder X173.27 X177.42 Ground X173.28 X177.43 Track 1 + X173.29 X177.44 Track 1 - X173.30 X177.45 Track 2 + X173.31 X177.46 Track 2 - X173.32 X177.47 Zero mark + X173.33 X177.48 Zero mark - SINAMICS DC MASTER Migration Guide 26 Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 Terminal assignment SIMOREG DC-MASTER - SINAMICS DC MASTER 4.6 Interfaces 4.6 Interfaces Table 4- 6 Interfaces Terminal number SIMOREG DC-MASTER Terminal number SINAMICS DC MASTER Comment X165 X165 Parallel interface X166 X166 Parallel interface RS232/G-SST1 X300.1 Housing ground X300.2 X179.4 Receive line RXD1 X300.7 X179.3 Transmit line TXD1 X300.5 X179.2 Ground X300.3 X178.3 Transmit and receive line RxD/TxD-P X300.8 X178.4 Transmit and receive line RxD/TxD-N X300.9 X178.5 Ground RS485/G-SST1 RS485/G-SST2 -if parameter 790 = 2 X172.58 Not replicated Transmit and receive line RxD/TxD-P X172.59 Not replicated Transmit and receive line RxD/TxD-N X172.60 Not replicated Ground RS485/G-SST2 -if parameter 790 = 5 X172.56 X177.37 Transmit line TX+ X172.57 X177.38 Transmit line TX- X172.58 X177.39 Receive line RX+ X172.59 X177.40 Receive line RX- X172.60 X177.35, X177.36 Ground X162.61 Not replicated Transmit line TX+ X162.62 Not replicated Transmit line TX- X162.63 Not replicated Receive line RX+ X162.64 Not replicated Receive line RX- X162.65 Not replicated Ground X162.63 Not replicated RS485/GSST3 RS485/G-SST3 SINAMICS DC MASTER Migration Guide Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 27 Terminal assignment SIMOREG DC-MASTER - SINAMICS DC MASTER 4.6 Interfaces SINAMICS DC MASTER Migration Guide 28 Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 Commissioning SINAMICS DC MASTER using the BOP20 operator panel 5.1 5 Preconditions Fundamentals of SINAMICS If you do not already know the fundamentals of SINAMICS (parameters, drive objects, BICO technology etc.), then before starting commissioning, in the SINAMICS DCM operating instructions in Chapter "Operation" read the "Fundamentals" section. BOP20 basic operator panel If you still do not know the BOP20 operator panel, before commissioning, in the SINAMICS DCM operating instructions, in Chapter "Operation", read the section "Parameterizing using the BOP20". Parameter notation A complete parameter comprises drive object + parameter number + index the following notation (oo)pxxxxx[ii] for indexed parameters (oo)pxxxxx for non-indexed parameters To improve readability, in this chapter, the drive object is omitted for all parameters belonging to the drive object "Closed-loop drive control" (= drive object 2). For example, p50076[1] means parameter (2)p50076[1] (= drive object 2, parameter 50076, index 1). SINAMICS DC MASTER Migration Guide Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 29 Commissioning SINAMICS DC MASTER using the BOP20 operator panel 5.2 Commissioning steps 5.2 Commissioning steps Note Parameter with [D] depend on a data set. Commissioning must be carried out for each data set. 1Access authorization In order to be able to set access authorization, at the BOP20 basic operator panel, drive object 1 (DO1) must be activated; see the operating instructions of SINAMICS DCM, Chapter 9, Section Display and operation using the BOP20 basic operator panel. Access level (1)p0003 = 1 Standard (1)p0003 = 2 Advanced (1)p0003 = 3 Expert 2Adapting the rated device currents Note For the base drives produced in North America (Type 6RA80xx-2xxxx), the US rating must be adjusted at p50067. The rated armature DC current for the unit must be adjusted by setting p50076[0] (in %) or p50067 if: Maximum armature current < 0.5 x rated armature DC current for the unit The rated field DC current for the unit must be adapted by setting p50076[1] (in %) if: Maximum field current < 0.5 x rated field DC current for the unit 3Adapting the actual device supply voltage p50078[0] Rated DC converter input voltage, armature (in Volt) p50078[1] Rated DC converter input voltage, field (in Volt) SINAMICS DC MASTER Migration Guide 30 Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 Commissioning SINAMICS DC MASTER using the BOP20 operator panel 5.2 Commissioning steps 4Entering the motor data The motor data according to the motor rating plate must be entered into the following parameters (see also the operating instructions of SINAMICS DCM, Chapter "Thermal overload protection of the DC motor" and "Speed-dependent current limiting"): Fig. p50100[D] Rated armature current (in amperes) p50101[D] Rated armature voltage (in volts) p50102[D] Rated excitation current (in amperes) p50104[D] Speed n1 (in rpm) p50105[D] Armature current I1 (in amperes) p50106[D] Speed n2 (in rpm) p50107[D] Armature current I2 (in amperes) p50108[D] Maximum operating speed n3 (in rpm) p50109[D] 1 = Speed-dependent current limitation active p50114[D] Motor thermal time constant (in seconds) 5Speed actual value sensing data 5.1Operation with analog tachometer p50083[D] = 1 The actual speed value comes from the "Main actual value" (r52013) channel (terminals XT.103, XT.104). p50741[D] Tachometer voltage at maximum speed (- 270.00 to +270.00 V) Remark: The value set here defines 100% speed for the closed-loop speed control. p2000 Speed in rpm for tachometer voltage set on p50741[0] Comment 1: Parameter p2000 is used to convert from a "physical speed" (rpm) into a "relative speed" (%) and vice versa. This conversion is required for: * Speed setpoint input via the operator panel in the STARTER commissioning tool * Speed setpoint input via the operating screen form of the AOP30 advanced operator panel * Calculating the display values r020, r021, r060 and r063 Remark 2: Parameter p2000 and parameters r020, r021, r060 and r063 are not data-set dependent. This is the reason that the physical speed can only be displayed correctly for one data set (DDS). SINAMICS DC MASTER Migration Guide Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 31 Commissioning SINAMICS DC MASTER using the BOP20 operator panel 5.2 Commissioning steps 5.2Operation with pulse encoder p50083[D] = 2 The speed actual value is received from a pulse encoder (r0061) connected at terminal block X177 p0400[0] Encoder type selection p2000 Speed in rpm at 100% speed Remark: The value set here defines 100% speed for the closed-loop speed control. 5.3Operation without tachometer (EMF control) p50083[D] = 3 The actual speed value comes from the "Actual EMF value" channel (r52287), but is evaluated with p50115. p50115[D] EMF at 100% speed (1.00 to 140.00 % of the rated device supply voltage (p50078[0]) Remark: The value set here defines 100% speed for the closed-loop speed control. p2000 Speed in rpm for EMF set on p50115[0] Comment 1: Parameter p2000 is used to convert from a "physical speed" (rpm) into a "relative speed" (%) and vice versa. This conversion is required for: * Speed setpoint input via the operator panel in the STARTER commissioning tool * Speed setpoint input via the operating screen form of the AOP30 advanced operator panel * Calculating the display values r020, r021, r060 and r063 Remark 2: Parameter p2000 and parameters r020, r021, r060 and r063 are not data-set dependent. This is the reason that the physical speed can only be displayed correctly for one data set (DDS). 5.4Freely wired actual value p50083[D] = 4 The actual-value input is defined with p50609[C] p50609[C] Number of the parameter that is switched to the actual speed controller value SINAMICS DC MASTER Migration Guide 32 Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 Commissioning SINAMICS DC MASTER using the BOP20 operator panel 5.2 Commissioning steps p2000 Speed in rpm at which the parameter selected on p50609[0] accepts the value 100% Comment 1: Parameter p2000 is used to convert from a "physical speed" (rpm) into a "relative speed" (%) and vice versa. This conversion is required for: * Speed setpoint input via the operator panel in the STARTER commissioning tool * Speed setpoint input via the operating screen form of the AOP30 advanced operator panel * Calculating the display values r020, r021, r060 and r063 Remark 2: Parameter p2000 and parameters r020, r021, r060 and r063 are not data-set dependent. For that reason, the physical speed can only be displayed correctly for one data set (CDS). 5.5Operation with pulse encoder and SMC30 p50083[D] = 5 The actual speed value comes from an incremental encoder connected to an SMC30 (r3770). p0400[1] Encoder type selection p2000 Speed in rpm at 100% speed Remark: The value set here defines 100% speed for the closed-loop speed control. 6Field data 6.1Controlling the field p50082 = 0 Internal field is not used (e.g. for permanent-magnet motors) p50082 = 1 The field is also switched with the line contactor (the field pulses are energized de-energized simultaneously with the line contactor) p50082 = 2 The selected standstill field set using p50257 is automatically activated after a time that can be parameterize using p50258 after operating state o7 or higher is reached p50082 = 3 Field current permanently switched on 6.2Field weakening p50081 = 0 No speed or EMF-dependent field weakening p50081 = 1 Field weakening operation using the internal EMF control, so that in the field-weakening range, this means speeds above the rated motor speed (= "Transition speed"), the motor EMF is kept constant at the setpoint "EMFset" (r52289) = p50101 - p50100 * p50110. SINAMICS DC MASTER Migration Guide Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 33 Commissioning SINAMICS DC MASTER using the BOP20 operator panel 5.2 Commissioning steps 7Setting the basic technological functions 7.1Current limits p50171[D] System current limit in torque direction I (as % of p50100) p50172[D] System current limit in torque direction II (as % of p50100) 7.2Torque limits p50180[D] Torque limit 1 in torque direction I (as % of rated motor torque) p50181[D] Torque limit 1 in torque direction II (as % of rated motor torque) 7.3Ramp-function generator p50303[D] Ramp-up time 1 (in seconds) p50304[D] Ramp-down time 1 (in seconds) p50305[D] Initial rounding 1 (in seconds) p50306[D] Final rounding 1 (in seconds) 8Completing fast commissioning Set p3900 = 3. This triggers the calculation of the motor data (Ra, La, Lf) as well as the calculation of the controller parameters resulting from the data that was entered in the previous steps. p3900 is then set back to 0 and fast commissioning completed; this means that p0010 is reset to 0. 9Executing the optimization runs Perform the optimization runs one after the other: p50051 = 24 Optimization of closed-loop field-current control p50051 = 25 Optimization of closed-loop armature current control p50051 = 26 Optimization of speed control p50051 = 27 Optimizing the EMF control (including plotting the field characteristic) p50051 = 28 Plotting the friction characteristic p50051 = 29 Optimization of closed-loop speed control for drives with a mechanical system capable of oscillation For more detailed information, refer to the SINAMICS DCM operating instructions, Chapter "Drive optimization". If an optimization run is not carried out, the motor control uses the motor characteristic values calculated from the rating plate data rather than the measured values. SINAMICS DC MASTER Migration Guide 34 Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 Commissioning SINAMICS DC MASTER using the BOP20 operator panel 5.2 Commissioning steps DANGER During optimization runs, the drive initiates motor movements that can reach the maximum motor speed. The EMERGENCY OFF functions must be fully operational during commissioning. To protect man and machines, the relevant safety regulations must be observed. 10Checking and possibly finely calibrating the maximum speed Once the optimization runs have been executed, the maximum speed needs to be checked and, if necessary, the setting for it corrected. If the maximum speed has now shifted by more than around 10%, the control response of the closed-loop speed control circuit will need to be checked; it may be necessary to repeat the optimization run for the speed controller or carry out re-optimization manually. The optimization runs for field weakening and for friction and moment of inertia compensation must be repeated if there is any change to the maximum speed. 11Checking the drive settings The optimization runs do not produce the best results for every application, so in all cases it is necessary to check the controller settings using the appropriate tools (oscilloscope, STARTER trace, and so on). Some cases may require manual re-optimization. 12Manually (post) optimizing (if required) If the result of the optimization runs is not satisfactory, then manual post or new optimization can be performed. The procedure is described in the operating instructions, in Chapter "Manual optimization". 13Saving the setting values in a non-volatile fashion Previously, all changes in the set values were made in the RAM (Random Access Memory). If the device is switched off in this state, all settings made previously are lost. To permanently store the settings in the ROM (non-volatile memory), a RAM to ROM must be triggered by setting p0977 to 1 (p0977 is allocated to the DO 1). While data is being saved, the BOP20 flashes (and the RDY-LED on the CUD also flashes); this takes approx. 45 s. After the save operation the settings are backed up in the ROM. The drive can now be switched off (POWER OFF) without losing the settings that have been made. Also refer to the "Operation" chapter, "CompactFlash Card functions" section. SINAMICS DC MASTER Migration Guide Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 35 Commissioning SINAMICS DC MASTER using the BOP20 operator panel 5.2 Commissioning steps 14Documenting the setting values The following facilities are available so that the settings made can be recorded outside the unit: External CompactFlash Card was inserted during the RAM to ROM (p0977=1). The parameters were therefore also transferred to the external CompactFlash Card. Write the parameters to a CompactFlash Card (p0804). Document the parameters in a STARTER project (load to PG). Also refer to the "Operation" chapter, "CompactFlash Card functions" section and "Commissioning with the STARTER commissioning tool" chapter. SINAMICS DC MASTER Migration Guide 36 Reference Manual, 06/2015, A5E35776390A/RS-AA/001;1 Siemens AG Division Process Industries & Drives Postfach 48 48 90026 NURNBERG GERMANY Subject to change without prior notice 6A5E35776390A/RS-AA/001;1 (c) Siemens AG 2015 DC Converters SINAMICS DCM www.industry.siemens.com/drives