De DR-SL150 en 01 V6 PDF

Private copy for Gustavo Alonso Roman Duenas, gustavo_rd88@hotmail.
com
Siemens AG
DEUTSCHLAND
Industry Sector
90475 NÜRNBERG
Gleiwitzer Str. 555
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Siemens Certified Service Technician Level 1
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(inkl. SPS-Techniker entspr. VDMA/ZVEI)
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(DR-SM150)
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SITRAIN:
SINAMICS SM150 Service and Commissioning

Training for Industry
siemens.com/sitrain
1 Overview and Function
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2 Power Circuits
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3 Objects, Components and Topology
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4 Configuration
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SITRAIN
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Training for Industry 5 Basic Commissioning
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6 Setpoint Processing
Private copy for Gustavo Alonso Roman Duenas, gustavo_rd88@hotmail.com
SINAMICS SL150
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7 Diagnosis
Service and
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Commissioning 8 Control Circuits

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Course DR-SL150 9 PROFIBUS

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10 Drive Control Chart

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11 ETHERNET om
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12 Operating Panel OP 177

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Name:
13 Personal Safety
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Course from: to:

14 Commissioning Common Functions
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Trainer:
15 Commissioning the Power Section

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Training site:
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This document was produced for training purposes. 16 Miscellaneous

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SIEMENS assumes no responsibility for its contents. The

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reproduction, transmission, communication or use exploitation

of this document or its contents is not permitted without
express written consent authority. Offenders will be liable to 17
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damages. Non-compliances with this prohibition make the

offender inter alia liable for damages.
Copyright © Siemens AG 2011. All rights, including

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particularly the rights created by to file a by patent and/or 18

other industrial property right application and/or cause the
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patent and/or other industrial property right to be granted

grant or registration of a utility model or design, are reserved.
19
SITRAIN courses on the internet: www.siemens.com/sitrain
Course folder Version: V6.0 20

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Overview
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and
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Principle of Operation
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SITRAIN
Function page 01 © Siemens AG 2011 - all rights reserved
List of Contents
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SINAMICS Medium Voltage Converters ….......................................................................... 3
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SINAMICS offers a Solution ... ……………………………………………………................... 4
SINAMICS Examples of Application …................................................................................ 5
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Operating Type “SERVO” and “VECTOR” …....................................................................... 6

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Design “6-pulse, Star” and “6-pulse, Open” …..................................................................... 7

Design “2*6-pulse, Star” …................................................................................................... 8
Cyclo-Converter (6-pulse, Star) …....................................................................................... 9
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SCR-Stacks …..................................................................................................................... 10
Output Voltage as Function of the Firing Angle …............................................................... 11
Sequential Change of the Firing Angle …............................................................................ 12
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Resulting Motor Voltage ….................................................................................................. 13

Generating Output Voltage as Function of the Firing Angle …............................................ 14
Generating Voltage at a Frequency of 12.5 Hz …............................................................... 16
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Generating Voltage at a Frequency of 25 Hz ….................................................................. 17

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page 02
SINAMICS Medium Voltage Converters
25 000 25 000
3 000
SL150
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SCR water
~
~ M
3 000
SL150
SCR air
cabinet
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10 500
31 500
SM150
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~ = IGCT water
= ~ M
3 400
SM150
7 200
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modular
IGBT * * air, water
95 000
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6 000
GL150
~ = SCR water
= ~ M
19 400
2 800
GL150
@
cabinet
SCR air
10 000
28 000
GM150
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IGCT water
~ =
M
10 000
2 000
= ~ GM150
IGBT water
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cabinet 7 900
GM150 supply voltages:
700
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IGBT air depending on type, 1.0 to 12.0 kV

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0.5 1 10 100 MVA

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SITRAIN
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SINAMICS offers a Solution ...
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… for every power range

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SINAMICS
SINAMICS
SINAMICS
G110 G120 S120 G130 S120 S120 G150/S150 GM/GL/SM/SL150

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0,12 kW General Purpose Drives G 1xx / S 1xx low voltage 4,5 MW 95 MVA
(GL150)
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Sophisticated Drives X M 150 / X L 150 medium voltage

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… for every application

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SINAMICS
SINAMICS
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G110/120 G130 G150 S150 GM/GL/SM/SL150 S120 S120
partly in conjunction with technology controllers

Standard drives Sophisticated standalone drives Coordinated drives / MC
SITRAIN
SINAMICS Examples of Application
“Sophisticated“
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Basic standalone drives Coordinated drives Servo drives
standalone drives
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drilling platforms propulsion cold rolling mills printing machines
Vector (MV) Vector (MV) Vector (MV) Servo (LV)
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pumps compressors hot rolling mills sag mill

Vector (MV, LV) Vector (MV, LV) Vector (MV) Vector (MV)
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SITRAIN
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Operating Type “SERVO” and “VECTOR”
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• operating type SERVO for fast response, motion control (positioning),

Drive object type
low inertia, high mechanical stiffness, short
scan times, simplified speed control algorithm
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• operating type VECTOR for high torque, power and speed control quality,
extensive speed loop functionality
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SERVO: VECTOR:
8
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Position
r
Speed Speed
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typically: Torque Torque typically:

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J_load J_load
< 5...10 > 10...100
J_mot J_mot
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overall moment of inertia overall moment of inertia

= small = large
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rated motor torque rated motor torque
Any type of SINAMICS medium voltage converters feature the “operating type” VECTOR exclusively.
SITRAIN
Design “6-pulse, Star” and “6-pulse, Open”
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V, f = constant
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i.e. 4 kV, 50 Hz
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1U1, 1V1, 1W1 2U1, 2V1, 2W1 3U1, 3V1, 3W1 1U1, 1V1, 1W1 2U1, 2V1, 2W1 3U1, 3V1, 3W1
tm
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1U2 2U2 1V2 2V2 1W2 2W2 1U2 2U2 1V2 2V2 1W2 2W2
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V, f = variable
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General
General properties
properties of of Cyclo-Converters
Cyclo-Converters Specific
Specific properties
properties ofof “6-pulse,
“6-pulse, Open”
Open”
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++ direct
direct conversion “AC –– AC”
conversion “AC AC” (no
(no DC-link)
DC-link) only one converter-transformer required
only one converter-transformer required
++ high
high efficiency
efficiency // high
high overload
overload (
( SCRs)
SCRs) several
several converters
converters onon one
one transformer
transformer
++ very
very compact
compact // superior
superior MTBF
MTBF electrically
electrically independent
independent phase-converters
phase-converters
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–– maximum
maximum output
output frequency:
frequency: about
about 45%
45% ffLine
Line simplified
simplified trouble
trouble shooting
shooting
–– reactive
reactive power
power // line
line side
side harmonics
harmonics
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SITRAIN
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Design “2*6-pulse, Star”

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1U2 2U2 1V2 2V2 1W2 2W2 1U3 2U3 1V3 2V3 1W3 2W3
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harmonics
Specific
Specific properties
properties ofof “2*6-pulse,
“2*6-pulse, Star”
Star” 12-pulse
by using two transformers with a relative phase
by using two transformers with a relative phase shift
shift of 3000 load
of 30 load to
to the
the
line side acts as 12-pulse considerable reduction of line side harmonics
line side acts as 12-pulse considerable reduction of line side harmonics 3 5 7 9 11 13 15 17 19
SITRAIN
Cyclo-Converter (6-pulse, Star)
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1U1 1V1 1W1 2U1 2V1 2W1 3U1 3V1 3W1
line side voltage
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measurement
via Voltage Sensing
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Module VSM10
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motor voltage
motor current *
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3.3 kV
1U2 2U2 1V2 2V2 1W2 2W2
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MΩ
* depending on the power rating,

current is alternatively picked up kΩ V
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on the three phase input
attenuation operational principle

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network “Hall-transformer“
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SITRAIN
SCR-Stacks
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1U1 1V1 1W1 1U1 1V1 1W1
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111 141
line phase U
111 211
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111 141
241 211
241 141
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241 211
131 161
line phase V
131 231
131 161
261 231
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261 161
261 231
151 121
line phase W
151 251
151 121
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221 251
221 121
d8
221 251
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1U2 2U2 1U2 2U2

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The 12 SCRs of one motor phase (two anti-

parallel B6 circuits) are arranged in two
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power stacks.
The SCRs are contacted by pressure to the
adjacent heat sinks and thus to each other.
SITRAIN
Output Voltage as Function of the Firing Angle
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L1 L2 L3
L1L2 L1L3 L2L3 L2L1 L3L1 L3L2
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α = 00 α = 300 α = 600
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α = 900
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α = 1200 α = 1500
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SITRAIN
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Sequential Change of the Firing Angle
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L1L2 L1L3 L2L3 L2L1 L3L1 L3L2 L1L2 L1L3 L2L3

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rd
current flow through SCR 1+2 2+3 3+4 4+5 5+6 6+1 1+2
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participating line voltage L1L3 L2L3 L2L1 L3L1 L3L2 L1L2 L1L3
firing angle α (degrees) 0 15 45 60 70 80 90
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torque direction I 1 4 1 4
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torque direction II
3 6 3 6
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5 2 5 2
SITRAIN
Resulting Motor Voltage
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The output voltage of the converter consists of segments of
I
sine curve of a frequency up to 50% of the line frequency.
the line voltage which, if sequentially arranged, produce a
II I
V
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III IV
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0 zero current interval
tm
(SCR recovery time)
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IV I. Quadrant II III
converter converter
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section I section II
0 0
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SITRAIN
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Generating Output Voltage as Function of the Firing Angle
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tm
L1 L2 L3
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u1 u2 u3
@
u13
1 4
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U.D = 100 %
3 6
curves for ohmic or inductive load
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α = 00
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5 2
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I.D
U.D = 87 %
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U.D
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I.D
α = 300
SITRAIN
Generating Output Voltage as Function of the Firing Angle
u1 u2 u3
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u13
1 4 U.D = 13 %
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α = 900
ohmic
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3 6
tm
5 2
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U.D = 0 %
α= 900
I.D inductive
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U.D
I.D
1 .0 ohmic
o h m ' sload
che Last
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oohmic
h m ' sand
c h inductive
u n d i n dload
u k tiv (60
( 6 0 –-120
1 2 degrees)
0 G ra d )
0 .8
U . G =RU.D.max
U.D = U .G R a xcos[ (1α ++ c 60
* .[m1 + o s ) (] α + 60 ) ]
0 .6
0 .4
rd
0 .2 ohmic
o h m 's c h
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2 0 4 0 6 0 8 0 1 20 1 40 1 60 1 80 G ra d
-0 .2
ohmic
o h m 'and
s c h inductive
e u n d i load
ndu k t iv e L a s t
-0 .4 (0
( 0 – -60
6 0degrees)
G ra d )
iinductive
n d u k t iv
-0 .6 U . G=RU.D.max
U.D . m aαx
= U . G *R cos cos α
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-0 .8 pure
r e i n inductive
i n d u k t iload
ve Last
(0
( 0 – -180
1 8 degrees)
0 G ra d )
-1 .0
U . G=RU.D.max
U.D . m aαx
= U . G *R cos cos α
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SITRAIN
Function page 15
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© Siemens AG 2011 - all rights reserved
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Generating Voltage at a Frequency of 12.5 Hz
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Voltage [%] 0 26 50 71 86 96 100 96 86 71 50 26 0

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Firing angle [ ] 90.0 74.9 60.0 44.8 30.0 16.2 0 16.2 30.0 44.8 60.0 74.9 90.0
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8
r d8
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0 3.3 6.6 10.0 13.3 16.6 20.0 23.3 26.6 30.0 33.3 36.6 40.0 ms
SITRAIN
Generating Voltage at a Frequency of 25.0 Hz
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Voltage [%] 0 50 86 100 86 50 0
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Firing angle [ ] 90.0 60.0 30.0 0 30.0 60.0 0
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rd
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0 3.3 6.6 10.0 13.3 16.6 20.0 ms

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SITRAIN
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tm
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tm
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Circuit Diagrams
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and
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tm
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Power Section Hardware
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SITRAIN
Siemens AG 2011. All rights reserved.Hardware page11
page SITRAIN
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Sag Mill Gearless Drive, 24 000 kW
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Installation of
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rotor segments
tm
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Stator shifted off
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l.c
rotor to the left
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rd
tm
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ho
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st
@
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rd
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Installation of
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stator segments
Siemens AG 2011. All rights reserved. page 2 SITRAIN
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Design Type “2x6-Pulse, Star”
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synchronizing voltage
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HV circuit breaker
tm
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∆ T1 T2 T3
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@
Dy5do Dy5do Dy5do
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ai
rd
tm
1U1, 1V1, 1W1 2U1, 2V1, 2W1 3U1, 3V1, 3W1 4U1, 4V1, 4W1 5U1, 5V1, 5W1 6U1, 6V1, 6W1 U1, V1, W1
o_
ho
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A B C D E F
@
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1U2 1V2 1W2 2U2 2V2 2W2 D C

phase A phase B phase C phase A phase B phase C
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system 1 system 1 system 1 system 2 system 2 system 2

88
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Siemens AG 2011. All rights reserved.

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page 4
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tm tm
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l.c l.c
SITRAIN
om om
om
l.c
to VSM10
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tm
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ho
HV switchgear
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ai
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tm
rd
ho
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@
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88
st
gu
rd
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av
st
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to Xformer 1 to Xformer 2 to Xformer 3

om
l.c
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tm
line current metering
ho
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@
l.c
to transformer protection
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- over current
- differential
tm
rd
ho
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@
av
st
transformer 1
88
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rd
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av
st
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to system 1 / phase A to system 2 / phase A

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from transformer 1
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tm
om
ho
to transformer current
differential protection
l.c
@
ai
88
tm
to line side current monitoring
rd
via ET200_motor
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@
av
st
88
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to SCR stack
rd
system 1 / phase A
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av
st
gu

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from transformer 1
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tm
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current sensing via AVT-C
system 1 / phase A
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@
88
l.c
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rd
tm
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ho
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st
@
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motor voltage sensing via AVT-C
rd
system 1 / phase A
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to motor
st
system 1 / phase A
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from SCR stack / system 1 from SCR stack / system 2
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phase A phase B phase C phase A phase B phase C
l.c
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tm
ho
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@
l.c
88
stator
ai
winding
rd
systems
tm
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ho
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@
st
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exciter
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winding
rd
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to motor side current monitoring

st
via ET200_motor
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Medium Voltage Converter SL150 / Cabinet-Design “6-Pulse”
l.c
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tm
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@
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88
l.c
rd
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tm
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ho
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st
@
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88
rd
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st
Control Power Module Power Module Power Module

Module Phase A Phase B Phase C
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d8 rd
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page 11
ho ho
tm tm
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l.c l.c
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Medium Voltage Converter SL150 / Container-Design “2x6-Pulse”
SITRAIN
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Container-Design “VFD SL150”
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tm
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om
88
l.c
rd
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tm
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internal SIPRO- 6W1 6V1 6U1 5W1 5V1 5U1 4W1 4V1 4U1 3W1 3V1 3U1 2W1 2V1 2U1 1W1 1V1 1U1
Simatic power marshalling cabinets TEC control
A/C
SL150
ho
av
st
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Battery
UPS
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SCR rack SCR rack

system 2 system 1
88
UPS
MCC MCC MCC MCC
230
rd
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cooling unit excitation

fire ext. A/C
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st
gu

Cooling System / Motor Control Center (MCC)
om
l.c
ai
tm
2 3 4
ho
om
5
@
1
l.c
MCC draw-out units
ai
88
tm
9
rd
ho
8 8
6
o_ 10
7
av
@
st
8
gu
d8
1 expansion tank 6 heat exchanger circuit 1
_r
2 fine water pump 1 7 heat exchanger circuit 2

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3 fine water pump 2 8 strainer / filter

4 control, monitoring 9 raw water circuit
a
st
5 de-ionization tank 10 fine water circuit

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page 14
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tm tm
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l.c l.c
SITRAIN
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Line Side Installation, Container-Design
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l.c
line side C.T.s
for protection and
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monitoring via ET200
tm
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om
@
l.c
88
ai
GND
SCR rack,
tm
rd
one system
ho
o_
av
@
st
overvoltage 8
gu
d8
arrestors
_r
avo
st
grounding
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ball pin


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PSA,
st st
one phase
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page 16
one phase
SCR stack,
ho ho
tm tm
ai ai
SCR Racks, Container-Design
l.c l.c
SITRAIN
om om
SCR Stack
om
l.c
ai
disk
springs
tm
om
ho
SCRs +
cooling
l.c
plates
ai
88
tm
snubber
circuit
rd
water flow
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resistors
equalizer
o_
@
av
88
st
gu
rd
TAS
interface
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boards
snubber Fiber optical links between
av
circuit components (TAS PSA,

capacitors AVT-C PSA) use plastic
st
fiber. To refurbish an optical

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fiber end, an appropriate tool

kit has to be used to ensure
the low damping as required.

TAS-Module / Updating the Firmware
om
l.c
ai
tm
programming
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access
ho
24 VDC
l.c
@
auxiliary
power
ai
88
tm
rd
access for
ho
programming
24 VDC
o_
@
auxiliary
av
power
88 connection
st
to laptop
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rd
o_
av
st
The firmware of the ASIC on the TAS-modules can be updated via programming interface and freeware “XILINX”.
gu
If required, update-files are provided by SIEMENS.

om
Replacing a SCR / Example “Air-Cooled”
l.c
ai
tm
ho
@
om
TAS module
88
l.c
rd
ai
o_
tm
av
ho
st
@
gauge-key
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88
rd
o_
av
wrench
st
The gauge-key has to be inserted first. Next the pressure built up

via the disk-type springs is released using an automatic wrench.
gu

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Replacing a SCR / Example “Air-Cooled”
l.c
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tm
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om
@
l.c
88
ai
rd
tm
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ho
av
@
st
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88
rd
o_
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After having replaced the faulty SCR, pressure on the disk springs
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is built up via wrench until the gauge-key can be removed correct

gu
pressure is applied.

SCR-Rack for one System
om
l.c
2U1, 2V1, 2W1 3U1, 3V1, 3W1 PSA
ai
tm
ho
om
@
l.c
ai
88
tm
rd
PSA
ho
o_
av
@
st
PSA PSA 88 PSA

gu
rd
o_
av
SCR rack,
PSA
one system
st
gu
2V2 2W2
to motor winding system 1

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Current- and Voltage-Measurement
l.c
1U1 1V1 1W1 2U1 2V1 2W1
ai
tm
AVT AVT
current current
ho
phase A phase B
AVT AVT
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AVT AVT
l.c
88
111 112 141 142 111 112 141 142
ai
1 4
rd
tm
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241 242 211 212 241 242 211 212
ho
av
131 132 161 162 131 132 161 162
3 6
st
@
261 262 231 232 261 262 231 232
gu
151 152 121

88
122 151 152 121 122
5 2
rd
221 222 251 252 221 222 251 252

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voltage phase A voltage phase B

av
AVT AVT
st
1X1 1X2
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1U2 motor phase A 1V2 motor phase B

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Optical links / PSA TAS
l.c
1-T1 2-T1 1-T2 2-T2
ai
X11 X12 X13 X14 X15 X16
tm
1U1 1V1 1W1
X11 X21 X32 X42
ho
111 112 141 142
1 4
om
X21 X22 X23 X24 X25 X26
@
241
4 242 211
1 212
l.c
X34 X44 X13 X23
88
ai
X31 X41 X52 X62 3-T1 4-T1 3-T2 4-T2
rd
131 132 161 162
tm
3 6 X31 X32 X33 X34 X35 X36
6
o_ 3
ho
261 262 231 232
av
X54 X64 X33 X43
@
X41 X42 X43 X44 X45 X46
X51 X61 X12 X22
st
151 152 121 122

gu
5 2
88
221
2 222 251
5 252
5-T1 6-T1 5-T2 6-T2
rd
X14 X24 X53 X63

X51 X52 X53 X54 X55 X56
o_
1U2 1X1
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st
X61 X62 X63 X64 X65 X66

gu

from 1U1
optical signals from PSAs
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X11 X21 X32 X42
l.c
ai
TAS
Module
tm
(SCR-interface;
power supply off
om
SCR-voltage)
ho
l.c
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88
tm
rd
ho
o_ TAS interface boards
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av
88
st
gu
rd
o_
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X34 X44
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optical signals to SCR
l.c
gating interfaces TAS
ai
DI/O
tm
AI/O
ho
feedbacks 24 VDC
om
UU IU1 IU2 IU3
88
l.c
Essential functions of the Power Stack Adapter (PSA) are
rd
ai
the generation of the gating signals for the SCRs and the
unit specific scaling of voltage and current feedbacks
tm
o_ (all above mentioned links via optical cables) .
ho
av
st
@
gu
X11 X12 X13 X14

88
rd
optical signals to SCR gating interfaces

o_
av
st
gu

1U1
om
overvoltage arrestors
l.c
ai
tm
om
ho
l.c
@
ai
88
tm
rd
ho
o_
@
av
88
st
gu
rd
o_
“motor” current measurement (phase A / system 1)

av
(on the line side via standard C.T.)

st
gu
to SCR bridge

om
l.c
X2
ai
tm
ho
@
om
AVT-Cs for current (voltage) measurement
88
l.c
rd
ai
tm
o_
ho
av
st
@
gu
88
Connection 13+n is
located within plug –X2.
rd
It defines the unit-

specific current scaling.
o_
av
st
AVT-C current L1 of phase A in system 1

gu

om
AVT
starpoint
l.c
ai
tm
ho
motor attenuation
phase A
@
resistors
om
(system 1)
88
l.c
12V/60kHz power supply
rd
ai
attenuation
o_
tm
resistors
av
ho
potential
insulation
st
@
gu
88
rd
v o_
potential
ta
insulation
s
gu

om
Hall-effect Alternative current and voltage measurement
current (smaller power ratings / cabinet design).
transformer
l.c
ai
tm
motor voltage attenuation resistor
phase A
ho
12V/60kHz power supply
om
@
l.c
88
ai
rd
tm
o_
ho
av
@
st
gu
8
d8
_r
AVT-C “current” phase A AVT-C “voltage” phase A

vo
Connection 13+n is located

within plug –X2.
a
It defines the unit-specific

st
current scaling.
gu


gu gu
st st
avo av
_r o_
d8 rd
8 88
@ @
page 30
ho ho
tm tm
ai ai
l.c l.c
om om
from exciter
circuit breaker
SITRAIN
Excitation unit SIMOREG DC-Master
om
l.c
ai
tm
om
ho
l.c
@
filter
ai
88
phase
tm
modules
rd
ho
o_
@
av
st
88
gu
rd
o_
SICROWBAR
av
(DC surge DC Master CM

suppressor) (conversion
st
module)
gu

om
l.c
ai
tm
om
ho
l.c
@
ai
88
tm
rd
ho
connection to ibaPADU-8 (@)

In addition to generating the
gating signals for the SCRs
o_
@
the PSA also offers digital
av
and analog channels.
88
st
gu
rd
@ @
o_
av
st
Recording of analog and

digital signals (source:
gu
PSA) by external laptop.

om
l.c
ai
tm
ho
@
om
88
l.c
rd
ai
o_
tm
av
ho
st
@
gu
88
rd
o_
The functional assignment of the PSA-channels

is inherent in its drive specific programming.
av
Manipulation of these channels, however, may

be possible on “parameter level”.
st
gu

om
l.c
ai
tm
ho
@
om
TM15
88
l.c
rd
phase A phase A
ai
system 1 system 2
tm
o_
ho
av
CBE20
st
@
phase B phase B
SINAMICS
gu
system 1 system 2
CU320-2 DP
88
rd
o_
phase C phase C
system 1 system 2
av
st
VSM10 SMC30
gu

om
Component Names / Circuit Diagrams and Project
l.c
ai
Configuration
tm
Port 0 Port 2
ho
om
@
l.c
phase A
88
ai
rd
tm
o_
ho
Topology
phase B
av
@
phase A
st
gu
88 phase B
rd
phase C phase C
o_
av
st
CU320 =.HA-A1150 CU_SL_L1.Control_Unit_1 (1)

gu
PSA = CC.DA-A3 VECTORSL_L1.Motor_Module_2 (2)

TM15 =.HB-A1160 TM15_HB_A1160_L1.TM15_7 (7)

optionally

TM31
gu gu
st st
av av
o_ o_
rd rd
88 88
@ @
page 36
ho ho
tm tm
OP177
ai ai
l.c l.c
om om
D445
SIMOTION
SITRAIN
om
SL 150 Control Cabinet
l.c
ai
tm
SINAMICS control components
ho
om
@
l.c
88
ai
tm
rd
door-lock
o_
ho
release
button ET200-M
av
@
st
88
gu
rd
Bender LV MV
o_
Iso-meter adapter
av
st
gu

om
24VDC C.B. Trip by any one of
l.c
the three PSA (L-active)
ai
tm
door lock
release
ho
C.B. Enable
om
by all three
@
PSA (H-active)
l.c
88
ai
rd
tm
o_
ho
av
@
st
gu
88
rd
o_
av
st
gu

om
l.c
“H” “L” “L”
ai
tm
ho
@
om
88
l.c
rd
ai
o_
tm
av
ho
st
@
gu
88
Circuit Breaker Motor Isolator C.B. PSA
rd
ON / “1” OFF / “0” ON / “1” OFF / “1” Trip / “0”

v o_
s ta
gu

PSA C.B. C.B. ON C.B. OFF
om
Enable command command
(H-active) (H-active) (L-active)
l.c
ai
tm
om
ho
l.c
@
PSA C.B. Enable
ai
PSA
88
tm
Trip
rd
ho
PSA
Trip o_
@
av
88
st
PSA C.B.
gu
Enable
rd
(H-active)
o_
av
st
gu

om
l.c
OFF cmd
ON cmd
ai
-K1220
-K1120 L-active
tm
H-active
om
ho
l.c
@
ai
88
tm
rd
ho
PSA trip
-K1520 o_
L-active
@
av
OFF cmd
-K1220 88
st
L-active
gu
rd
o_
control of C.B.
av
OFF
control of C.B.
st
OFF ON
gu

Safety interlocking for cabinet design
om
enabling of:
“release all doors“
from PSA
l.c
ai
tm
switching
ho
“interlocking magnets” contact
om
to release the doors
l.c
switching contacts of the MV cabinet doors
88
ai
tm
rd
o_
ho
av
@
st
88
gu
message: “all doors

closed“ to PSA
rd
o_
av
st
gu
interlocking
magnet

CUD1

gu gu
Excitation Unit / DC Master
st st Hardware
av av On Enable
o_ o_
rd rd
88 88
@ @
page 43
ho ho
tm tm
ai ai
l.c l.c
SITRAIN
om om
om
Exciter circuit fault evaluation via DC-Master
l.c
ai
tm
ho
om
@
l.c
88
ai
tm
rd
o_
ho
av
overvoltage
@
CUD2 protection
st
88 DC-side
gu
rd
o_
av
st
gu


gu gu
st st
av av
o_ o_
rd rd
88 88
@ @
page 45
ho ho
tm tm
ai ai
l.c l.c
SITRAIN
om om
om
l.c
ai
Components, Objects
tm
ho
and
@
Topology
88
rd
o_
av
st
gu
SITRAIN
Topology page 01 © Siemens AG 2011 - all rights reserved
List of Contents
om
l.c
Electronic Components of the SL150 …................................................................................ 3
Control Units of the SINAMICS-Family (Selection) …........................................................... 4
ai
Technological Operation with SINAMICS S120 and SIMOTION …...................................... 5

tm
Control Units D445 and CU320-2 in Cyclo-Converter SL150 …........................................... 6

Technology is what you do with the Drive …......................................................................... 7
SIMOTION Control Unit D445 …........................................................................................... 7
ho
SINAMICS Control Unit CU320-2 …..................................................................................... 8

Extension Boards for Control Units …................................................................................... 10
Interface Modules as Link to the Power Stack ….................................................................. 11
@
Terminal Modules (TM) …..................................................................................................... 12

Voltage Sensing Module (VSM) / Sensor Module Cabinet (SMC) ….................................... 13
Connection of Components; Example S120 …..................................................................... 14
88
DRIVE-CLiQ and Electronic Rating Plates; Example S120 ….............................................. 15

Internal Communication by Means of DRIVE-CLiQ ….......................................................... 16
rd
Drive Objects and Drive Components …............................................................................... 17

Configuration, Topology Tree, Objects and Components …................................................. 18
o_
Access to Information and Functions of Objects …............................................................... 19

av
st
gu
page 02
Electronic Components of the SL150
om
control phase L1 phase L2 phase L3
l.c
ai
tm
ho
PSA PSA PSA
fiber optic links fiber optic links fiber optic links
@
AVT-C AVT-C AVT-C
88
D445 CU320
rd
o_
PROFIBUS
Terminal Modules
TM31 2 x TM15 + VSM,
av
SMC30
st
gu
SITRAIN
Control Units of the SINAMICS-Family (Selection)

om
l.c
SIEMENS PM-E 4 DI 4 DI 2 DO 2 DO 2 AI PM-D FX1 xB1
SF SF IPM25
SINAMICS G110:
BF
CPM110
ai
ON
FRCE
RUN
STOP
ICU24F
IM 151 CPU
PWR SG1 SG2 Stat

SG4
SG5 SG6
DC LINK
U/f
ON
1 2
5 2
tm
1 2
6 3
2
6
1
3
SINAMICS G120: CU220 (DP) CU230 (DP) CU240 (DP) (F) ET200S-FC
ho
U/f U/f + FCC Vector

@
SINAMICS S120:
CU310
(AC/AC Powerblocks)
DP PN
88
CU310
SINAMICS G130:
SINAMICS G150:
rd
SINAMICS S120: CU320

o_
SINAMICS S150:
CU320-2
SINAMICS GM150:
av
drive controller
SINAMICS GL150: CUA31
SINAMICS SL150: CU320 CUA31 CUA31 PM340

st
BOP20
CU Adapter for
S120 AC/AC
gu
SINAMICS SM150: D445 + CX32

drive and technology controller
SINAMICS SL150: D445

technology controller
SITRAIN
Technological Operation with SINAMICS S120 and SIMOTION
om
l.c
SIMOTION / SINUMERIK
ai
or
tm
Ethernet
ho
@
88
rd
o_
SINAMICS “CU320” in combination with SIMOTION SINAMICS “CU320” integrated in SIMOTION D4xx
av
The modular platform principle extends into the fusion of Drive and Technological Functionality
(SINAMICS “CU320” and SIMOTION) into one single component (D415, D425, D435, D445).
st
gu
SITRAIN
Control Units D445 and CU320-2 in Cyclo-Converter SL150

om
l.c
ai
SIMOTION D445 SINAMICS_Integrated SINAMICS CU320-2

tm
8
ho
3
@
“external”
PROFIBUS
88
D445 CU320-2 DP
rd
SIMOTION SINAMICS
D445 SL150
o_
av
st
technological functionally not used controlling the

programming in SL150 applications operation of the drive
gu
SITRAIN
Technology is what you do with the Drive
om
l.c
MES/ ERP
e.g.
ai
Industrial PC
Process Control
tm
e.g.
Base Automation TECHNOLOGY
ho
SIMATIC S7-400
@
e.g. Drive Technology
SIMOTION D445,
SIMOTION Kernel
88
e.g. Speed Control DRIVE
rd
SINAMICS CU320
or Torque Control
o_
SIMOTION D445,
Drive Kernel
av
Motor
st
gu
SITRAIN
SIMOTION Control Unit D445

om
l.c
ai
66 DRIVE-CLiQ
DRIVE-CLiQ ports
ports for
for
tm
communication
communication with
with further
further
drive
drive components:
components: 88 digital
digital inputs
inputs
Power
Power Stack
Stack Adapters;
Adapters; 88 bidirectional
bidirectional DI/DO
DI/DO
ho
Terminal-,
Terminal-, Sensor
Sensor Modules
Modules
24VDC
24VDC input
input for
for
electronic
electronic power
power supply
supply
@
Cover
Cover
88 “3-coloured”
“3-coloured” status
status LEDs
LEDs Option
Option slot
slot for
for interface
interface
extension
extension (TB30,
(TB30, CBP10,
88
CBP10,
CBC10,
CBC10, CBE30)
CBE30)
33 measuring
measuring sockets
sockets toto
rd
observe
observe signal values
signal values
o_
22 Ethernet
Ethernet interfaces
interfaces
Compact
Compact Flash
Flash Card
Card IE1/DP
IE1/DP and
and IE2/NET
IE2/NET
for
for the
the software
software and
and for
av
for
parameter
parameter settings
settings 22 PROFIBUS-DP
PROFIBUS-DP
interfaces
interfaces
st
DP1
DP1 and
and DP2/MPI
DP2/MPI
Operating
Operating mode
mode switch
switch
gu
under the cover

under the cover RS232
RS232 terminal
terminal (not
(not used)
used)
SITRAIN
SINAMICS Control Unit CU320-2
om
44 DRIVE-CLiQ
DRIVE-CLiQ ports
ports for
for
communication
communication with
with further
further 12
12 digital
digital inputs
inputs
l.c
drive
drive components:
components: 88 bidirectional
bidirectional DI/DO
DI/DO
Power
Power Stack
Stack Adapters;
Adapters;
Terminal-,
Terminal-, Sensor
Sensor Modules
Modules Option
Option slot
slot for
for interface
ai
interface
extension
extension (TB30,
(TB30, CBP10,
CBP10,
CBC10, CBE20
CBC10, CBE20 inserted)
tm
24VDC
24VDC input
input for
for inserted)
electronic
electronic power
power supply
supply
ho
PROFIBUS
PROFIBUS DP
DP
interface
interface
@
44 “3-coloured”
“3-coloured” status
status LEDs
LEDs
ETHERNET
ETHERNET
88
interface
interface
Software
Software “power-on”
“power-on”
rd
Compact
Compact Flash
Flash Card
Card PROFIBUS
PROFIBUS address
address switch;
switch;
o_
for
for software
software and
and for
for connection
connection for
for BOP20
BOP20 (basic
(basic
parameter
parameter settings
settings V02.05.03
operator
operator panel)
panel)
av
Diagnosis
Diagnosis button
button 33 measuring
measuring sockets;
sockets;
RS232
RS232 terminal
terminal (not
(not used)
used)
st
gu
SITRAIN
Extension Boards for Control Units

om
l.c
ai
Terminal Board TB30

D445 shown;
tm
same boards for CU320-2 • Digital In-/outputs: 4 DI, 4 DO

• Analog In-/outputs: 2 AI, 2 AO, i.e. for
ho
analog setpoint interface
Communication Boards
@
• CAN-Bus interface with CAN protocol

according to CANopen drive profile CBC10
88
• Second PROFIBUS interface CBP10

• PROFINET (IRTE) CBE20 (for CU320-2)
rd
CBE30 (for D445)

o_
SINAMICS SIMOTION
CU320-2 D445
av
CBE 20 CBE 30
TB30 yes yes

st
Device Controller
TCP/RT/IRT TCP/UDP/RT/IRT
gu
IRTE = Isochronous Real Time Ethernet CBC10, CBP10 CBE20, CBE30
SITRAIN
Interface Modules as Link to the Power Stack
om
Power Stack Adapter (PSA)
l.c
• Interface between the control components
and the power stack
ai
• Fiber-optic interface to the gate drive units
tm
• Actual value signal interface
• Analog and digital inputs and outputs
ho
@
Actual Value Transmitter (AVT-C)

88
• Signal level adaptation between current-/voltage
transformers and control unit
rd
• Digitalization of the measuring values

o_
(sigma-delta A/D-conversion)
• Fault-proof coding (manchester-coding)
av
• Fiber-optic interface to the powerstack adapter

st
gu
SITRAIN
Terminal Modules (TM)

om
l.c
ai
tm
D455-2 DP/PN
ho
@
88
TM31 TM15 TM150

rd
terminal module terminal module temperature evaluation

2 analog inputs 24 bidirectional up to 12 channels:
2 analog outputs digital channels PT100
o_
8 digital inputs PT1000

2 relay outputs KTY84
4 bidirectional digital channels PTC
av
temperature sensor evaluation

KTY84, PTC
For Medium Voltage Drives several of these modules are part of the standard
st
configuration controlling “drive-internal” functions.

gu
Optionally any additional number of TMs might be used as customer interface for
digital and analog in- and outputs.
3 Profinet
2 Ethernet Additionally modules TM41 (similar to TM31 / with encoder emulation) and modules TM17
2 USB (similar to TM15 / 1µs resolution, only for D4xx) are available.
SITRAIN
Voltage Sensing Module (VSM) / Sensor Module Cabinet (SMC)
om
• Used for detection of the line voltage on
the incoming side of the circuit breaker.
l.c
• Voltage transformers have to be installed
on the incoming side of the circuit breaker.
ai
tm
Analog
Analog inputs
inputs // temperature
temperature sensor
sensor input
input
ho
100V
100V inputs
inputs (phase
(phase –– phase)
phase) // not
not released
released
690V
690V inputs
inputs (phase
(phase –– phase)
phase) // V
Vmin = 80V
min = 80V
@
Circuit Breaker Transformer Inverter 88Current & Voltage Sensors new
Speed controlled operation of

rd
synchronous motors only with
Motor
new SMC30.
o_
av
Control and Interface

st
VSM 10
gu
SITRAIN
Connection of Components; Example S120

om
l.c
Controller HMI (OP177) PG/PC CPU 317T-2 DP
ai
tm
PROFINET
ho
PROFIBUS
@
DRIVE-CLiQ
88
rd
o_
av
ET 200S
st
gu
3AC
3AC / 380 ... 480 V 0 … 400V
SITRAIN
DRIVE-CLiQ and Electronic Rating Plates; Example S120
• All the components
om
connected via DRIVE-
CLiQ have an elec-
tronic rating plate.
l.c
• The respective technical
data are automatically
loaded to the CU.
ai
• DRIVE-CLiQ is based
tm
on Ethernet technology
with 100 Mbps.
ho
grey without 24 V / fixed in cabinet
green with 24 V / fixed in plant
@
red with 24 V / highly flexible
“Drive Component Link with Intelligence Quotient“
DRIVE-CLiQ
88
rd
reserved, do not use

o_

Note:
Terminals A and B are used for the supply of the measuring system
av
evaluation only. These terminals are short-circuit proof.

st
om
SITRAIN
gu
l.c
Internal Communication by Means of DRIVE-CLiQ
ai
tm
Standard components of the SL150

control phase L1 phase L2 phase L3
ho
@
88
PSA PSA PSA

fiber optic link fiber optic link fiber optic link
rd
... ... ...

AVT-C AVT-C AVT-C
o_
av
D445 CU320
Terminal Modules
TM31 2 x TM15 + VSM,
st
PROFIBUS
SMC30
gu
All components connected to the D445 or to the CU320-2 by means of DRIVE-CLiQ operate on a firmware of their own.
If required, this firmware can be upgraded using the tool SCOUT/STARTER_Integrated which retrieves the data from the
CF-Card of the D445 respectively from the CF-card of the CU320-2.
SITRAIN
Drive Objects and Drive Components
example
om
CU320 ALM MM SINAMICS S150
X103
TM31 TM31
l.c
X102 X402 X402
X101 X401 X401 X501 X501
ai
X400 X400 X500 X500
X100
tm
VSM SMC
1 4 5
M
ho
Netz
X500 X500
2 3
@
Project
88
Drive Device
AA Drive
Drive Component
Component is is aa hardware
hardware unit
unit with
with
DRIVE-CLiQ
DRIVE-CLiQ ports (including motors and
ports (including motors and encoders)
encoders)
rd
A Drive Object
A Drive Object is an autonomous software functionality
Drive Object is an autonomous software functionality
DO
o_
with
with its
its own
own parameters,
parameters, faults
faults and
and alarms.
alarms.
ItIt may
may consist
consist of
of one
one or
or of
of several
several drive
drive components.
components.
right mouse click: DO
AA Drive
Drive Device
Device isis an
an assembly
assembly of of drive
drive objects
objects controlled
controlled
av
Expert > Expert list DO

by
by one
one main
main processor
processor (e.g.
(e.g. D445
D445 Drive
Drive Kernel).
Kernel). DO
st
SITRAIN
om
gu
l.c
Configuration, Topology Tree, Objects and Components
ai
tm
Configuration (listing of objects) “DRIVE-CLiQ wiring” of components

ho
@
88
rd
o_
av
st
Parameters for the

gu
component number
p0121[P]: Power unit
p0131[M]: Motor
p0141[E]: SMx
p0142[E]: Encoder
p0151 TM31
p0161 TB30
SITRAIN
gu gu
st st
Topology
av av
o_ o_
rd rd
88 88
@ @
page 19
ho ho
tm tm
ai ai
l.c l.c
Access to Information and Functions of Objects
om om
SITRAIN
om
l.c
ai
Configuration of SL150
tm
ho
with
@
SIMOTION D445
88
rd
o_
av
st
gu
SITRAIN
Configuration page 01 © Siemens AG 2011 - all rights reserved
List of Contents
om
l.c
SINAMICS SL150, integrated in “Totally Integrated Automation” ……………...................... 3
Installation of SCOUT and STARTER ……………................................................................ 4
ai
Engineering Tools …............................................................................................................. 5

Elements of the SCOUT- / STARTER-Workbench …........................................................... 6
tm
Selecting the Language for SCOUT in STEP 7 …................................................................ 7

Creating a New SIMOTION Project ….................................................................................. 9
ho
Creating a SIMOTION Device ….......................................................................................... 11

SL150-Application / Variant “SINAMICS S120 Integrated” …............................................... 13
Definition of Properties of the Interface “PROFIBUS DP2/MPI” …....................................... 15
@
Adding Drive Device “SL150 CU320-2 DP” …...................................................................... 17

Clock Synchronization SIMOTION D445 Drive Unit …................................................. 21
Adding Drive Device “GM150_CU320” …............................................................................. 23
88
Configuration Wizard …........................................................................................................ 25

Configuring Drive Unit “GM150_CU320” ….......................................................................... 27
rd
Topology and Components of Drive Unit “GM150_CU320” …............................................. 29

Objects and Components of Drive Unit “GM150_CU320” …................................................ 31
o_
Global Commands (acting on all “published” Nodes) …....................................................... 33

av
st
gu
page 02
SINAMICS SL150, integrated in “Totally Integrated Automation“
om
l.c
Systems Tools
ai
SIMATIC S7
S I N A M I C S SL150 SIZER
tm
engineering SINAMICS-drives
ho
SIMATIC STEP 7
@
configuring SIMATIC-applications
88
SIMOTION D
SIMOTION SCOUT
rd
Induction configuring SIMOTION-applications
Motors
o_
and
Synchronous STARTER
av
Motors
commissioning SINAMICS-drives
st
gu
SITRAIN
Installation of SCOUT and STARTER

om
l.c
SINAMICS SINAMICS with higher-level control

ai
stand-alone
tm
SIMATIC S7 SIMOTION T-CPU
SINAMICS
ho
@
88
T-
rd
CONFIG
o_
STARTER STEP 7 DRIVE ES

V4.1.5.5 V5.4.5.4 Basic V5.4.5 SCOUT V4.1.5.6 T-CONFIG
v
with with with

STARTER STARTER_Integrated STARTER_Integrated
ta
new STARTER new STARTER new STARTER via new SCOUT / T-CONFIG
s
by installation by installation
gu
STARTER and SCOUT respectively STARTER and SIMOTION / T-CONFIG must not be installed on the
same operating system. To parameterize a SINAMICS_CU, tool SCOUT can be used without restrictions.
SITRAIN
Engineering Tools
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STARTER_Integrated and other SIMOTION tools
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SIMOTION SCOUT
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ST Structured Text DCC Drive Control Chart
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The drive Sinamics SL150 is controlled via CPU
“CU320_2”; any programming of this CPU can be
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done via STARTER_Standalone.

Applications additionally use a “SIMOTION D445”
controller for technological programming. Since this
fact requires the tool SIMOTION SCOUT; the CPU
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CU320_2 is programmed via STARTER_Integrated.

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Elements of the SCOUT- / STARTER-Workbench

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Menu bar
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Toolbars
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Project navigator
(for SIMOTION and
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for SINAMICS) Main working area

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Detail view
(i.e. faults messages / system information / symbol browser)
SITRAIN
Selecting the Language for SCOUT in STEP 7
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any language
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selected
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language
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SITRAIN
1 Configuration of SIMOTION D445

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1.1 Editing a SIMOTION-D445 project
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Comprehensive commissioning of a SINAMICS SL150 requires the commissioning and service tool SCOUT. On the
PG/PC provided by the training center for this training SCOUT is installed already; after switching on your PG/PC
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select the partition ”SCOUT” and start the program. Select “English“ as language if SCOUT should open in “German”.
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Topics listed beyond this step and the affiliated lab cover engineering issues.
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Given time and personal interest they can be dealt with optionally.
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page 08
Creating a New SIMOTION Project
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project name
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storage location
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SITRAIN
To edit a new SIMOTION-D445 project, follow the steps suggested below:

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Project > New…. Textline in header
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a table listing existing projects pops up
- define a new project by assigning Project name: SL150_offline
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- accept the prompted Storage location (…\Programme\Siemens\Step7\s7proj)

 OK  “Button” in menu
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in window “Project navigator“ (on the left) project SL150_offline is inserted

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page 10
Creating a SIMOTION Device
3. select interface
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“PROFIBUS DP2/MPI”
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1. select
“SIMOTION
device"
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2. select
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“SINAMICS
integrated“
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(type S120)
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SITRAIN
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To continue, two approaches are available:
- Create new device to edit SIMOTION hardware (C230, D445, …)
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- Insert single drive unit to edit drives (SINAMICS or MICROMASTER) without SIMOTION hardware
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Create a new device as follows:

Create new device (double click on the left mouse key) Project navigator
- select CPU-type: D445 V4.1 (or as intended for use)
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- mark Variant: D445-1 DP; SINAMICS S120 Integrated V2.6.2

 OK  “Button” in menu
- define PROFIBUS DP2/MPI as interface to the PG/PC
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 OK
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page 12
SL150-Application / Variant “SINAMICS S120 Integrated”
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HW-Config
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> “right mouse click” on D445
> Open HW-Configuration
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NetPro
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> Project
> Open NetPro
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SITRAIN
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After acknowledgement of the newly created device menu “hardware configuration” (HW Config) opens up and shows
the motor module ”SINAMICS_Integrated, node no.3” already connected to the PROFIBUS_Integrated.
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page 14
Definition of Properties of the Interface “PROFIBUS DP2/MPI”
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HW Config
right mouse click
> Object Properties
> Operating mode
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address of master
SIMOTION_D
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Now you should verify and if necessary adapt the settings needed for the communication D445 PG/PC:
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- right Mouse Click on line “X136, DP2/MPI > Object properties
> tab. “Operating mode” verify “Operating mode = “DP master” and “DP mode = DPV1”
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> tab. “General” verify “Interface type = PROFIBUS”

 Properties
> tab. “Parameters” verify “Address = 2” and “Subnet = PROFIBUS(1)” with 1.5 Mbps
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 Properties
> tab. “Network settings” verify “Transmission rate = 1.5 Mbps and “Profile = DP”
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If you had to make any changes, they have to be saved and compiled:
Station > Save and compile
 OK > OK > OK
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Close menu hardware configuration

Station > Exit
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in the project navigator the device D445 is added to project “offline”

From time to time, also save your project on the harddisk:
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Project > Save

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page 16
Adding Drive Device “SL150 CU320-2 DP”
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right mouse click on
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“DP master system (2)
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Configuration page 17
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The concept of SL150 uses CPU “CU320-2 DP” to control the operation of the drive (drive kernel
SINAMICS_Integrated is an inevitable drive device of SIMOTION D445 but will not be used).
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Controller “CU320-2 DP” for the SL150 has to be added to “Profibus Master System (2)” on port DP2/MPI:
- Open menu “hardware configuration”
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right Mouse Click on “D445”

left Mouse Click on “Open HW configuration”
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- Position the cursor on “Profibus Master System (2)” and use a right Mouse Click to pop up a table
- Select “Insert Object” by a left Mouse Click
- In sequence, select “SINAMICS”, “SINAMICS SL150” and “SL150 CU320-2 DP”
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- Assign the intended node-address in the pop-up table “Properties PROFIBUS Interface” (i.e. 10)
- In “Properties > tab. “Network settings” verify: “Transmission rate = 1.5 Mbps and “Profile = DP”
 OK > OK
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page 18
Adding Drive Device “SL150 CU320-2 DP”
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SITRAIN
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If the message frame (type of Profibus telegram) to be used for Profibus communication is known already it can be
selected in the popped-up table “DP slave properties, tab “Configuration”.
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(Typically this definition will be made in configuring object “drive” (power section and motor) and transferred from there
to menu “HW configuration”.)
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 OK
drive device “SL150_CU320_2_DP” is added to “Profibus Master System (2)”
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Save and compile your changes in menu “HW configuration”:

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Close menu “HW configuration”

Station > Exit
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in the project navigator the device “SL150_CU320_2_DP” is added to project “offline”

Save your project on the harddisk:
Project > Save
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Verify that drive device “SL150_CU320_2_DP” has been added in NetPro as well.
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page 20
Clock Synchronization SIMOTION D445 Drive Unit
> Project
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> Open NetPro
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> “right mouse click” on D445
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> Open HW-Configuration
The Profibus data exchange
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between drive units SIMOTION
D445 and SL150_CU320_2_DP
has to be “clock-synchronous”
with values as listed.
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right mouse click

> Object properties
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> Isochronous operation
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Button “Align” automatically tunes

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the settings in SIMOTION D445

and in SL150_CU320_2_DP to the
same values.
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SITRAIN
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For a SINAMICS SL150 application a few settings have to be adapted regarding the ”Clock Synchronization” in
”Object properties” of device ”SL150_CU320_2_DP”:
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- open menu “HW configuration”

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- with the right Mouse Key click on block ” SL150_CU320_2_DP”

- select ”Object properties” and tab. “Isochronous Operation”
- tick the box “Synchronize Drive to equidistant DP cycle”
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- set following values: Tmapc = 1.5 ms / Tdp = 1.5 ms / Ti = 0.5 ms / To = 1.0 ms

(start by assigning the factor for Tdp)
 Align > OK
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To have these settings available and valid for a later download, they have to be saved and compiled:
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page 22
Adding Drive Device “GM150_CU320”
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- select drive device in catalog
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- keeping the left mouse key pressed
- shift it to “Profibus Master System”
- release left mouse key
drive device is inserted
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SITRAIN
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1.2 Configuring drive unit “SL150_CU320_2_DP”
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Open drive device “D445” and the then additionally visible device “SL150_CU320_2_DP”:
device “SL150_CU320_2_DP” lists object “Control Unit” as the only object.
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The configuration of this drive device is guided by the “Configuration Wizard” via “Configure drive unit”.
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At the present state of tool SCOUT this wizard is not (yet) implemented. To still be able to perform a wizard-guided
configuration of a medium voltage drive, add a drive device of the type “GM150_CU320” additionally:
- open the “HW configuration” and add drive device “GM150_CU320” to “Profibus Master System (2)” additionally
@
(i.e. by using the Catalog for “Profile = Standard” on the right end of the screen and the “drag and drop”
operation; set Address = 11 / Baud rate = 12 Mbps / Profile = DP / Version = V2.6.2)
- save and compile the changes in menu “HW configuration” and exit the menu
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drive device “GM150_CU320” has been added to the configuration menu

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page 24
Configuration Wizard
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a configuration wizard guides through the menus
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SITRAIN
In the next step the properties of the Motor Module have to be defined:
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GM150_CU320 > Configure drive unit
a configuration wizard pops up
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Following the steps prompted by the configuration wizard, now configure the drive unit according to the properties
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listed below:
- Connection voltage: All voltages
- Cooling method: Liquid cooling
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- Drive unit selection: 6SL3835-2LN41-8AA0

- Default macro: Standard cabling
- Options selection: L60 / EMERGENCY STOP Category 1
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G61 / User terminal block extension TM31 (A)

G63 / User terminal block extension TM15
K50 / SMC30 encoder module
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- Device connection voltage: 3200 V

- Rated supply frequency: 50 Hz
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- Function modules: none

- Control method: Speed control (with encoder)
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- Standard: IEC-Motor
- Connection voltage: 3100 V
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- Motor name: at will

- Motor type: Induction motor (rotating)
- Motor data: according to the rating plate
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page 26
Configuring Drive Unit “GM150_CU320”
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ed
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Don’t mark these boxes UNLESS
t us ns
no atio
you have reliable data available
(from provided data sheets)!
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on pplic
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m m a
Co L150
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Command and setpoint sources can be pre-

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assigned individually for each command data set.
With a pre-assignment all required binector- and

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connector connections are automatically inserted.

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SITRAIN
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- No entry of optional data

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- No entry of equivalent circuit diagram data
- Calculation of the
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motor/controller data: Complete calculation with equivalent circuit diagram data

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- Encoder to be used: Encoder 1

- Encoder evaluation: SMC30
- Encoder type: 1024 INC/rev, 24V, differential track, no zero-pulse
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- Default macro: Command / Setpoint sources CDS0: Profibus, CDS1: Terminal strip
- Profibus PZD-message frame: Standard telegram 2
- Motor current limit: 650 A
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- Minimum speed: 100 1/min

- Maximum speed: 1900 1/min
- Ramp-up time: 15 s
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- Ramp-down time: 25 s
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- Ramp-down time with OFF 3: 10 s

 Finish
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Checking the navigator section you will notice that device “GM150_CU320” is supplemented by following objects:
- Input/output components TM31_1, TM31_2, TM15IO_1, TM15IO_2, TM15IO_4
- Drive_1
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Compare the project tree which has been generated with the configuration you have just carried out.
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Supplement an “Input/output component TM31“ for device “GM150_CU320”:

Insert Input/output component [double click with the mouse key on the left]
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- Name: TM31extra
- Drive objects type: TM31
 OK
in the project tree the additional input/output component “TM31extra“ is added
page 28
Topology and Components of Drive Unit “GM150_CU320”
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SITRAIN
Configuration page 29
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1.3 Analyzing the topology (DRIVE-CLiQ connections) of device “GM150_CU320”
Analyze the Project Set Topology of device “GM150_CU320” in display mode “only DRIVE-CLiQ components”
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and “all components”:

SL150_offline > GM150_CU320 > Topology
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Add the TM-identifiers (TMxx_0x) and complete the drawing below to show the DRIVE-CLiQ wiring:
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TM15 TM31 CU320 PSA SMC TM15 TM15 TM31 TM31extra

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…….. …….. …….. …….. …….. ……..

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Port 0
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page 30
Objects and Components of Drive Unit “GM150_CU320”
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After finishing the configuration,

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components and objects of the

Drive Device “GM150_CU320”
are automatically added to the
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configuration menu.
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SITRAIN
1.4 Identification of the component and object numbers of the drive device m
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In the overview prepared below, assign the numbers allocated by the system to the drive components and to the drive
objects of device “GM150_CU320”; use information provided by SCOUT/STARTER_Integrated menus.
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TM15 TM31 CU320 PSA SMC TM15 TM15 TM31 TM31extra

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…….. …….. …….. …….. …….. ……..

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Port 0
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Component number
.... .... .... .... .... .... .... .... ....

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Motor ....
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Encoder ....
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Object number
.... .... .... .... .... .... .... ....
page 32
Global Commands (acting on all “published” Nodes)
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open connect to disconnect from
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save project
and compile all NetPro target system target system
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save project
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accessible nodes
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Most commands are accessible from either the menu bar, the tool bar or via project navigator.
Commands may act on all drive devices at the same time or only on the drive device which has been selected !
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SITRAIN
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1.5 Copying and adding objects and components
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You can copy objects and components of a drive unit along with all their properties and add them to the same or to
any other drive unit (if the hardware structure permits).
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Copy object “TM31_1“ of your drive device SL150_offline > GM150_CU320 and add it as “TM31_test“ on Port 0 of
component “Control Unit”:
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- select object “TM31_1“ in the project tree (it is highlighted in blue)

- right Mouse Key (rMK) Expert > Save project and export object
- define “C:\Temp“ as target directory > OK
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- in target device “GM150_CU320”, select the group to which the component is to be added (e.g. I / O component)
- right Mouse Key, Import object
- select the source directory and the object to be imported (TM31_1.xml) > Öffnen (open) > OK
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the imported object (TM31) is added to the drive device

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(possibly with a different name, refer to XML- status display in bottom line)
Open the topology tree
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- the imported object is included in the topology tree.

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if the imported object has not been added to the topology tree automatically, you will find it in the component
depot; in this case it must be added manually:
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- select the imported object in the component depot

- keeping the left mouse key pressed drag it up to the required port
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Now relocate object “TM31“ just added to port 1 of component TM31extra and assign “TM31_test“ as new name:
- in the topology tree, select the object to be relocated; keeping the left mouse key pressed drag it up to port 1
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of component “TM31extra”
- in the configuration tree, select the object to be renamed; reassign the name after a single click with the left
mouse key or via right Mouse Key, Rename.
Save your project on the harddisk not to loose the modifications if the PG/PC should be switched off unintentionally:
Project > Save
page 34
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Basic Commissioning Skills
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using
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SCOUT / STARTER_Integrated
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SITRAIN
Commissioning page 01 © Siemens AG 2011 - all rights reserved
List of Contents
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Training Unit SINAMICS S120 AC-DC/DC-AC with D445/CU320-2 …................................ 3
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Initial Requirements for Commissioning …........................................................................... 7
Structure of the Compact Flash Card (CF card) …............................................................... 9
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SIMOTION/SINAMICS Firmware; SCOUT/STARTER Software …...................................... 11

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Factory Default on SIMOTION D445 …................................................................................ 13

Setting up the PROFIBUS Communication …...................................................................... 15
Global Commands (acting on all “published” Nodes) …....................................................... 17
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Disconnecting the PG/PC from the MPI Network …............................................................. 19

Assigning the PG/PC to the PROFIBUS Network …............................................................ 21
Setting up the PG/PC Interface …........................................................................................ 23
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Connecting to Target System …........................................................................................... 25

Downloading to Target System …........................................................................................ 27
Global Commands / Commands for Individual Nodes …..................................................... 29
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Online-/Offline Comparison ….............................................................................................. 30

Scheme of Data Transfer via SIMOTION DCC_1 …............................................................ 33
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Online Search and Uploading the Drive Devices …............................................................. 35

Online Search and Automatic Configuration of Drive Devices …......................................... 37
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Data Storage …..................................................................................................................... 39

Definition “Infeed Operation“ / “Missing Enables” …............................................................. 43
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Substituting Inputs Connections …....................................................................................... 45

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Essential “Basic Settings” in STARTER_Integrated …......................................................... 47

Assigning Objects to Cyclic Data Exchange …..................................................................... 49
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Data Inconsistency …............................................................................................................ 51

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Components’ View …............................................................................................................ 53

First Test with Control Panel / Diagnostic Monitor …............................................................ 55
page 02
Training Unit SINAMICS S120 AC-DC/DC-AC with D445/CU320-2
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400VAC
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24VDC
on the
right
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NOT USED
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VSM TM15-1 SMC TM15-2 TM31
CX32
CU320-2 D445 ALM MM

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ASM 1LA2083
1LA7070
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Please use projects by

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names “SL_LVx.zip”.
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SITRAIN
2 Basic Commissioning with the SW-Tool SCOUT / STARTER_Integrated

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To gain basic commissioning skills by handling the tools SCOUT and STARTER_Integrated a Low Voltage, S120-type
training unit will be used.
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It features the same control components as the SL150, but uses LV Line and Motor Modules as a substitute for the
SCR power section and the Power Stack Adapter of the “real” SL150.
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Adapt the Drive-CLiQ wiring of your training unit to the topology which will be used in projects “SL_LVx” for this
training:
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page 04
Training Unit SINAMICS S120 AC-DC/DC-AC with D445/CU320-2
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400VAC
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NOT USED
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24VDC
CU320-2
TM15-2
TM15-1
ALM MM
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TM31
D445
SMC
VSM
CX32
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Please use projects by

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names “SL_LVx N .zip”.

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SITRAIN
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Out of the available I/Os of the components only a small selection is wired to a hand-held operator panel.
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The assignment of switches to Digital Inputs, of Digital Outputs to LEDs, of pots to Analog Inputs and of Analog
Outputs to the display is shown in the listing below and in section 16, page 3 (the listing acts as substitute for
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a circuit diagram).
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control box component designation

DI 0 TM15-1 X520: 2 DI/O 0
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DI 1 X521: 7 DI/O 13
DI 2 X521: 8 DI/O 14
DI 3 X520: 5 DI/O 3
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DI 4 TM15-2 X520: 2 DI/O 0

DI 5 X521: 3 DI/O 9 analog indication I/O
DI 6 X521: 5 DI/O 11
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DI 7 X520: 5 DI/O 3 indication changeover TM15-1

DI/DO 8 D445 X122: 2 DI 1
DI/DO 9 X122: 3 DI 2
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TM15-2
DI/DO 10 TM31 X541: 4 DI/O 10 TM31: analog input 0
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DI/DO 11 X541: 5 DI/O 11 D445 / TM31

X541: 1 (P24) TM31: analog input 1
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DI/DO 12 TM15-2 X522: 8 DI/O 22 TM15-2 / TM15-1

DI/DO 13 X522: 9 DI/O 23
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DI/DO 14 TM15-1 X522: 6 DI/O 20

DI/DO 15 X522: 7 DI/O 21
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AI 0 TM31 X521: 1 AI 0
AI 1 X521: 3 AI 1
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X521: 2+4+6 (M24)

AO 0 TM31 X522: 1 AO 0
AO 1 X522: 4 AO 1
X522: 2+5 (M24)
page 06
Initial Requirements for Commissioning
1.
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The cabinet is wired up to line and motor;
transformer and C.B. function is verified
2. The DRIVE-CLiQ wiring matches the
“factory”-condition ( circuit diagrams)
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3. A SIMOTION-project providing the 4
SIMOTION-programming is available
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4. SIMOTION D445 and CU320-2 are
tm
equipped with correct Compact Flash
Cards and the matching FC-structures 2
5. A matching SCOUT-release is installed
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6. The PROFIBUS-connection is set up
(respectively the ETHERNET-connection)
power
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transformer
6
circuit
breaker
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line
3+5
1
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SITRAIN
Commissioning page 07
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2.1 Retrieving a project from archive, going online and downloading the project
The command- and control-scheme of the medium voltage converter SL150 as well as the training device SINAMICS
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S120 AC-DC/DC-AC are based on following hardware components:

- Technology Control Unit SIMOTION D445 (processing the required technology control via programs in
tm
“Structured Text, ST” and “Drive Control Chart, DCC”)

- Drive Control Unit CU320-2 DP (controlling the Motor Module and other drive components)
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- Line voltage sensing module VSM 10

- Encoder evaluation module SMC30
- I/O-components TM15, TM31
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- HMI OP177 (application-specific menu for “Local Control”)

Every application using SIMOTION D445 is programmed and parameterized with the tool SIMOTION SCOUT which
includes the tool STARTER_Integrated (e.g. for the parameterization of SINAMICS CU320-2 DP).
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SL150 medium voltage converters most commonly use a configuration which includes a SIMOTION program
- for interaction between SL150 and plant periphery
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- for control via operator panel OP177.

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Firmware and user programs are provided on Compact Flash Cards (CF card) for both control units, SIMOTION D445
and SINAMICS CU320-2 DP.
The two CF cards differ in all aspects from each other and from other SINAMICS drives (memory space, boot loader,
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FW and user programs) and can only be used in the designated CPU and for the specific type of drive.
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page 08
Structure of the Compact Flash Card (CF card)
CPU FW
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SINAMICS SIMOTION
SL150 D445
CU320-2 DP PSA stamping D445
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Components’ FW
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Technology
programming
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“Backup” File Drive Configuration
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PF12 PF1
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SITRAIN
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By the time of delivery to the site the drive is not fully commissioned yet (i.e. specifics of the plant periphery or motor
data may be missing). A completely functional project is available only after the completion of commissioning.
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The project used for the current step of training represents the state after completion of commissioning; therefore it is
tm
instantly functional! On the Compact Flash Card this project is saved in archived version by the name “SL_LV1x.zip”.
If you use the training unit consisting of “one unit”, please use files “SL_LV1.zip”; if you use the training unit consisting
ho
of “two units”, please use files “SL_LV1N.zip”.

To be able to access the programming of all devices within the project (SIMOTION, SINAMICS), a matching D445-
project has to be available on the PG/PC.
@
Such a D445-project will be provided at site (as a zipped file) in at least one of the following two versions:
(1) saved on CD or DVD
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(2) saved on the Compact Flash Card as directly available zip-file (visible as “xxx.zip” via card reader)
in addition to the typically available “ready to run” programming
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In case (1) the project will be directly “retrieved from archive” (to …. \ Program files \ Siemens \ Step7 \ s7proj) and
opened with SIMOTION SCOUT.
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In case (2) the project is copied from the CF card to the PG/PC harddisk via card reader, then “retrieved from archive”
(to …. \ Program files \ Siemens \ Step7 \ s7proj) and opened with SIMOTION SCOUT.
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For the current step of training case (2) will be applied.

Using the card reader, copy the entire content of the Flash Card of SIMOTION D445, including file “0_Training” (which
st
contains the zipped projects “SL_LV1x.zip“, “SL_LV2x.zip“, “SL_LV2Fx.zip”, SL_LV4x.zip and “SL_LV4Fx.zip“) to
directory “C\Temp_Trainee\D445_CFC”.
gu
Execute the routine “remove hardware safely” (button at the right end of the bottom line) before removing the CF card
and the card reader; put the D445 CF card back into controller D445.
Take out the CF card from the CU320-2 DP and copy its entire content to directory “C\Temp_Trainee\CU320_CFC”.
Again execute the routine “remove hardware safely”, remove the CF card and the card reader and put the CU320 CF
card back into controller CU320-2 DP.
page 10
SIMOTION/SINAMICS Firmware; SCOUT/STARTER Software
om
Current FW version Current SW version
SIMOTION/SINAMICS: SCOUT/STARTER:
l.c
V4.1.5.6/V4.3.1.0 V4.1.5.6
ai
(Internal: V47.80.29.0/V40.30.18.0) (Internal: V47.80.29.0)
tm
ho
@
88
SIMOTION / SCOUT +
rd
SINAMICS STARTER
FW 4.0 / FW 2.4 V 4.0
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• SINAMICS firmware and SIMOTION firmware FW 4.1 / FW 2.5 V 4.1

are part of the respective Compact Flash Cards
FW 4.1.5.6 / FW 4.3.1.0 V 4.1.5.6 (2011)
av
• The validity of the Boot sector has to be checked

when copying new firmware onto the CF card (FW 4.0: 512 MB CFc, FW 4.1: 1024 MB CFc)
st
SITRAIN
gu
Start program SIMOTION SCOUT. If any project should open automatically, please close it:
om
l.c
Project > Close
Check whether project “SL_LV1x.zip” already exists on the harddisk other than in directory
ai
“C\Temp_Trainee\D445_CFC” to which you have just copied it. If so, please delete it from any other location:
tm
Project > Delete

- select project “SL_LV1x.zip”
 OK > OK > OK
ho
project “SL_LV1x.zip” has been deleted.

With any SIMOTION_D4xx it is NOT POSSIBLE to upload the programming of an already commissioned system
@
to an “empty” project (as can be done with a SINAMICS_CU3xx).

Retrieve project “SL_LV1x.zip” from archive to the prompted directory (…. \ Programme \ Siemens \ Step7 \ s7proj):
Project > Retrieve from archive
88
- select project “SL_LV1x.zip” in directory “C \ Temp_Trainee”

 Öffnen (open)
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- accept the suggested directory “…. \ Programme \ Siemens \ Step7 \ s7proj”

 OK > OK > Yes
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project “SL_LV1x” is opened.

The firmware release of the tool SCOUT/STARTER has to be compatible with the firmware version used in SIMOTION
av
D445 and in CU320-2 DP since the CU-FW is booted out of the Compact Flash Card.
Verify that this prerequisite is given on your training unit:
st
FW-release SCOUT/STARTER ............................

gu
FW-release CF card of D445 ............................

FW-release CF card of CU320-2 DP ............................
Verify that the Flash Cards contain the FW for the type of drives you are commissioning.
At the training rack (table unit) a SINAMICS S120 is being used.
page 12
Factory Default on SIMOTION D445
om
A
A “Factory
“Factory Default”
Default” of
of SIMOTION
SIMOTION D445 D445 will
will be
be aa reasonable
reasonable measure
measure ifif
all
all programs
programs of
of the
the D445
D445 are
are to
to be
be deleted
deleted (SIMOTION
(SIMOTION and and SINAMICS_Integrated)
SINAMICS_Integrated)
an
an online
online connection
connection toto SIMOTION
SIMOTION D445 D445 fails
fails to
to be
be set
set up
up despite
despite correct
correct configuration
configuration
l.c
operating mode via hardware switch or graphically via menu
ai
position “F”
to operate
tm
the serial 0
interface
as Hyper- 1
ho
terminal
@
3
0 RUN cyclic SIMOTION program is processed
1 STOP-U SIMOTION user program processing is accessible in online mode via:

88 interrupted; technology programs and D445 > (right mouse click)
SINAMICS_Integrated are active target unit > operation mode
2 STOP technology programs are interrupted;
rd
SINAMICS_Integrated is active
3 MRES General system reset
o_
Default values of the communication parameters read as follows:

PROFIBUS-address (DP1, DP2) 2 (1.5Mbit/s)
av
IP-address (IE1) 192.168.214.1 / subnet 255.255.255.0

IP-address (IE2) 169.254.11.22 / subnet 255.255.0.0
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SITRAIN
gu
Project “SL_LV1x“ includes following devices:

om
l.c
- D445_Hardware with a SIMOTION program (type DCC),
- CU320_2_Drive with the Motor Module programming and I/Os,
ai
- SINAMICS_Integrated (inevitable Drive Kernel of D445; not used in SL150 applications).

tm
In a plant-situation the CF card will contain a “ready-to-run” programming (to some extent only; a good amount of
commissioning work is still required).
ho
On your training unit the CF card might contain an uncertain programming state. For this reason, first perform a
hardware-reset AT THE TRAINING UNIT (NOT AT SITE, unless necessary for some reason):
- verify that all power supplies are switched off (two mcbs on the right hand side; 3ph - 400 VAC, 1ph - 24 VDC)
@
- insert the CF card

- select switch position “3” on the “PLC-switch” below the blue cover
- switch on the 24 VDC supply (1ph mcb)
88
- wait until the LEDs on component D445 indicate: RDY = green, STOP = orange
- select switch position “0” on the “PLC-switch”
rd
- LEDs indicate: RDY = green, RUN = green

The state of operation of controller “CU320-2 DP” (its programming has not been affected by Defaulting controller
o_
D445) can be ignored since a download (following later) of drive device “CU320_2_Drive” will overwrite any
programming in full anyhow.
av
st
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page 14
Setting up the PROFIBUS Communication
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Profibus connection and Bus termination
l.c
ai
tm
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• As tool a matching SCOUT release is installed
• Communication link from Laptop to D445 (CU320) is set up
via PROFIBUS observing the wiring rules.
@
• Properties of the PROFIBUS-DP master system are defined
• PG/PC is assigned to the PROFIBUS
• The PG/PC interface is set up

88
VP (Pin 6)
rd
390 Ω
o_
RxD/TxD-P (Pin 3)
220 Ω
RxD/TxD-N (Pin 8)
av
390 Ω
DGND (Pin 5)
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SITRAIN
gu
om
To download the (retrieved) project to the CF card, an online-connection has to be set up between PG/PC and D445.
l.c
First satisfy the hardware condition required for the communication with PROFIBUS
- by connecting the PG/PC to socket DP1 on component D445 and
ai
- by connecting control unit CU320-2 DP to socket DP2/MPI on component D445

tm
Verify that the bus terminating resistors are properly assigned.

ho
@
88
rd
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page 16
Global Commands (acting on all “published” Nodes)
om
l.c
ai
save project open connect to disconnect from
and compile all NetPro target system target system
tm
save project
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accessible nodes
@
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> Target system
> Select target device
rd
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av
st
SITRAIN
om
gu
l.c
The project might include devices which are not intended to be part of the active PROFIBUS Network. If you find any
such device, please exempt it from the request for online connection:
ai
Target system > Select target devices

- verify that there is NO check-mark to the left of the “device in question“
tm
 OK
Have a look at the PROFIBUS-network as seen in NetPro:
ho
Project > Open NetPro

To be able to access the PROFIBUS-network via PG/PC, its interface has to be assigned to the PROFIBUS-network.
@
(1) Check whether following condition is valid (in menu NetPro):

- the connection from the PG/PC to the PROFIBUS-network is highlighted in yellow
if you find this NOT to be true, continue with (2 / page 20)
88
if you find this to be true, continue with (3 / page 24)

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o_
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st
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page 18
Disconnecting the PG/PC from the MPI Network
om
right mouse click
> Object properties
l.c
or directly
ai
tm
ho
@
88
rd
If the PG/PC is assigned to some other interface than PROFIBUS (i.e. MPI), the interface assignment must be redefined:
o_
disconnect from the presently assigned interface

If the “PROFIBUS interface” is not listed in “Configured Interfaces”, it has to be configured:
av
add a “PROFIBUS interface” and configure the Network settings to 1.5 Mbps with Profile “DP”
st
SITRAIN
om
gu
l.c
(2) Open the “Object Properties” of the PG/PC:
- Click with the right Mouse Key on “PG/PC”
ai
 Object Properties
- select the assigned interface in the table “Assigned” (i.e. MPI interface …)
tm
 Disconnect
the assigned interface is removed from the table “Assigned”
ho
@
88
rd
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av
st
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page 20
Assigning the PG/PC to the PROFIBUS Network
om
l.c
ai
(1)
tm
(2)
ho
(3)
@
88
rd
o_
To assign the PG/PC to the PROFIBUS network, select “PROFIBUS interface” and define CP5xxx (PROFIBUS) for
the PG/PC; button “Assign” and selection of the assigned interface activates the PROFIBUS connection to the PG/PC.
av
If “PROFIBUS interface” is not listed in the list of “Configured Interfaces”, add it as “New Interface” in tab “Interfaces”.
st
SITRAIN
om
gu
l.c
- select “PROFIBUS interface” …” in table “Configured Interfaces”
[ If “PROFIBUS interface” is not listed, select tab “Interfaces”,  “New”, select “PROFIBUS interface”,  OK
ai
table “Properties PROFIBUS Interface” pops up,

select “PROFIBUS (1),  Properties, Network settings: 1.5 Mbps / DP
tm
PROFIBUS Interface (1) is added the PG/PC is connected to it in NetPro ]

- select interface “CP5xx (PROFIBUS) in table “Interface Parameter Assignment in the PG/PC”
ho
[for a PG: module CP561x, for a PC: module CP551x]

 Assign
“PROFIBUS interface” is inserted in table “Assigned”
@
 OK
the connection from the PG/PC to the PROFIBUS-network is highlighted in yellow
8
r d8
o_
av
st
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page 22
Setting up the PG/PC Interface
om
> Options
> Set PG/PC Interface
l.c
PG
ai
tm
ho
@
“User-Defined” if set via
NetPro (Button “Nein”)
88
rd
o_
when requesting Properties
• Test O.K.
av
“Ja” Properties become available • Bus nodes 20 (PG/PC)

“Nein” Properties can be seen 2 (D445)
st
gu
SITRAIN
(3) Verify that nodes PG/PC and D445 are both linked to the PROFIBUS-network:
om
l.c
Options > Set PG/PC Interface - Access point of the Application: S7ONLINE
- Interface Parameter Assignment Used: CP5xxx (PROFIBUS) <active>
 Properties warning “…Do you want to change the parameters” pops up
ai
 Ja (yes) table “Properties – CP5xxx (PROFIBUS) pops up

tm
- no check-mark at “PG/PC is the only master”

(in this project the D445 has the state of master)
- Address = as set for the PG/PC (refer to NetPro)
ho
- Transmission Rate = 1.5 MBit/s

- Highest Station Address = 126 (or as used)
- Profile = DP
@
warning “…changing parameters that were set” pops up

 Ja (yes) > OK > Diagnostics > Test OK
88
 Read “Station active” at Bus Nodes “20” (PG/PC) and “2” (D445; internally
assigned address on socket DP2/MPI)
 OK > OK
rd
If table CP5xxx with message “Invalid assignment” pops up - select “CP5xxx (PROFIBUS)”
 Activate
o_
If you had to make NO changes in NetPro, close NetPro: Network > Exit
av
If any changes were made, “Save and Compile” NetPro first: Network > Save and Compile
- Compile and check everything
 OK
st
Close message “no errors”: [x]

gu
Close NetPro Network > Exit
page 24
Connecting to Target System
> Project
om
> Accessible nodes
> Project
l.c
> Connect to Target system
ai
tm
Unless device D445 is
ho
Online connection to SIMOTION D445
downloaded, online red-green (but inconsistent data)
connection to other
devices will fail due to
the missing routing in
@
No online connection to CU320_2_Drive
D445 to PROFIBUS. red-red

88
rd
o_
av
om
SITRAIN
st

gu
l.c
Establish an online connection between PG/PC and D445:
ai
Project > Connect to target system
message: no connection to “CU320_2_Drive”
tm
 OK
A connection to “CU320_2_Drive” will be possible only after a project-download to D445_Hardware since the
ho
PROFIBUS link between D445 and “CU320_2_Drive” has to be set up first (routing through D445).
If a project has been “retrieved from archive”, it should be “saved and recompiled” once before being downloaded:
Project > Save and recompile all
@
message: … no errors
 OK
8
Before starting the download, select tab “Target system output” (bottom line) and open up the information window for a
d8
few lines so you can read the messages displayed during the download.
r
o_
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page 26
Downloading to Target System
> Project
om
> Download to Target system
l.c
ai
The download of device D445 is possible only in operating mode STOP; the first download will take several minutes.
tm
ho
After the successful download all (selected) devices are online.
> Options
> Settings
@
> Download
88
rd
o_
No online connection to SINAMICS_Integrated

white-white (device was not selected to go online)
av
om
st
SITRAIN
gu
l.c
Now download project “SL_LV1” to component D445:
ai
- click on Icon-button “Load project to target system”
- assign the check-mark next to “After loading, copy RAM to ROM”
tm
 Additional CPU options >>

- remove the two check-marks next to “Initialization of the non-RETAIN data”
 Yes
ho
- acknowledge the requested changeover to “STOP” mode

 Yes
(please be particularly patient at 5% and at 9%)
@
you will notice, that the function “Copy RAM to ROM” is carried out for two devices:
“D445_Hardware” and “CU320_2_Drive”
88
- accept the suggested changeover to “RUN” mode

 Yes
all devices (“D445_Hardware” and “CU320_2_Drive”) are online (consistency plugs are closed and
rd
read green – green)

o_
This state will be true regardless of the initial condition of the CU320-2 programming; either the already
functionally correct program or the corrupted, wrong, missing etc. program is overwritten by the programming
of the PG/PC project.
av
in the alarm tab, both devices read “OK”, device “D445” indicates steady green for RDY and RUN,
device “CU320-2” indicates steady green for RDY and DP
st
the system is ready to operate according to its programming.

gu
page 28
Global Commands / Commands for Individual Nodes
manipulate device data of the

• drive unit of the project as marked
om
(i.e. CU320_2_Drive or SINAMICS_Integrated)
Start Object
load project to
l.c
comparison
target system
ai
load project to target system copy RAM to ROM *
• all project data to all target devices
tm
SIMOTION D445_Hardware * also for
load to PG SIMOTION
SINAMICS CU320_2_Drive
SINAMICS_Integrated
ho
(if connected and online) download to target *
• with / without copy RAM to ROM:
restore factory settings
@
> Options > Settings with / without copy
RAM to ROM
88
rd
o_
av
om
st
SITRAIN
gu
l.c
Online-/Offline Comparison
ai
tm
IfIf STARTER
STARTER identifies
identifies data
data inconsistency
inconsistency when
when the
the operating
operating mode
mode is
is changed
changed from
from Offline
Offline to
to Online,
Online, the
the inconsistency
inconsistency is
is
monitored by menu “Online-/Offline-comparison (“Settings > Workbench”).
monitored by menu “Online-/Offline-comparison (“Settings > Workbench”).
ho
@
8
r d8
o_
av
PG-project data are in the configuration

not identical with of the Offline-project
the CU-RAM data some objects of the
st
Online-configuration
are missing.
gu
If the Offline-project matches the plant requirement, data consistency is restored by a Download
SITRAIN
Online-/Offline Comparison
change
change of
of operating
operating mode
mode Offline
Offline to
to Online change
change of
of mode
mode Online
Online to
to Offline
om
Online Offline
l.c
ai
tm
ho
@
88
This menu will only pop up, if parameters
have been changed while in online mode.
rd
Prior to “disconnecting from target system“

the routines as marked will be executed.
If a data inconsistency is identified within some objects, the
o_
objects concerned are listed. Whether to carry out an upload

or a download will typically have to be decided by knowledge
of the “history” of steps taken previously or by analyzing the
av
difference in settings ( menu “parameter comparison”).

st
SITRAIN
om
gu
l.c
If SIMOTION should not be in operating mode “RUN” (yellow light on LED “STOP”), the RUN-mode can be requested
either by changing the switch position of the “PLC-switch” (below the blue cover) from “0” to “1” to “0” or via “D445 >
ai
(right mouse click) Target device > Operating mode > switch position “RUN” and acknowledgement of the “Timeout”
messages.
tm
Test the function as provided by chart DCC_1 in project SL_LV1 using the hand-held operator panel (initially set all
switches to off-position):
ho
1) Switch on the 400 VAC supply via 3-phase mcb on the right hand side of the training unit
2) Open tab “Alarms” to view the operating state of the three drive devices
@
3) Change the Operating Mode to STOP Faults “Profibus: Setpoint timeout” are indicated for all objects
4) Change the Operating Mode to RUN Faults “Profibus: Setpoint timeout” are acknowledged (via DCC_1)
5) Switch on DI 4 Control command OFF3 is cancelled
8
(verify via “missing enables” in “Diagnosis”)

d8
6) Switch on DI 0 ALM is switched on

(“infeed enable missing” is cancelled)
r
7) Switch on DI 1 MoMo is switched on (bit “0” changes to “H”)

o_
but MoMo is not yet enabled for operation

8) Switch on DI 2 MoMo is enabled
av
(drive runs with setpoint via “AI1”)

9) Set the speed via AI 1 (DI 5 = off) values between -1400 rpm and +1400 rpm can be set
st
gu
page 32
Scheme of Data Transfer via SIMOTION DCC_1
om
PROFIBUS I/O program DCC_1 I/O PROFIBUS
via object via object
l.c
sheet A1 sheet B1 sheet C1
Vector di_0
ai
Vector di_1 sequence
Vector di_2 control
stw_1
tm
Vector
Vector di_4
Vector di_3
ho
sheet A2 ack_dump TM15_2
@
init reset
from
TM15_2
_alm
88
sheet A1 sheet B2
rd
Vector di_5
o_
n_set Vector
Vector ai_1
av
do_12 TM15_1
speed do_13 TM15_1
Vector n_act
st
monitor do_14 TM15_1

do_15 TM15_1
gu
SITRAIN
10) Check the indication of the actual

om
speed on LEDs DO12 to DO15
l.c
(switches 12 to 15 in off-position) n = 0 % no indication
0 % < n < +/- 20 % DO 12
ai
+/- 20 % < n < +/- 40 % DO 13

+/- 40 % < n < +/- 60 % DO 14
tm
+/- 60 % < n < +/- 80 % DO 15

+/- 80 % < n < +/- 90 % DO 12 to DO 15
ho
11) Switch on DI 5 the speed changes to zero

after 2 s the speed changes from 0 to -90 % to 0o to +90 % to 0 etc.
12) Switch off DI 5 the speed changes to the value set by AI 1
@
13) Switch off DI 0 ALM and MoMo switch off

fault message “Drive: Infeed operation withdrawn”
14) Temporarily switch on DI 3 fault “Infeed operation withdrawn” is acknowledged
88
15) Switch on DI 0 ALM is switched on immediately

MoMo remains in state “switched off”
16) Switch DI 1 off and on again drive runs with speed as set by AI 1
rd
17) Switch off DI 1 MoMo is switched off

o_
18) Switch off DI 0 ALM is switched off (no fault message!)

av
st
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page 34
Online Search and Uploading the Drive Devices
om
1
l.c
- define a project
- search for nodes
ai
tm
ho
once ONLINE:
- drive devices are inserted
once uploaded as shown on page 37

including the assigned CU
@
- other objects are missing
If drive devices are commissioned already:

88
2A - connect to target system and upload all drive devices

rd
o_
av
st
after UPLOAD: all objects of device “Drive_unit_1” are supplemented

gu
SITRAIN
2.2 Online-connection to drive device “CU320_2_Drive” without available SIMOTION project m

co
If no matching project is available in any of the required approaches, access for parameterization can be established
only to drive device “CU320-2 DP”:
l.
Project > New

ai
- Name: “wo_d445”
- Storage location: … \ Programme \ Siemens \ Step7 \ s7proj (accept the prompted location)
tm
 OK
project “wo_d445” is initialized
ho
Search for accessible nodes:

Project > Accessible nodes
Device_1 is indicated
@
- access further details by clicking on [ + ] to the left of “Device_1” and on [ + ] to the left of “DP2/MPI”:
SINAMICS S120 CU320-2 DP (address 8) is inserted
88
(SINAMICS_Integrated is irrelevant as it is not used in SL150 applications)

- select device “CU320-2 DP” by inserting a checkmark
 Accept > Close
rd
“Drive_unit_1” is added to the configuration tree

o_
Close menu “Accessible nodes” via button “Close”.

av
st
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page 36
Online Search and Automatic Configuration of Drive Devices
om
If drive devices still have to be commissioned:
2B - connect to target system and trigger the Automatic Configuration from page 35
l.c
ai
tm
ho
@
88
rd
3 - all objects of the drive device CU320_2_Drive are supplemented
o_
4 - objects without Drive-CLiQ still have to be configured ( motor and encoder)

av
-- The
The automatic
automatic configuration
configuration is
is limited
limited to
to drive
drive devices
devices other
other than
than SIMOTION.
SIMOTION.
-- The
The SIMOTION
SIMOTION program
program cannot
cannot be be uploaded;
uploaded; itit has
has to
to be
be available
available within
within aa project.
st
project.
gu
SITRAIN
The functional assignment of “Drive_unit_1” and of the respective objects will now be uploaded:
om
l.c
a table to select any of the available target devices pops up
ai
- select “Drive_unit_1”
 OK
tm
online connection is established to drive device “Drive_unit_1”

“Device_1” is added; all objects other than the CU are missing
- mark drive device “Device_1”
ho
- start the upload via “Icon” or via right mouse click on “Device_1 > Target device > Load to PG”
“Device_1” is renamed to “CU320_2_Drive” (name of the online device)
all “I/O-objects”, object “A_INF_02” and object “Vector” are added
@
all parameters and functions of device “CU320_2_Drive” are accessible.

Change to offline mode, ignore messages you might get, close and delete project “wo_d445”.
88
If drive device “CU320_2_Drive” still has to be commissioned, the “Automatic Configuration” will supplement all
rd
objects of the drive device. Only objects without DRIVE-CLiQ (motor, encoder) have to be configured manually.
o_
av
st
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page 38
Data Storage ”CU320-2 DP”
om
Offline Online
l.c
ai
tm
PG/PC-RAM CU320-RAM
ho
Load to Copy RAM to ROM
Open project
@
target Save parameters
HD RAM RAM
88
V02.02.03
rd
Reboot
Save project Load Parameter
o_
to PG reset
PG / PC SINAMICS_CU320
av
st
SITRAIN
gu
om
l.c
2.3 Saving data on the Compact Flash Card and in the PG/PC-project
If data have been changed in the working memory (RAM) of device “CU320_2_Drive” while redefining the
ai
parameterization in Online-mode, they have to be saved both on the CF card (ROM) and in the offline-project in non-
volatile mode.
tm
Execute the necessary steps:

- save in ROM (CF card) ......................................................
ho
- save in offline-project 1) . . . . . . . . . . . . . . . . . . . . . . . . . 2) . . . . . . . . . . . . . . . . . . . . . . . . .
The necessary routine of “Copy RAM to ROM” has to be performed for each of the drive devices individually
@
(if any of the programming has been changed):

- SIMOTION D445 (SIMOTION program)
- SINAMICS CU320_2_Drive (MoMo)
88
The necessary routine of “Uploading” prior to “Saving on harddisk” is required for “CU320_2_Drive” only.
rd
o_
av
st
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page 40
Data Storage ”SIMOTION D445”
om
Actual data
Offline Online to RAM *
NV
l.c
RAM
Download
ai
RAM
Copy RAM to ROM
tm
PG-RAM D445-RAM * special type of
SIMOTION variables Reboot
ho
for: for:
SIM_D445 SIN_Int. SIMOTION_D445
SIN_Int. (SIM_D445)
Data saving via “Copy RAM to
@
ROM” is required individually for: D445
Load to - SIM_D445 ( - SIN_Int ) CF card
target
Open project 88 Copy RAM to ROM

Save parameters
HD RAM
rd
RAM
o_
Save project Reboot

av
Load Parameter reset

to PG
not for
PG / PC SINAMICS_Integrated
st
SIM_D445
gu
SITRAIN
om
For SIMOTION_D445 all essential changes of the program can be done in offline-mode only ( in the RAM
l.c
of the PG/PC) with an inevitable download after programming. For this reason an “Upload” prior to “Saving on
harddisk” is neither required nor possible.
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Further commissioning steps –as will be done in lab-work to come– will require:
- the function assignment by parameterization,
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- an optimization of all controllers.

The (still missing) adaptation of the PROFIBUS communication will be omitted at this stage of training since a section
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of its own will deal with this topic in detail.

@
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Topics listed beyond this step and the affiliated lab cover less frequently required issues.
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page 42
Definition “Infeed Operation“ / “Missing Enables”
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infeed in
operation
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ALM CX
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r863.0
right mouse key
PROFIBUS
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SIMOTION
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program
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D445 MM
p864
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PROFIBUS
ready to
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after ON switch on
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Bits 0 and 30 are

set via ON/OFF
simultaneously
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SITRAIN
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l.c
2.4 Preparing for the configuration of object “Drive“
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Save your project “SL_LV1” by redefining the name to “SL_LV1C”:
Project > Save As > new name: “SL_LV1C”
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project “SL_LV1” is closed and the as yet identical project “SL_LV1C” opens up.
Verify the present state of operation (DI2 = on, DI4 = on, DI5 = off):
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- DI 0 = on ALM switches on
- DI 1 = on MM switches on
- AI 1 sets speed within -1400 … +1400 rpm
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You can observe that the drive trips with message “Infeed operation withdrawn if you switch off the ALM (DI 0 = off).
This trip is triggered because the state “ALM in operation” is interlocked with “enable motor operation”.
88
As substitute, parameter “Infeed operation” on the Motor Module (p864) can be set to a permanent logic “1”. In this
case, however, the motor can be switched on while the ALM is switched off.
On the booksize training unit the DC supply is then provided via freewheeling diodes and pre-charging resistors of
rd
the ALM power section (this state is not acceptable for permanent operation).
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In an SL150 application this issue is irrelevant since the functional concept of the SL150 doesn’t use an Infeed
(like the ALM) as an individual device. For a SL150 the Infeed function is part of the Motor Module function.
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page 44
Substituting Inputs Connections
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l.c
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tm
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SITRAIN
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If any object of a drive device is to be deleted with the intention of putting it back in again, its participation regarding
PROFIBUS communication has to be adapted manually in the re-inserted object to match the assignment of the
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deleted object.
Open “CU320_2_Drive > Communication > Message frame configuration” and note down the “Input Data” and “Output
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Data” for object VECTOR:

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Input Data . . . . . . . . . . . . . . . . . . . . Output Data . . . . . . . . . . . . . . . . . . . .

To become familiar with the steps involved in deleting and re-inserting objects, drive object “VECTOR” will now be
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deleted so that a new one can be added.

To create this condition, change to offline-mode and delete drive object “VECTOR”
(assign the “factory setting” to the prompted parameters of all indicated objects):
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drive object “VECTOR” is deleted

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page 46
Essential “Basic Settings” in STARTER_Integrated
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1
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2
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6
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3
4
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1 2 3
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4 5 6 7 8
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Status bar
In
In addition
addition to
to the
the given
given possibility
possibility of
of selecting
selecting
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elements
elements they
they can
can also
also be
be positioned
positioned at at various
various
locations
locations of
of the
the screen.
screen.
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SITRAIN
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2.5 Configuration and commissioning of the drive object “VECTOR”
As first step, a “drive” has to be inserted:
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D445_Hardware > CU320_2_Drives > Drives > Insert drive

- select “Drive objects type = Vector” (for SL150 only type Vector will be used)
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Configure following data and properties for object “Drive_1”:

- no additional function modules - Encoder 1
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- n-/M-control - Encoder evaluation: SMx

- Speed control (with encoder) - Encoder name: at will
- Component name, connection voltage, cooling method - enter “Encoder data” manually: Rotary / Incremental
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and type: keep “as prompted” HTL, TTL / 24V / Terminal / 1024 / HTL /
- Motor module: 6SL3120-1TE13-OAxx Bipolar / no track monitoring / no zero mark
Once the configuration has been finished
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- no filter, no choke
- no voltage sensing module respectively in online-mode the type of encoder
- Standard: IEC-Motor can be changed via expert list as follows:
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- Connection voltage: 600 V p0010=1 / p0400=type of encoder / p0010=0

- Motor name: at will - Technological application: Standard drive VECTOR
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- Enter motor data - Motor identification: Motor data identification at standstill

- Induction motor (rotating) (this step includes the current controller optimization)
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- Motor data: as per motor rating plate (refer to the motor - Profibus PZD message frame = as noted down for object
rating plate of the motor assigned to your training unit VECTOR on the previous page
- Motor current limit: 110% of the rated motor current
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(page 5); note the star-winding on the training device !)

- WITHOUT entry of ”optional data” - Minimum speed n.min = 0 rpm
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- WITHOUT entry of ”equivalent circuit diagram data” - Maximum speed n.max = 1200 1/min
- complete calculation WITH ”equivalent circuit data” - Ramp-up time = 2 s
(else the optimization will take very much time) - Ramp-down time = 5 s
- no motor holding brake - Ramp-down time with OFF3 = 1 s
 Finish
page 48
Assigning Objects to Cyclic Data Exchange
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tm
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SITRAIN
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When comparing the “Message frame configuration” now valid with the note you took before deleting object VECTOR
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you will notice that the re-inserted object “Drive_1” is located in the group “without data exchange” and that the
communication I/O-addresses are not assigned as yet.
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Mark the line of object “Drive_1” and shift it to the position the deleted object VECTOR occupied previously. You will
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notice that communication I/O-addresses previously assigned to object VECTOR are now automatically assigned to
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the re-inserted object “Drive_1”.

Save your project on the PG/PC (Project > Save).
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page 50
Data Inconsistency
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offline-project data are not
identical with the CU-RAM
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data (online-project)
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tm
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The object (motor) which has been configured in offline-mode has to be downloaded to drive device “CU320_2_Drive”
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to replace object VECTOR (motor) previously defined:
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the consistency indicators of drive device “CU320_2_Drive” and of the re-inserted object “Drive_1”
read “red/green”
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Download > Yes > OK

several faults and warnings are displayed
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 Acknowledge all
most of the faults cannot be acknowledged
You will notice that all messages relate to topology stating “missing components”.
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page 52
Components’ View
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PG/PC-RAM CU-RAM Hardware
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tm
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SITRAIN
Open menu “Topology” and compare the “Actual topology” to the “Project set topology”. m
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You will notice, that component TM15_2 (with component TM31 connected to it) is connected
- to port 1 of “Drive_1.Power_unit” in the “Actual topology” but
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- to port 1 of “A_Inf_02.Line_Module_2” in the “Project set topology”.

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In the “Project set topology”, shift “TM15_2” (along with the connected TM31) to their physical position
tm
(for some shifting operations you may have to use the “Component depot” as temporary location).
Save the modified project and download drive device “CU320_2_Drive”.
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Acknowledge all fault/alarm messages; which message persists?

..................................................................................
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page 54
First Test with Control Panel / Diagnostic Monitor
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To
To reach
reach the
the control
control panel:
panel:
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1.
1. Drive
Drive >> Commissioning
Commissioning >> Control
Control panel
panel
2.
2. Assume
Assume control
control authority
authority
3.
3. Switch
Switch onon the
the ALM
ALM
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4.
4. Set
Set the
the Enables
Enables
1 5.
5. Switch
Switch on
on MoMo
MoMo
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after ON 6.
6. Set
Set speed
speed with
with setpoint
setpoint and
and scaling
scaling
Be
Be aware
aware that
that On/Off
On/Off commands
commands via via
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control
control panel
panel will
will invariably
invariably switch
switch the
the
medium
medium voltage
voltage circuit
circuit breaker!
breaker!
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2 control diagnosis
3 6
5
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4
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after ON
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SITRAIN
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Warning “Motor data identification activated” is issued since a “Motor data identification” had been requested during
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configuration.
Start the requested routine via Control Panel (CU320_2_Drive > Drives > Drive_1 > Commissioning > Control panel;
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if necessary activate buttons “Show control panel” and “Show diagnostics overview”):
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1. assume control priority and open "Diagnostics“

2. switch on the Infeed (ALM)
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3. request the enable signals (checkmark); observe the feedback in section “diagnostics overview“
OFF1 is missing
3a) switch the drive on (via ON-button)
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the “Motor data identification” is performed

once finished, message “Ready for switching on” is shown on the control panel
Once the “standstill measurement” has been finished, the drive can be run via control panel:
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4. set the scaling slider to 0%

5. define the 100% setpoint as i.e. 1500 rpm
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6. press the ON button and alter the scaling (the drive switches on and can be run between +1500 rpm)
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7. once you have carried out the test, return the control priority.
Switch the Infeed off (DI 0).
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page 56
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l.c
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Setpoint Processing
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Signal “Wiring”
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Data Sets
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Setpoint Processing page 01 © Siemens AG 2011 - all rights reserved
List of Contents
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l.c
Changing Control from PROFIBUS to “Local Control” via TMx …........................................ 3
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Internal Control of the Drive ……………................................................................................ 5

Function Diagram for Lab Work …........................................................................................ 7
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“Signal-Wiring” via Expert List (BICO-Connections) …......................................................... 9

BICO-Connections via Graphical Menus ….......................................................................... 11
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BICO Signal Sources / Assignment “Source to Target” ….................................................... 13

Assigning Control Commands …........................................................................................... 15
Standard Response to Control Bits ON, OFF …................................................................... 17
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Overview of Signal Sources and Functions of the Setpoint Channel …................................ 19

Speed Limiters ….................................................................................................................. 21
Ramp Function Generator …................................................................................................ 23
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Motorized Potentiometer (Function Scheme) …................................................................... 25

Fixed Setpoints …................................................................................................................. 27
Saving and Defaulting Device or Object Data via Expert List …........................................... 29
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Data Sets ….......................................................................................................................... 31

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Data Sets viewed in Expert List …........................................................................................ 32

Command Data Sets …........................................................................................................ 33
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Drive Data Sets …................................................................................................................. 37

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page 02
Changing Control from PROFIBUS to “Local Control via TMx”
SIMOTION D445
DCC
Automation
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l.c
A connector or binector input
is disconnected by assigning
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PROFIBUS a fixed “0%”
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TM15
Clicking on an already
selected connector or
@
binector deletes the
existing connection
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Commands
Commands andand setpoints
setpoints coming
coming in in from
from DCC
DCC are
are
removed
removed to
to directlyoperate
directlyoperate the
the drive
drive via
via TM15/TM31.
TM15/TM31.
TM31
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Setpoint selection Processing Control Loops

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SITRAIN
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3 Setpoint Processing
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3.1 Assignment of control- and status-words / Selection and processing of setpoint-values

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In project “SL_LV1C” you are currently using the operation of the drive is controlled by the SIMOTION programming
(switches trigger the SIMOTION program to perform actions).
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For the current lab you will use a project in which the drive’s operation is controlled directly via the hand-held operator
panel.
Perform following steps to have your training unit quickly back in “perfect operation”:
@
- close and delete project “SL_LV1C”

- retrieve project “SL_LV1.zip” from archive
- open project “SL_LV1”
8
- save project “SL_LV1” by the name “SL_LV1S”

d8
- download drive device “CU320_2_Drive” including the routine “Copy RAM to ROM”
- set SIMOTION D445 to Operating state RUN
r
- test the operation:

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DI 5 = off / DI 2 = on / DI 4 = on / DI0 = on ALM = on / DI 1 = on MoMo = on; speed via AI 1

To both control the drive directly and to evaluate status messages via the hand-held operator panel, delete the links
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between SIMOTION and drive as follows:

1) CU320_2_Drive > VECTOR > Communication > tab “Receive direction”
- delete the connection of all control bits of process data word 1 (PZD 1) coming in from SIMOTION
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- delete the connection of the SIMOTION setpoint to parameter 1070 via PZD 2+3
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2) CU320_2_Drive > VECTOR > Communication > tab “Transmit direction”

- delete the four process data words (PZD 1 to PZD 4) linking the SIMOTION program to the drive
the ALM can still be switched on via DI 0; any control of the motor is cancelled.
page 04
Internal Control of the Drive
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l.c
r0722.8
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r0722.9
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24V
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p740
r0722.11
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By
By selecting
selecting “Optimize
“Optimize view”
view”
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only
only “wired”
“wired” connections
connections are
are
shown;
shown; this
this choice
choice is
is given
given
for
for many
many graphical
graphical menus.
menus.
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SITRAIN
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In simple applications an internal control of the drive is performed via digital and analog inputs for control respectively
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digital and analog outputs for status and feedback evaluation.
The connection to the field (in this section of lab-work the hand-held operator panel) is set up by means of I/O-
ai
interfaces like terminals of D445 or CU320, of TM15, TM31 or of TB30.

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Many of the digital channels are bidirectional; both digital and analog inputs can be set on “simulation” to substitute the
field signal by a menu set value.
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page 06
Function Diagram for Lab Work
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l.c
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tm
DI 14
DI 15
14+15
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SITRAIN
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Use the "graphic function menus“ to define the assignment of setpoints and control commands such as shown in the
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function diagram above.
Follow the sequence as suggested on the subsequent pages and test each function you have parameterized before
l.
continuing with the next function.

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page 08
“Signal-Wiring” via Expert List (BICO-Connections)
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p1113 = 4022.1
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10 V switch
r4022.1 p1113
DI 1
0V
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tm
analog analog r4055 p1075 -1 r1114
input inverter input
p1075 = 4055
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target source
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The Suppl. setpoint of object “Servo_02“ is provided via analog input AE0 of object TB30
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p1075 Servo_02 = r4055 TB30

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target source
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SITRAIN
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The functional connection of signal sources (i.e. Digital Input) to signal targets (i.e. ON-Command to the drive) is
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carried out by means of “signal wiring”.
Boolean signals are specified as “Binectors” (binary connectors), physical variables (signals representing physical
l.
quantities in %, A, rpm, …) are defined as “Connectors”.

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The signal wiring via “Expert List” starts at the target (p-parameter) and assigns the signal source (r-parameter) to it
tm
(the source is assigned to the target).

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page 10
BICO-Connections via Graphical Menus
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Using
Using the
the graphical
graphical menus
menus signals
signals can
can be
be connected
connected both
both from
from target
target to
to source
source and
and from
from source
source to
to target.
target.
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tm
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@
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source target
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For
For multiply
multiply assigned
assigned connectors
connectors all
all of
of the
the
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connections
connections can
can be
be checked
checked via
via scroll
scroll bar
bar
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SITRAIN
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l.c
In the graphical menus, signals can be wired both from “source to target” and from “target to source”.
If connectors are assigned to more than one target, the targets are indicated via “tool tip text”; alternatively the
ai
connector connections can be scrolled.

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page 12
BICO Signal Sources / Assignment “Source to Target”
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l.c
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drive selection of
tm
objects source object
table
table of
of objects
objects
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selection of source connector and
and connectors
connectors
typically
typically used
used
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drive
objects
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table of all
table of all available
available objects
objects source connectors
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with all
with all connectors
connectors assigned
assigned
to
to these
these tables
tables
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SITRAIN
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Always keep in mind that source and target may but rather typically will not belong to the same object.
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This fact requires you to follow a specific sequence (example “source to target”):
- select the target-object to which a signal should be wired
l.
- select the target-parameter (input) you want to use

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- select the source-object you intend to use as signal source

- select the specific source-signal of this object
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The basically same sequence will be applied for the “graphical wiring” from “target to source”.
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page 14
Assigning Control Commands
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Control
Control Word
Word of
of Execution
Execution Control
Control
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Setpoint Processing page 15
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l.c
Assign following control commands to the switches of the operator box as listed below:
- On/Off 1 DI 4
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- Off 2 DI 5
- Acknowledge DI 7
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page 16
Standard Response to Control Bits ON, OFF
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OFF 3
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OFF 2
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ON / OFF 1
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magne-
tizing
current
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speed
actual
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“ON“ has to be given as a positive flank after Deceleration with Deceleration with Coasting according to load,
both “OFF2“ and “OFF3“ are set to H-level “OFF1“-ramp “OFF3“-ramp friction, moment of inertia
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SITRAIN
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Control bits 3 to 6 (enable operation, enable ramp function generator, continue ramp function generator, enable speed
l.c
setpoint) are activated in this very sequence by the CU sequence control with every ON-command respectively
deactivated in inverse sequence with every OFF1-command (provided the default setting, fixed value “1”, is true).
ai
By specific manipulation this sequence can be modified; in part, the reaction to these control commands can be
tm
redefined as well (refer to the parameter description in the list manual).

Assign the required fixed values “1” to the above mentioned bits, assign a fixed “1” to bit “OFF 3” and test the function
ho
of OFF 2 (DI 5) and of ON/OFF 1 (DI 4).

You will notice that fault “Infeed operation missing” pops up once you apply an ON-command to the drive.
Acknowledge the fault with DI 7 and assign a fixed “1” to parameter p864 in object Vector. This fixed “1” simulates
@
“Infeed in operation”; the actual feedback is missing since it has been deleted along with the other control bits of
process data word 1 (PZD 1) coming in from SIMOTION.
88
Again test the response to an ON-command (DI 4).

Now fault “Master Control by PLC missing” pops up (once you apply an ON-command to the drive).
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Acknowledge the fault with DI 7 and assign a fixed “1” to the bit in question.
Now the drive can be switched on; since no setpoint is assigned yet, however, the drive stays at “zero speed”.
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page 18
Overview of Signal Sources and Functions of the Setpoint Channel
Fixed setpoint scaling
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r1024
r1024 main SP
additional
p1001 [3010] p1070 cw/ccw limiting RFG setpoints
...
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add. SP r1170
r1170
p1015 [3060]
p1075 [3030] [3040] [3050] [3070] [3080]
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inching
r1114
r1114 r1119
r1119 r1150
r1150
p1058
tm
p1059 p1160
Automatic Motorpot p1155
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setpoint r1050
r1050
p1042 [3020]
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PROFIBUS p1070
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r2050
r2050
[2400]
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scaling parameters
p2000 speed
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p2001 voltage
Analog p1075 p2002 current
p2003 torque
r4055
r4055
[9104]
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[9586]
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SITRAIN
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A combination of internal sources (fixed setpoint, motorpot) and external sources (analog input, PROFIBUS) can be
l.c
defined to provide the speed setpoint.
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The conversion of an input value in “%” to “rpm” is defined by scaling parameter p2000. Other physical quantities are
scaled as well (Drive > Configuration > Reference parameters).
tm
The speed setpoint can either be connected to the speed controller directly (p1155, p1160) or it can first be processed
by functions of the setpoint channel (scaling, polarity assignment, limiting, ramp function generator).
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page 20
Speed Limiters
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r1114
r1114 p1080 r1119
r1119
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tm
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@
p1083
p1082
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t r1112
r1112
pu
in
rd
output
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p1091 p1086
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p1101
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SITRAIN
Setpoint Processing page 21
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Define following speed limits:
speed range - 1200 rpm to +1600 rpm
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tm
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page 22
Ramp Function Generator
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p1135
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p1120 p1121
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SITRAIN
Parameterize following settings for the ramp function generator:

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l.c
- ramp-up time = 2s
- ramp-down time = 5s
- ramp-down time off 3 = 1.0s
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- no initial rounding
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- no final rounding
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page 24
Motorized Potentiometer (Function Scheme)
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On/Off1
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motorpot
raise
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motorpot
lower
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automatic-
setpoint
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automatic
setpoint
@
MOP MOP
UP DOWN
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MOP MOP
UP DOWN
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speed setpoint
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On
On changing
changing from
from “manual-“
“manual-“ to
to “automatic-setpoint“
“automatic-setpoint“ the
the automatic
automatic setpoint
setpoint takes
takes over
over immediately,
immediately,
for
for aa changeover
changeover from
from “automatic-“
“automatic-“ to
to “manual
“manual setpoint“
setpoint“ the
the speed
speed setpoint
setpoint remains
remains unaltered.
unaltered.
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SITRAIN
Parameterize the motorpotentiometer functions for following tasks:

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l.c
- setpoint “higher“ DI 10
- setpoint “lower“ DI 11
- selection of automatic setpoint DI 6
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- operating range in manual mode: - 1000 rpm to +1400 rpm

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- ramp-up and ramp-down time both

in manual and in automatic mode: 5s / without rounding
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- automatic setpoint via “selected fixed speed setpoint”

- motorpotentiometer output as main setpoint; scaling 100%
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page 26
Fixed Setpoints
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p1001
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tm
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p1015
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p1001 88
r1024
r1024
...
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p1015 •• By
By defining
defining 44 control
control bits
bits p1020
p1020 .... p1023
p1023
15
15 fixed
fixed setpoints p1001
p1001 .... p1015
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setpoints p1015
and
and “0“0 ““ can
can be
be selected.
selected.
•• You
You can
can “wire”
“wire” the
the selected
selected value
value r1024,
r1024, as
as
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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
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SITRAIN
Define the selection and the values of the fixed setpoints as follows:
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- fixed setpoint FS 0 0 rpm DI 14 = 0 DI 15 = 0
l.c
- FS 1 + 800 rpm DI 14 = 1 DI 15 = 0
- FS 2 - 1000 rpm DI 14 = 0 DI 15 = 1
ai
- FS 3 +1400 rpm DI 14 = 1 DI 15 = 1
tm
Take appropriate measures to make sure that your online-changes

- are still valid after re-energizing the 24VDC-supply of CU320-2
ho
measure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- and that your offline-project on the PG/PC includes the online-changes you made
measure 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
@
measure 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
r d8
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Topics listed beyond this step and the affiliated lab cover less frequently required issues.
av
st
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page 28
Saving and Defaulting Device or Object Data via Expert List
om
Target device > Copy RAM to ROM
Data in (all RAM data to SIMOTION,
Data on PF1: User data
RAMs SINAMICS_Integrated-PF1, CU320-PF1) D445
CF-Card
D445_SIM
l.c
PF10, 11, 12: Customer data
D445/SIN_Int. Above data (at restart / with RESET button)
CU320-2
ai
Copy RAM to ROM
tm
p977 = 1, 10, 11, 12 (object CU)
Data in (all RAM data in File PF 1..12)
RAMs
ho
D445/SIN_Int. Copy ROM to RAM: PF1
CU320-2 p009 = 30 / parameter reset (object CU)
p976 = 100 / only BICO (object CU) PF12
@
p976 = 1, 2, 10-12, (20-26) / all parameters refer to page 5-9
DEF PF1
88 PF20 .. 26:
factory: reserved,
Drive Object read only access
Copy RAM to ROM
p971 = 1 (drive object)
rd
(RAM data of one Object in PF1
Reset button
o_
D445/CU320
Drive Copy ROM to RAM: acts like:
Object p010 = 30, parameter reset (drive object) p009=30
DO x p970 = 1 Object parameter (drive object) p0976=2
av
p970 = 100 only BICO in Object

st
SITRAIN
gu
3.2 Saving settings in the non-volatile memory as back-up files

om
l.c
In addition to the Icon- or Menu-controlled “Save” commands (which always transfer the CU-RAM data to “parameter
file PF1” on the CF card, three back-up files (PF10, PF11, PF12) can be generated and copied to the CF card as well.
ai
These user-defined back-up files (and seven possibly existing factory files) can be transferred to the CU-RAM via the
tm
request “Default to File …..”.

Some major transfer operations can also be carried out on the level of individual objects.
ho
Use parameter p0977 to create a backup copy PF10:

CU320_2_Drive > . . . . . . . . . . . . . . . . . . . . . > p . . . . . . . . . . . . . . = . . . . . . . . . . . .
@
(during the process of “Saving“ the RDY-LED of the CU320-2 is flashing)

Default drive object “VECTOR” to factory settings:
CU320_2_Drive > Drives > VECTOR > Expert > Expert list > p0010 = . . . . . . / p0970 = . . . . . . .
88
Try to run the motor as programmed previously (i.e. ON via DI 4):

rd
the motor can no longer be switched on via DI 4 (all parameters of object “VECTOR” have been defaulted
to factory settings; all BiCo-assignments have been deleted).
o_
Now recreate the previous programming condition (On via DI4) by “Defaulting to PF10”:
( loading PF10 from ROM to RAM):
av
CU320_2_Drive > . . . . . . . . . . . . . . . . . . . . . > p . . . . . . . . = . . . . . . . . / p . . . . . . . . = . . . . . . . .

Verify the function of the drive (i.e. On via DI4).
st
gu
page 30
Data Sets
p0170: total nr. of DS
om
PROFIBUS
p0810f: selection
object “motor”
p0840: data
Terminals p0844
p1070 ...
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ai
CDS
tm
p0180: total nr. DS DDS EDS G1
ho
p0820f: selection
p1080: data
p1210 G2
p1240 ...
@
MDS
G3
88
p0130: total nr. DS p0140: total nr. of DS
p0186: MDS nr. p0187f: EDS number
p0300: data p0141: data
M1
rd
M16 p0142
p0304
p0330 ... p0400 ...
o_
Changeable
Changeable whenwhen “motor
“motor isis energized”:
energized”:
-- CDS:
CDS: without
without restriction;
restriction; new
new CDS
CDS active
active after
after “OFF
“OFF // ON”
ON”
av
-- DDS:
DDS: only
only ifif same
same MDS
MDS isis assigned
assigned to
to either
either DDS
DDS
st
SITRAIN
om
gu
l.c
Data Sets viewed in Expert List
ai
tm
ho
CDS
@
88
DDS
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av
MDS
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EDS
SITRAIN
Command Data Sets viewed in graphical Menu
om
For applications with i.e. Local / Remote Control, different
signal sources are selected for the two command data sets.
l.c
ai
tm
ho
CDS
CDS 00 signal
signal wiring
wiring is
is
@
shown
shown inin the
the menu
menu
BUT
BUT
CDS
CDS 11 is
is active
active and
and
defines
defines the
88
the functionality
functionality
rd
the
the signal
signal wiring
wiring shown
shown inin
o_
the
the menu
menu isis active
active and
and
defines
defines the
the functionality
functionality
av
st
SITRAIN
gu
3.3 Application of Command Data Sets (CDS)

om
l.c
Go offline with the project currently in use and copy command data set CDS 0 to CDS 1
(via VECTOR > Configuration > folder “Command data sets” > Assignment of the copy-request, Button “Copy“):
ai
Take a note of the actual “wiring”-state of the following BICO-connections:

tm
Data set CDS 0 CDS 1

On/Off1 p0840[0] = p0840[1] =
ho
Off2 p0844[0] = p0844[1] =

Main Setpoint p1070[0] = p1070[1] =
@
Suppl. Setpoint 1 p1075[0] = p1075[1] =

As a consequences of the copy job both command data sets show the same BICO connections.
Use the expert list to redefine the assignment of the switches in command data set CDS 1 for On/Off1 and Off2:
88

d
Switch DI 4 On/Off1 Off2

_r
Switch DI 5 Off2 On/Off1

Check your programming using the respective graphical menu for digital inputs (VECTOR > Control logic).
o
Change over to the menu “Speed setpoint“ and define following changes in command data set CDS 0:
av

st
Main Setpoint Fixed setpoint 1 Motor potentiometer

Suppl. Setpoint 1 Fixed setpoint 3 Fixed setpoint 10
gu
Check your programming in the expert list.

Save the offline parameterization on the harddisk , go online and download the modified project to the target system.
page 34
Command Data Sets
om
l.c
ai
tm
ho
presently
presently only
only CDS
CDS 00 and
and
CDS
CDS 11 are
are available
available
@
88
rd
o_
av
st
om
SITRAIN
gu
l.c
Cancel the “manual – automatic” function of switch DI 6 in both command data sets (p1041[0] = 0, p1041[1] = 0) and
parameterize switch DI 6 for the selection of the command data sets as follows:
ai

tm
Switch DI 6 0 1
ho
Open the CDS display on the lower left so that both data sets are displayed and check whether switch DI6 activates
the data set according to the table above.
Check the functions assigned to the command data sets.
@
Switch DI 6 = off On/Off 1 DI 4

(CDS 0) Off2 DI 5
Setpoint FS 1 + FS 3 (”2200” rpm; because of limiting: 1600 rpm)
88
Switch DI 6 = on On/Off1 DI 5
(CDS 1) Off2 DI 4
d
Setpoint MOP + FSP 10 (MOP= 0)

o _r
av
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page 36
Drive Data Sets
om
l.c
ai
tm
ho
@
88
rd
Drive Data Sets (other than DDS 0) exist only after

they have been added (button “Add DDS…”).
o_
The added DDS always will be a copy of any DDS

already existing with any of the already existing
MDS or with a new MDS still to be configured.
av
The new DDS is “configured” to fit the requirement.

st
om
SITRAIN
gu
l.c
Drive Data Sets
ai
tm
ho
DDS
DDS 22 is
is
selected
selected
@
88
the
the parameter
parameter setting
setting
shown
shown in
in the
the menu
menu is is
NOT
NOT active
active (10/50ms)
(10/50ms)
d
_r
the
the parameter
parameter setting
o
setting
shown
shown inin the
the menu
menu is is
av
active
active and
and defines
defines the
the
functionality
functionality (10/80ms)
(10/80ms)
st
gu
Values
Values assigned
assigned to
to different
different DDS
DDS are
are listed
listed
in
in the
the respective
respective indices
indices of
of the
the parameters.
parameters.
The
The active
active DDS
DDS isis signaled
signaled by by r51.0
r51.0 …
… 4.4.
SITRAIN
om
l.c
ai
Diagnosis
tm
ho
using
@
STARTER_Integrated
88
rd
o_
av
st
gu
SITRAIN
Diagnosis page 01 © Siemens AG 2011 - all rights reserved
List of Contents
om
l.c
LED Status Indications on Components …………………………………………................... 3
Diagnosis with the Fault Buffer [8060] ……………………………………………................. 4
ai
Diagnosis with the Alarm Buffer [8065] ….......................................................................... 5

tm
Alarm Indication and Alarm History ….................................................................................. 6

Configuring Faults and Alarms [8075] ……………............................................................. 7
Existing Control Bits / Missing Enables …............................................................................ 8
ho
Expert Functions …............................................................................................................... 9

Parameter Comparison ….................................................................................................... 11
Saving the Comparison Result …......................................................................................... 13
@
Object Comparison …........................................................................................................... 17

Basic Settings of the Trace Function …............................................................................... 21
88
Signal-Specific Display of Recorded Traces …................................................................... 23

Trigger by Bit Pattern / Endless Trace …............................................................................. 25
Function Generator ….......................................................................................................... 27
rd
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page 02
LED Status Indications on Components
om
RDY
l.c
RDY RDY RDY
OUT>5V
ai
tm
ho
RDY
TM31 TM15 VSM SMC
RUN
@
PSA
88
rd
D445
o_
PWR
RUN/ERR
av
st
SITRAIN
om
gu
l.c
Diagnosis with the Fault Buffer [8060]
ai
tm
ho
@
8
r d8
o_
Real time assignment to faults and alarms

via SIMOTION program or on OP177
av
st
r0945 Fault code

gu
r0949 Fault value
SITRAIN
Diagnosis with the Alarm Buffer [8065]
om
l.c
ai
tm
ho
@
Real time assignment to faults and alarms

88
up to Alarm 64 via SIMOTION program or on OP177
rd
r2122 Alarm code

o_
r2124 Alarm value

av
st
SITRAIN
Diagnosis page 05
om
gu
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Alarm Indication and Alarm History
ai
tm
highlight the fault and double click with left mouse key
ho
@
8
rd8
o_
av
st
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SITRAIN
Configuring Faults and Alarms [8075]
om
l.c
[5] current >0 at n=0
[6] internal armature
short circuit / SYN
[6] DC stator current
Fault response Acknowledge mode ?
ai
injection / ASM
[7] response as set
in p0491 (loss of
tm
encoder)
current >0 at n=0
ho
(if pulses are blocked)
@ only for medium voltage

88
Fault or alarm
rd
o_
A06601 (F) Offset measurement interrupted

The alarm A06601 can be redefined as fault F06601
av
st
SITRAIN
Diagnosis page 07
om
gu

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Existing Control Bits / Missing Enables / Drive Navigator
ai
tm
ho
@
“Missing enables” allow:

- easier analysis of control bits
still missing
- access to missing “internal bits”
88
Detailed information: Online Help

rd
o_
av
st
gu
SITRAIN
Expert Functions
om
create save edit
new list list list
l.c
ai
tm
ho
@
create / open indication extended access hex generate
user defined list filter search level bin DB for PLC
88
rd
o_
(rMC) Expert >

Expert list
av
st
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SITRAIN
4 Basic Diagnosis m
co
4.1 Preparing the drive to test selected diagnosis functions
l.
To continue with the current lab-work you should choose one of the suggested approaches.
ai
Approach 1: your drive is operating as per yesterdays lab-work (ON-OFF, setpoint)

tm
continue directly with lab-work 4.2 on page 12

Approach 2: your drive is not in “ready to run” state
ho
carry out following steps to have your training unit quickly back in a suitable operating state
@
- save project “SL_LV1” by the name “SL_LV1D”,

- download project “SL_LV1D” and
- set SIMOTION to RUN.
88
Test the operation:

DI 5 = off / DI 2 = on / DI 4 = on / DI 0 = on ALM = on / DI 1 = on MoMo = on; speed via AI 1.
rd
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page 10
Parameter Comparison
om
l.c
ai
tm
ho
@
88
rd
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SITRAIN
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l.c
4.2 Comparison of parameter files
Using the expert function “Comparison of parameter files“ you can identify differences of parameter values of
ai
- the online-parameterization (CU-RAM)

tm
- the offline-parameterization (PG/PC-harddisk) and

- the default-parameterization of drive devices (within comparable objects: CU, TMs, PSA, SMC).
ho
First upload the currently valid online-parameterization of device “CU320_2_Drive” to the harddisk of the PG/PC via:
1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AND 2) .....................................
Trigger a parameter comparison to find out whether there are any differences in the values of the online- and offline-
@
projects:
CU320_2_Drive > Drives > VECTOR
- Expert > Expert list
88
 Comparison
Select a comparison between “CU-RAM” and “PG/PC-project” of “CU320_2_Drive > Drives > VECTOR” for “Unequal
rd
values” in Display filter mode “No filtering according to ….. without enabling access level 4“:
 Start comparison
o_
the result of the comparison shows several “r-parameters“

Since a comparison of r-parameters (typically actual values) is mostly neither helpful nor necessary, r-parameters
av
should be excluded from the comparison by means of a “filter” before starting the comparison:
- Display filter mode as “Parameter filter activated“
st
 Display filter
- Remove the “check-mark“ to the left of “Display parameters (read-only)“
gu
 OK
after another (automatically started) comparison the comparison-result shows no parameters with
unequal values
Close the menu “Comparison“.
page 12
Saving the Comparison Result
om
l.c
ai
tm
ho
@
.cdl
88
.xml
rd
* If the “user defined list of parameters“
parameters (.cdl)
o_
is selected, a list containing the parameter

numbers of the comparison result is edited;
this list can be opened via .
*
av
In online mode this list indicates the currently

valid values of these parameters.
st
gu
SITRAIN
Change some parameter values (WITHOUT ”Copy RAM to ROM”), i.e.:

om
l.c
- fixed setpoint 10 / p1010 = 150 rpm
- ramp-up time / p1120 = 2.5 s
- ramp-down time / p1121 = 5.5 s
ai
Verify that an online-, offline-comparison will show exactly these three parameters with their respective values
tm
as “unequal”.
In a first step save the “comparison result” as “user defined parameter list” in file “delta_1”,
ho
e.g. in directory “C \ Temp_Trainee”.

Now save the “comparison result” as “user-defined value list” for value-column “VECTOR_Online”
in file “delta_2”, e.g. in directory “C \ Temp_Trainee”.
@
Finally save the “comparison result” as “Executable script at source object VECTOR” for value-column
“VECTOR_Online” e.g. in directory “C \ Temp_Trainee” by the name “script_1”.
88
Exit menu “Comparison” and close the script-file which has been opened automatically; verify that file “script_1” has
been added in file “scripts” assigned to object “VECTOR”.
rd
In online-mode, change following parameter values as suggested:

o_
- ramp-up time / p1120 = 2.45 s

av
Mark file “script_1” and (with a right Mouse Click) activate the function “Accept and execute”:
parameter values as listed in the script-file are downloaded.
st
gu
page 14
Saving the Comparison Result
om
l.c
ai
tm
ho
If the “user defined list of values“
values (.xml) is selected, a list containing the parameter numbers and the values of
the comparison result is edited. If this list is opened its values are indicated along with the currently valid online
values. Via “Accept values” the offline values as saved in the list are transferred to the CU-RAM.
@
If the comparison result has been saved as “executable script“, this
script file can be used for parameterization to the same effect.
88
rd
o_
av
st
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SITRAIN
Again change following parameter-values in online-mode as suggested:

om
l.c
- ramp-up time / p1120 = 2.45 s
ai
Press the button “New tab for user-defined parameter-list” and select “Open available user-defined parameter list”:
tm
as previously saved in …\Temp\... you will find file “delta_1.cdl”.

Mark and open the user-defined parameterlist “delta_1.cdl”:
the list indicates those parameters which had been identified as “comparison result”
ho
the values of these parameters correspond to those last programmed in online-mode

Press button “Open user-defined list of values”:
@
as previously saved in …\Temp\... you will find file “delta_2.xml”.

Mark and open the user-defined list of values “delta_2.xml”:
the pop-up menu lists the parameters which had been identified as “comparison result”;
88
one column reads the values of these parameters as saved in file “delta_2.xml”,
the other column displays the respective online-values.
rd
Activate the function “Accept values”:

the values as previously saved in file “delta_2.xml” are downloaded to the CU-RAM.
o_
av
st
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page 16
Object Comparison
om
l.c
Comparing different drive
ai
devices within one project
tm
ho
Comparing drive devices
of two different projects
@
88
rd
Comparing the entire drive

device “online offline”
o_
av
st
SITRAIN
Diagnosis page 17
om
gu
l.c
The “Parameter comparison” accessible via “Expert functions” as just tested offers a comparison between objects of
the same type, provided they are part of one drive device only; the comparison only looks at parameter values.
ai
The function “Object comparison” provides extended possibilities:

- type 1 / comparison of different drive devices within one project,
tm
- type 2 / comparison of drive devices between different projects,

- type 3 / comparison of the entire drive device as regards the online- and the offline-view (CU-RAM PG/PC).
ho
The comparison not only compares parameter values ( “Loading parameter” / next slide), but also topology, function
modules, structure definitions and units.
@
88
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page 18
Object Comparison
om
l.c
ai
The comparison attribute is the same
tm
Difference in at least one subordinate
object or comparison attribute
ho
@
Start detailed comparison
88
rd
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SITRAIN
m
For the last time change following parameter-values in online-mode in object “VECTOR” as suggested:
co
- ramp-up time / p1120 = 2.45 s
l.

ai
In object “Control_Unit” (specific name: “CU_S_004”) set the following: p2104 = TM15_1.r4022:Bit 3
tm
Use the assigned button of the Toolbar to start an “Object comparison”, select the offline-version of “CU320_2_Drive”
as comparison partner A, the online-version of “CU320_2_Drive” as comparison partner B and start the comparison.
Use the table popping up as “Comparison result” to start a detailed comparison for objects “CU” and “VECTOR”:
ho
the requested “detailed comparison” indicates the values you have just changed in these objects.
@
88
rd
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av
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page 20
Basic Settings of the Trace Function
1 2 1 = Trace 1 or 2 2 = Drive device

3 = Start, Stop Trace 4 = Upload curve
3 4
om
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ai
signals to be
measured
tm
5
5 = Mathematics function / 6 = Bit tracks (settings are valid for all subsequent recordings)
6
ho
recording
@
time
88
rd
trigger
o_
conditions
7 = maintain scaling settings for subsequent recordings
definitions valid for all
av
7 subsequent recordings
om
st
SITRAIN
gu
l.c
4.3 Monitoring signals via trace function
ai
Redefine following settings in the setpoint selection: change the scaling for the main setpoint to 0 % and
assign a fixed speed setpoint of 750 rpm as Additional setpoint.
tm
The Trace function enables you to record up to two times eight signals (connectors, binectors) in a way very similar to
using an oscilloscope. The two trace channels can be triggered by individually set properties or simultaneously.
ho
Define the following recording signals and criteria for "Trace 1":
- speed setpoint (r0062) - actual speed (r0063) - actual current (r0068)
- recording time approx. 2 s
@
- trigger signal = speed setpoint - trigger threshold for n.set > 100 rev/min - pre-trigger = 500 ms
Start the trace recording:
8
checkback message "Trace 1 waiting for trigger“

d8
Start the ALM (DI 0 = on), start the drive (DI 1 = on)
checkback message "Trace 1 running“
r
once the recording is finished and the recording data are uploaded to the PG/PC, the signals are displayed.
o_
A range of post-recording processing-options are available for the signals that have been recorded (i.e. amplitude and
time zoom, mathematical operations, signals in Fourier transformation or as Bode diagram, export and import).
av
Test some of the signal post-processing options, i.e:

in the "Time Diagram" tab
- an axis label is assigned when you select a signal name
st
- the signal can be moved in the Y direction when you select the axis label
gu
- a signal section can be magnified with the X and Y zoom bar or when you select a signal section
- using the right mouse key + you can reduce or undo the zoom factor
+ you can insert a measuring cursor for the time and amplitude axes
+ you can define the scaling (same as one of the other signals / definable range)
in the "Measurements" tab + you can hide signals in the time diagram display under "Selection“
+ you can edit the signal name under "Comment"
page 22
Signal-Specific Display of Recorded Traces
rMK in Trace-diagram
om
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n.set r62 / curve 3.1
ai
n.act r63 / curve 3.2
m.set r72 / curve 3.4
tm
Initially curves are displayed with their peaks on the same level.
By suitable “Scaling” the true magnitude relation will be shown.
ho
Control- / Status-bits
@
88
Measurements can be
rd
1 = Mathematics function / 2 = Bit tracks selected / deselected

(settings are valid for the selected recording only) to be displayed in the
o_
“Time diagram” in full

or per individual curve.
1 “Processing” applies
av
2 for already recorded

signals only.
st
SITRAIN
om
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l.c
Define the following recording signals and criteria for "Trace 2":
- control word of sequence control (r0898)
ai
- status word of sequence control (r0899)

- recording time: as for "Trace 1“
tm
- trigger signal etc.: as for "Trace 1“

Record the defined signals for a ramp-up operation following an ON command.
ho
At first glance, the signals "Control word" and "Status word" merely exhibit a step change.
As the control and status words do not represent connectors in the true sense ("analog quantity"), but a collection of
@
16 individual bits in one word, they must also be displayed bit-by-bit for the purpose of interpretation.
Open tab “Measurements”, click on button “Bit tracks”, select the control word, bit 0 for track 1 and select the status
word, bit 0 to 2 for tracks 2 to 4:
88
the bit-by-bit display in tab “Time diagram” shows the chronological interaction of the control and status bits.
Hints about other options:
rd
- different trigger conditions can be selected for Trace 1 and 2

- both trace recordings can be activated simultaneously, data are recorded as individually defined for trace 1 and 2
o_
- each of the curves saved under "Measurements" can be selected for display in the time diagram
- measurement data which are no longer required, can be deleted both as individual curves or in full
av
+ an individual curve is deleted by selecting the curve > “close curve” (right mouse click)
+ a complete measurement is deleted by selecting the measurement > “close measurement”.
st
gu
page 24
Trigger by Bit Pattern / Endless Trace
om
l.c
ai
In
In case
case of
of “Trigger
“Trigger on
on bit
bit pattern“
pattern“ those
those bits
bits which
which should
should act
act asas trigger
trigger events
events
must
must be
be assigned
assigned asas “1”
“1” in
in the
the “bit
“bit mask”
mask” (i.e.
(i.e. bits
bits to
to select
select aa fault
fault // alarm
alarm code).
code).
tm
The
The assignment
assignment ofof “bit
“bit pattern“
pattern“ defines
defines whether
whether aa positive
positive edge
edge (“1“)
(“1“) or
or aa
negative
negative edge
edge (“0“)
(“0“) edge
edge triggers
triggers the
the recording.
recording.
ho
triggered with: Bit 3 / positive level
@
(fault 7403)
Bit 6 / negative level
& (alarm 34851)
Bit 8 / positive level
(fault 7900)
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In
In “Endless
“Endless trace“
trace“ subsequent
subsequent recordings
recordings
rd
(each
(each with
with the
the length
length of
of the
the specified
specified time)
time)
are
are successively
successively added
added toto each
each other;
other; the
the
o_
overall
overall trace
trace compresses
compresses continuously.
continuously.
av
The
The feature
feature “Ring
“Ring buffer“
buffer“ adapts
adapts thethe time
time
axis
axis automatically
automatically such
such that
that the
the time
time span
span
specified
specified for
for “Maximum“
“Maximum“ is is displayed
displayed
st
periodically
periodically (
( scope
scope in
in “Refresh
“Refresh Mode”).
Mode”).
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SITRAIN
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Apart from the instantaneous or threshold-dependent triggering, it is also possible to trigger according to a bit pattern
(control word, status word, PCD word).
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Trigger-capable faults and warnings can be selected by parameter p2128[0...15]. If one of the faults or warnings you
ai
have selected is activated, the bit pattern of parameter p2129 changes. By triggering the tracer in response to this
change in bit pattern, a signal recording is started specifically in reaction to a defined fault or warning.
tm
Enter error message F7011 (motor over-temperature) i.e. in p2128[5] and alarm message A7910 (motor over-
temperature) i.e. in p2128[12].
ho
As a result of this setting, bit 5 respectively bit 12 in p2129 will change from 0 to 1 when the specified events occur:
r2129 = x x x 1 x x x x x x 1 x x x x x
A7910 F7011
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Select "Bit pattern" as the trigger criterion for i.e. Trace 1, "r2129, VECTOR" as the trigger source and a pre-trigger of
90% of the recording time.
Finally define the bit mask and bit pattern via button "bin..." in such a way that a recording is triggered in response to
88
i.e. A7910, motor over-temperature alarm.

Bit mask
rd
hex
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Bit pattern
hex
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Start the trace recording and start the drive (have it run with n = 750 rev/min):
tracer 1 is waiting for the trigger signal.
st
Activate alarm message A7910 by reducing the warning threshold to 10 degrees centigrade via
"VECTOR / Drive Navigator / Motor (via Icon) / Temperature:
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the signal recording is started.

Repeat the test with "Trigger by F7011": Bit mask = Bit pattern = . . . . . . . . . Hex
If several bits of the Bit mask are set, they act according to a Boolean AND-function.
page 26
Function Generator
Operating modes of the function generator:
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1. Connector output (as signal source) • The function generator can be used to generate a
number of different signal shapes.
1. Speed setpoint after filter (speed setpoint)
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2. Speed setpoint before filter (speed setpoint) • By selecting the operating mode the signal is
connected to a predefined position within the control
3. Fault torque (after current setpoint) system.
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4. Current setpoint after filter (current setpoint) • The influence of superposed control loops is
5. Current setpoint before filter (current setpoint) automatically eliminated.
tm
1. 2. 3.
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@
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Configurable “Signal types”:
rd
• Rectangle
• Step
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• Triangle
• Sine
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• PRBS (white noise;

pseudo random binary)
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SITRAIN
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4.4 Application of the function generator

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l.c
A range of different test signals for diagnostic and optimization tasks can be generated by means of the "Function
generator" accessible via tracer. In operating mode “connector-output” these test signals can be assigned to any
ai
signal input as a signal source. In operating mode “commissioning tool” the test signals act as “step of reference” or
tm
“step of disturbance variable”. They are automatically “wired” to the correct access point of the control structure, the
influence of superposed control loops is automatically eliminated and the drive is automatically switched on with the
start of the function generator.
ho
Parameterize the function generator as an independent signal source as suggested (“connector output”):
1) the function generator feeds a square-wave signal into the setpoint channel (in addition to the existing settings)
@
in such a way that the square-wave signal is NOT carried via the ramp-function generator
2) the generated step of setpoint reads 7.5 rev/min in addition to the operating speed, it is effective for one second
and repeated every 3 s:
88
Lower limit = .......... Upper limit = .......... Amplitude = ..........

Period width = .......... Pulse width = .......... Offset = ..........
rd
With the drive switched off, start the function generator, check the generated signal (CU_r4818) using the tracer
(recording time approx. 6 s) and switch off the function generator.
o_
Define the trace function to record following signals:

- actual speed (r0063) - speed setpoint (r0062) - torque-generating actual current (r0078)
av
Set a recording time of about 0.7 s, a pre-trigger of 80 ms and define the trigger condition such that the recording is
started if the output signal of the function generator exceeds 0.5%.
st
Run the drive at 750 rpm, first start the function generator and then the trace function:
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the trace recording monitors the assigned signals; all signals are scaled to a “common maximum value“.
To analyze the recorded signals of speed setpoint and actual speed these two signals should be scaled to “common
resolution“; select this assignment as follows: time diagram > scaling > “r0062” same as ”r0063“ > OK.
Define this assignment as “valid for all subsequent measurements“.
page 28
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tm
Control Loop Circuits
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@
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rd
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SITRAIN
Control page 01 © Siemens AG 2011 - all rights reserved
List of Contents
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Induction Motor / Synchronous Motor …............................................................................... 3
Available Types of Control (SM150) ……………………………………………......................... 5
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Open Loop Control …........................................................................................................... 6

Closed Loop Control (Vector Control with Encoder) …......................................................... 7
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Closed Loop Control (Sensorless Vector Control) …............................................................ 8

Identification of the “Substitute Circuit Diagram Data” …...................................................... 9
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Control Loops and Torque Limits …...................................................................................... 10

Speed Controller [6040] ….................................................................................................. 11
Encoder Interface SMC30 …................................................................................................. 12
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Torque Setpoints [6060] ….................................................................................................. 13

Menus to set the Torque Limit [1700] …................................................................................ 14
Setting the Torque Limits ….................................................................................................. 15
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Setting the Current Limit / Setting the Power Limits ….......................................................... 16

Transient Function, Step Response ….................................................................................. 17
rd
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page 02
Induction Motor / Synchronous Motor
Induction
Induction motors
motors require
require AC
AC input
input to
to the
the stator
stator only
only (1)
(1)
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1
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VFD
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tm
VFD
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magnetizing current
torque generating current
@
1
DC or AC
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Synchronous
Synchronous motors motors require
require
-- AC
AC input
input to
to the
the stator
stator (1)
(1) and
and
rd
-- DC
DC input
input to
to the
the rotor
rotor (2)
(2)
either
either DC
DC directly
directly via
via slip-rings
slip-rings or
or 2
o_
AC
AC via
via induction
induction with
with conversion
conversion
to
to DC
DC byby diodes
diodes fixed
fixed on
on the
the rotor
rotor
(as
(as shown
shown in in the
the example)
av
example)
st
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SITRAIN
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Induction Motor / Synchronous Motor
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Operation with induction motor cos ϕ = 0.8 … 0.9 / motor requires reactive power
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Stator Rotor
@
88
stator current
via Power Module flux generating current component
d
torque generating current component

_r
Operation with synchronous motor cos ϕ = 1.0 / motor power management via excitation
o
av
Stator Rotor
st
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exciter current via exciter current

stator current
slip ring contacts or via DC-Master
via Power Module rotating rectifier (30 … 1000 A)
SITRAIN
Available Types of Control (SL150)
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For applications with very high speed / torque
Vector control accuracy for a wide range of speed
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Closed loop control (Vector Control) P1300
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• Speed control without encoder 20
iS
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• Speed control with encoder 21 iSq
• Torque control without encoder 22
Φ
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• Torque control with encoder 23 iSd
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Open loop control For commissioning and servicing
88
Open loop control (V/Hz-Characteristic) P1300
U [V]
rd
• with linear characteristic 0
• with parabolic characteristic 2
o_
Open loop control (forced current) P1300

with constant current 18 f [Hz]
av
st
SITRAIN
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om
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Open Loop Control
ai
tm
I.S
3.3 kV
current
ho
p1300 = 18
V/f
field
@
weakening voltage
50 Hz
p1300 = 0 / 2
8
frequency
d8
flux = 100 %
nset
r
o_
actual voltage measurement

IUVW
av
actual current measurement
M
st
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Open-loop (general) for initial steps of commissioning to diagnose current and voltage
either as V/f-control or as I/f-control
SITRAIN
Closed Loop Control (Vector Control with Encoder)
om
speed torque current
controller controller
nset Iset, q
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coordinate
- nact - Iact, q transformation
Uset
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P
field field current
characteristic controller K
tm
θset Iset, d ϕ
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- Iact,d motor model IUVW
@
M
88 stator current is
torque gen. current iq G
rd
field generating current id
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Independent of the application of an Induction Motor or a Synchronous Motor the same basic control scheme is used.
av
The essential difference is found in the setpoint of the field generating current. For an induction motor the field current
setpoint will read 100% (field weakening excepted), for a synchronous motor the field current setpoint reads “zero”.
st
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SITRAIN
Closed Loop Control (Sensorless Vector Control)

om
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speed torque current

controller controller
tm
nset Iset, q
coordinate
- nact - Iact, q transformation
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P Uset
field field current
characteristic controller K
θset Iset, d ϕ
@
- Iact,d motor model IUVW

88
rd
M
o_
stator current is
torque gen. current iq
av
field generating current id

st
for
for stand-alone
stand-alone motors
motors of
of high
high power
power ratings
ratings and
and medium
medium to
to high
high dynamic
dynamic performance
gu
performance
for
for aa speed
speed // torque
torque range
range of
of up
up to
to 1:
1: 40
40 (>
(> 2.5
2.5 %
% fn)
fn)
SITRAIN
Identification of the “Substitute Circuit Diagram Data”
A first request for the automatic identification of the substitute circuit diagram data can be made during the
om
configuration of the drive ( configuration wizard / configure DDS):
Calculation motor module cable motor
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tm
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Complete calculation of the motor-/control-parameters on
the basis of the rating plate data of the motor
@
The substitute circuit diagram data calculated in the previous
Identification
step are adapted to the individual properties of the motor when
88
carrying out the (automatically run) identification routines.
The actual start of the identification routines is requested after
the download of the offline configuration.
rd
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first step: “standstill measurement“

second step: “rotating measurement“ LV
av
only “standstill measurement“ LV + MV

st
SITRAIN
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Control Loops and Torque Limits
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speed controller torque setpoint torque limit

tm
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“slip” or “load angle” torque

@
88
rd
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rotor
DRIVE CLiQ frequency
current setpoint filter current controller
av
st
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power unit
SITRAIN
Speed Controller [6040]
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SLVC VC
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p1470 p1460
p1472 p1462 IGBT/IGCT
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control
tm
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@
88
rd
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low frequency oscillation of the actual speed may have to be “filtered” before being fed to the IGBT/IGCT control
st
SITRAIN
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Encoder Interface SMC30

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tm
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@
d 88
o _r
av
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• 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
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(p0491 / fault is monitored, drive maintains operation).

• The sequence of “running measurement / encoder test” can be influenced via p1959.
• Change of direction of speed (with setpoint polarity unchanged) via p1821.
SITRAIN
Torque Setpoints [6060]
om
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tm
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@
88
rd
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SITRAIN
Control page 13
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Menus to set the Torque Limit [1700]
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tm
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@
r0079
88
rd
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av
st
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SITRAIN
Setting the Torque Limits
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A negative value at the output A positive value at the output
of the positive torque limit of the negative torque limit
results in an acceleration of results in an acceleration of
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the drive in negative direction the drive in positive direction
up to maximum frequency! up to maximum frequency!
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tm
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p1520
@
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p1524
rd
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SITRAIN
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Setting the Current Limit / Setting the Power Limits
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tm
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@
the limit is determined by the

smallest of the two currents
88
rd
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st
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SITRAIN
Transient Function, Step Response
om
x
overshoot
speed
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tolerance band
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tm
Trise t torque
Trecovery
ho
output (actual value)
too Increase the gain KP;
@
slow repeat measurement
output (actual value)
t
1 Set integral time TN to a
88output (actual value)
large value; i.e. 1000ms
1 KP is optimal
or define a P-controller
2 Now reduce TN
rd
2 Apply a Kp Tn
to allow only
step of reference
one undershoot
3 The manipulated value t
o_
must not go into limit output (actual value)

t
too
only one undershoot;
av
Reduce the gain KP;

dynamic in consequence an
repeat measurement overshoot of 20–50 %
example speed controller
t
st
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SITRAIN
om
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tm
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@
88
rd
v o_
s ta
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Communication
ai
tm
with
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PROFIBUS
@
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rd
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st
SITRAIN
Profibus page 01 © Siemens AG 2011 - all rights reserved
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l.c
List of Contents
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Application of selected PROFIdrive V4 Functions …........................................................... 3

tm
Equidistant DP-Cycle …....................................................................................................... 4

Drive Devices on PROFIBUS_Integrated …......................................................................... 5
Telegram Structure of Drive Devices …................................................................................ 6
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Telegram Structure and I/O-Addresses / Example S120 …................................................. 7

Standard Telegrams (Example SM150, Object “Drive”) …................................................... 8
Control Word 1 (Standard Telegram / PROFIdrive) …......................................................... 9
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Internal Control- and Status-Words ….................................................................................. 10

Control Word Sequence Control / Object VECTOR …......................................................... 11
PROFIBUS-Telegram and I/O-Variables ….......................................................................... 12
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Correlation of PROFIBUS Address to SIMOTION Address …............................................... 13

SIMOTION-Program / Chart “DCC_1” ….............................................................................. 15
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PZD Receive signals / Object “Drive“ ….............................................................................. 17

PZD Transmit Signals / Objects other than “Drive“ ….......................................................... 19
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Transmit Object “Drive”, Receive Object “Other” ….............................................................. 21

Adding “Slots” to a Standard Telegram …............................................................................ 23
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Extending a Standard Telegram …....................................................................................... 25

Scheme of Routing Control Bits …........................................................................................ 27
Script-Files for Parameterization …....................................................................................... 29
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Parameterization via Script-Files …....................................................................................... 31

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Correlation of PROFIBUS Address to SIMOTION Address …............................................... 33
page 02
Application of selected PROFIdrive V4 Functions
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Functionality
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Cyclic communication
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controlling the operating process
- assigning control bits / setpoint values Automation Engineering Operation
tm
- reading status and actual values (Master Class 1) (Master Class 2) (Master Class 2)
S7, D445, others SCOUT SIMATIC HMI
fast and permanently
ho
Acyclic communication
writing and reading parameter values
PROFIBUS-DP
- reading faults and diagnostic signals
@
- reading and changing function values
on request
cyclic channels acyclic channels
88
Clock synchronous operation PROFIBUS-communication

(“D445” / “S120 Servo“)
rd
SINAMICS SL150
o_
av
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Clock synchronous operation

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SITRAIN
Equidistant DP-Cycle
om
l.c
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cyclic part acyclic part

tm
GC Slave 1 Slave 2 Slave n Slave n PG/PC HMI GC

SPARE
PZD PZD PZD PKW PKW PKW
ho
i.e. cycle time: TDP = 1.5 ms (can be set)

@
After having transmitted all cyclic data, the acyclic services are carried out; if the
allotted time slot is insufficient, further cycles will be used for the transmission.
88
HW Config
rd
o_
av
st
Mouse click right

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> Object Properties

> Clock Synchronization
SITRAIN
Drive Devices on PROFIBUS / SL150
om
l.c
HW Config
ai
tm
ho
@
88
rd
SCOUT supports the communication via PROFIBUS:
drive device SINAMICS_Integrated is automatically
o_
inserted (though not needed for SL150)

drive device CU320-2 DP has to be added to the
DP-Mastersystem
av
configuration properties are set in the configuration of

object “drive” and then transferred to the HW Config
st
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SITRAIN
Telegram Structure of Drive Devices

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l.c
PROFIBUS PROFIBUS
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send telegram receive telegram

tm
Process data Process data

Drive object 1
ho
Process data Process data

Drive object 2
axis disconnector
@
88
type actual type setpoint

rd
SIMOTION
program
o_
av
Drive object 1
st
Drive object 2
drive Drive object 3
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device Drive object n
SITRAIN
Telegram Structure and I/O-Addresses / Example S120
3 Slave 1 15 Slave 2 Slave n
om
GC GC
H T H T H T
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INFEED SERVO_02 SERVO_03 CU 320 TB30 TM31
Header Trailer
ai
1
5
7
9
tm
28
30
30
25
28
29
I/O-addresses
…
…
…
8
6
4
25
25
28
29
30
30
DRIVE PLC
ho
CU320 > Communication > Message frame communication HW Configuration > Object properties > Configuration
@
256 1
256 1
258 7
88
258 12
282 4
rd
282 4
point of view PZD - 12 / 7

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Object Setpoint / Actual

PLC Output data; PQ / Input data; PI SIEMENS Telegram 370, PZD-1/1
Object Receive / Transmit SIEMENS Telegram 110, PZD-12/7
av
from PLC to PLC Standard Telegram 2, PZD-4/4

in Object from Object
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SITRAIN
Profibus page 07
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Standard Telegrams (Example SM150, Object “Drive”)
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Standard Telegrams Siemens-specific Telegrams Free

tm
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@
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SINAMICS_Integrated > Message frame configuration

rd
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Telegrams 1 to 20 manufacturer independent Standard Telegrams automatic configuration in SINAMICS

Telegrams 102 to 391 Siemens-specific Standard Telegrams automatic configuration in SINAMICS
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Telegram 999 free telegram manual configuration required
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 type of drive.
SITRAIN
Control Word 1 (Standard Telegram / PROFIdrive)
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E
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tm
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7 internal
internal
control
control
words
words
@
4
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rd
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SITRAIN
Profibus page 09
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Internal Control- and Status-Words
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PZD1
PZD1 Control
Control word
word STW1
STW1 PZD2
PZD2 Process
Process data
data word
word 22 PZD3
PZD3 Process
Process data
data word
word 33 PZD4
PZD4 Control
Control word
word STW2
STW2
all
all Standard
Standard Telegrams all
all Standard
Standard Telegrams some
some Standard
Standard Telegrams some
some Standard
Standard Telegrams
tm
Telegrams Telegrams Telegrams Telegrams

ho
SM150 S120
@
STW STW
88
ZSW
rd
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Internal ZSW
Control words (STW)
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and
Status words (ZSW)
st
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PZD1
PZD1 Status
Status word
word ZSW1
ZSW1 PZD2
PZD2 Process
Process data
data word
word 22 PZD3
PZD3 Process
Process data
data word
word 33 PZD4
PZD4 Status
Status word
word ZSW2
ZSW2
all
all Standard
Standard Telegrams
Telegrams all
all Standard
Standard Telegrams
Telegrams some
some Standard
Standard Telegrams
Telegrams some
some Standard
Standard Telegrams
Telegrams
SITRAIN
Control Word Sequence Control / Object VECTOR
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tm
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@
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rd
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SITRAIN
PROFIBUS-Telegram and I/O-Variables

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tm
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@
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“transmit” “receive”
object to DCC DCC to object
INPUT (PI…) OUTPUT (PQ…)
rd
v o_
input variable to chart

ta
s
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word PxW 256 258

byte PxB 256, 257 258, 259
bit Px 256.b, 257.b 258.b, 259.b
SITRAIN
Correlation of PROFIBUS Address to SIMOTION Address
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BiCo-Converter wired to:
Bytes of PZD 2 270 271
“object B, PZD 2, transmit”
address 270, 271
Bit in PZD 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
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Bit in Byte 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
“A”
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“B”
SIMOTION address 270.5 271.0
transmit receive
tm
BiCo-Converter
DI 3 on_off_1
ho
Bit 0
PI 271.0 Standard tel. 1
to VECTOR
@
ON / OFF 1
DCC_1
88 PI 270.5
Transmit
PZD 2
rd
PI 271.0
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DI 10 mop_up
Bit 13
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P I x.y Periphery Input (to PLC) to VECTOR

PQ a.b Periphery Output (from PLC) Raise MOP
st
SITRAIN
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5 Communication with PROFIBUS

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5.1 Assigning binectors and connectors to telegrams
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For the lab-work on PROFIBUS, project “SL_LV2” will be used.

tm
Check whether project “SL_LV2.zip” already exists on the hard-disk other than in directory
“C\Temp_Trainee\D445_CFC”.
ho
If so, please delete it from any other location.

Retrieve project “SL_LV2.zip” from archive, open it accepting the prompted directory, save and compile the project,
connect to target system, download the project (devices “SIMOTION_D445” and “CU320_2_Drive”) and change to
@
operating mode RUN.

Project “SL_LV2” is fully configured for the operation of the training unit, motor data are all set and the ALM can be
88
switched on via switch DI 0; test this function.

Profibus communication is configured with Standard telegram 1 for object VECTOR (and for other objects as well as
required for the overall functionality).
rd
The drive, however, cannot be operated via Profibus as yet since the “PLC-program” in chart “DCC_1” is not yet
o_
functionally “connected” to object VECTOR.

av
st
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page 14
SIMOTION-Program / Chart “DCC_1”
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tm
DCC_1 DCC_1
sheet A 2 sheet C 3
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@
Chart DCC_1 of project “SL_LV2” includes
other function blocks as well (for a later step

of training). The function given at the present
state, however, will be found as shown in this
88
view (with switch DI 6 = off).
rd
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DCC_1 DCC_1
sheet A 3 sheet C 2
av
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SITRAIN
st

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The SIMOTION-program of DCC_1 merely transfers inputs to outputs directly as follows:
ai
from TM31 – PZD 1 to PZD 1 – VECTOR
TM31 – PZD 2 PZD 2 – VECTOR
tm
VECTOR – PZD 2 PZD 1 – TM31

To control the drive via Profibus, control bits and speed setpoint have to be assigned to PZD 1 and PZD 2 of object
ho
TM31 in “Transmit direction”.

@
8
r d8
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page 16
PZD Receive signals / Object “Drive“
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STW 1
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n.set
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PROFIBUS
PROFIBUS receive
receive word
word PROFIBUS
PROFIBUS control
control word
word Internal
Internal control
control bits
bits
tm
r2090.0
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r2090.1
@
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CU320_2_Drive > VECTOR > Communication
from Master
rd
r2050[0]
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r2050[1]
max. 32
words
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st
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SITRAIN
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For object VECTOR, open menu “Communication > tab “Receive direction” and check the Profibus “signal wiring”
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within the drive:
the binector and connector wiring is “greyed out” and cannot be changed since the BICO connections had been
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assigned automatically as consequence of the definition of “Standard telegram 1“ during configuration.

tm
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rd
v o_
s ta
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page 18
PZD Transmit Signals / Objects other than “Drive“
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p2051[0]
to Master
p2051[1]
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p2080[0] r2089[0]
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SITRAIN
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Assign switches and functions as listed below to process data word PZD 1 of object TM31 via Binector-connector
converter “Status word 1 sources” in accordance with the bit position required for the control bits of object VECTOR
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(TM31–PZD 1 is transferred through DCC_1 to become PZD 1–VECTOR).

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switch function TM31, bit “wiring”

DI 3 ON/OFF1 ........ .............................
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DI 4 Acknowledge faults ........ .............................

DI 10 Raise motorpot ........ .............................
DI 11 Lower motorpot ........ .............................
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(Please don’t delete or change the “wiring” of bit 15 in object TM31 !)

Assign a fixed logical “0” or “1” to bits not listed above as necessary; concerned bits: . . . . . . . . . . . . . . . . . . . . . . . . .
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Define the motorpot (ramp times each 5 s, no initial rounding) to act as speed setpoint via PZD 2 of TM31. DON’T use
the motorpot as main setpoint “directly”; keep the speed demand coming in as main setpoint via Profibus!
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Change to operating mode “RUN”, switch on the ALM (DI 0) and verify that the motor can be switched on (DI 3) and
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that the speed can be controlled via motorpot (DI 10 / DI 11).

Check the status conditions of control bits and the setpoint value at following locations:
- outgoing PZDs of object TM31
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- variables of the I/O-container

- incoming PZDs of object VECTOR
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page 20
Assigning Control Bits and Setpoint Value
TM31 TM31 Vector Vector Vector
I/O BiCo Transmit Receive CoBi Control
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ON/OFF1
ON/OFF1
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OFF2
OFF2
program
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PZD1 PZD1
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1
DCC
Vector
I/O MOP
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SIMOTION
MOP
manual MOP
BiCo-wiring
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MOP as per lab-work
MOP
automatic BiCo-wiring Vector

via Standard Telegram 1 Setpoint
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PZD2 PZD2
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1
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TM31 Vector Vector

Receive Transmit Actual Value
1
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PZD1 PZD2
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SITRAIN
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Assign the actual speed as it comes in from SIMOTION as PZD 1 via object TM31 to be displayed on AO 0 of object
TM31 (read the output voltage on the display of the hand-held operator panel; selector switch in position “AO 0”).
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Carry out an Upload of the current parameterization of device CU320_2_Drive so you don’t overwrite all your Online-
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changes with the “old” project data if you make a download later on.
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page 22
Adding “Slots” to a Standard Telegram
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Actual value slot: data from drive

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Setpoint slot: data to drive
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Input data: transmit from object to PLC (periphery input) Output data: receive from PLC to object (periphery output)
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SITRAIN
5.2 Extending a telegram and assigning I/O-addresses

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If additional data have to be transferred within an object using a “Standard telegram” two solutions are possible:
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one on the “PLC-side” via “HW Configuration > Redefinition of slave properties” and the other on the “Drive-side”
via “CU320_2_Drive > Communication > Message frame configuration”.
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To add sending or receiving slots to a Standard telegram on the “PLC-side” following steps are involved
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(just for information, not a step of lab-work!):

- in menu “HW Config” > CU320_2_Drive > “Object properties” > Configuration > sheet “Details” a new slot of the
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required type (actual value, data from the drive / setpoint, data to the drive) is added to the standard telegram with
definition of the number of additional process data words.
- during the routine “Save and compile” the type of telegram is changed from “Standard message frame” to “User-
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defined” in sheet “Overview” and a still available address range is assigned in sheet “Details”.
- on the drive-side, menu “PZD message frames” (via CU320_2_Drive > Communication) lists a new line with the
number of additional words and the address range as just assigned by the compiler by the name “Supplementary
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data” below line “Standard message frame”.

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page 24
Extending a Standard Telegram
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“any object” > Communication > tab “Receive” or “Transmit” > Select message frame
“CU320_2_Drive” > Communication > Message frame configuration
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“transmit” “receive”
object to DCC DCC to object
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INPUT (PI…) OUTPUT (PQ…)
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adapt addresses
if applicable
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SITRAIN
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The second possibility, the extension of a Standard telegram on the “Drive-side” will now be carried out to add two
“input words” ( two PZDs from VECTOR to D445) and one “output word” ( one PZD from D445 to VECTOR) to the
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Standard telegram of object VECTOR:
- open menu “Message frame configuration” in operating mode Offline
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- mark the line of object VECTOR

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- insert a line of the type “Message frame extension”

line “Message frame extension” is added below line “Standard telegram 1” (the blue checkmark is changed to
two red exclamation marks indicating that the HW Config will reassign the address range)
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- define the number of words of the telegram extension as specified above

- start the automatic assignment of an available address range for the extended telegram via “Transfer to HW Config”
the message popping up indicates that
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+ the addresses of the PZDs of object VECTOR will have to be changed and that
+ a reassignment of the variables’ addresses may become necessary
the red exclamation marks are changed to red checkmarks indicating that the Standard telegram has been
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extended but is already aligned with the HW Config.

As prompted by the message, any programming which uses the addresses which were valid before the telegram
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extension has to be adapted.

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Open the I/O-container and adapt the addresses related to object VECTOR accordingly:
variable pzd_1_to_vector pzd_2_to_vector pzd_1_from_vector pzd_2_from_vector
previous address 256 258 256 258
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new address .............. .............. .............. ..............

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Start the routine “Save project and compile all”, verify the consistency via “Project > Check consistency”, go online,
download SIMOTION_D445 and CU320_2_Drive, acknowledge all alarms and change to “RUN”.
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Verify that the function of the drive is given as before the “Telegram extension”
(DI 6 = off / DI 0 = on ALM = on / DI 3 = on MoMo = on; DI 10 (11) = raise (lower) motorpot setpoint).
Verify that object VECTOR now features 3 PZDs in “Receive direction” and 4 PZDs in “Transmit direction”.
page 26
Scheme of Routing Control Bits
TM31 I/O TM31 I/O program DCC_1 I/O VECTOR VECTOR

BiCo converter Transmit Receive CoBi converter
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word bit bit word
off2
pzd_1_from_tm31
pzd_1_to_vector
“1” off3
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DI6 = off
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enable
= on
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TM31 I/O VECTOR
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BiCo converter Transmit
off_3
“0”
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TM15 I/O
BiCo converter I/O addresses
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have to match
with the PZD
enable
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“1” assigned for

data transfer
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SITRAIN
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In the next step, the operation of the drive will be controlled by sending individual bits to the SIMOTION program.
By closing switch DI 6 the DCC programming will reroute SOME control signals assigned to inputs of object TM31 and
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sent to DCC via process data word PZD1 of object TM31 (variable “pzd_1_from_tm31”) to control signals assigned to
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inputs of TM31 and TM15 and sent to DCC via process data words of object VECTOR (variables “off_3”, “enable” etc).
Activate the SIMOTION program available for this application by switching on DI 6:
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the ALM can still be switched on with DI 0, but the motor no longer starts with DI 3
The individual bits to control the drive are already specified as I/O-variables:
“number 8, pos_speed” through “number 15, on_off_1”.
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The I/O-addresses assigned to these variables, however, are all incorrect (deliberately, you will set them right in the
next step).
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page 28
Script-Files for Parameterization
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i.e. line 7: connect binector r2094 , bit 14 of object 3 (VECTOR) to parameter p4093 , index 0
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Implementation of signal “wiring” by execution of the script-file above

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SITRAIN
The I/O-addresses have to be defined in conjunction with the SIMOTION programming and the assignment of m
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commands (DIs) to respectively the feedbacks (DOs) from the communication channels.
Following functional assignment will be used:
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switch function assigned variable object DI/O binector bit transmit receive I/O-
/ LED via SIMOTION name name no. no. no. PZD no. PZD no. address
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DI 3 ON / OFF1 on_off_1 . TM15

. . . . .-1
.. . .3. . .4022.3
...... . 0. . . . . 4. . . . . . .- .- .- . . .PI. .271.0
....
. . .- .- .- . .
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DI 1 OFF3 off_3 ........ .... ....... ... ....... .......

DI 5 enable inverter enable ........ .... ....... ... ....... . . .- .- .- . . .......
DI 7 invert speed setpoint invert ........ .... ....... ... ....... . . .- .- .- . . .......
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DI 10 raise motorpot setpoint mop_up ........ .... ....... ... ....... . . .- .- .- . . .......
DI 11 lower motorpot setpoint mop_down . . . . . . . . .... ....... ... ....... . . .- .- .- . . .......
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DO 12 drive in operation operation ........ .... ....... ... . . -. -. -. . . ....... .......

DO 13 speed >/= zero pos_speed . . . . . . . . .... ....... ... . . -. -. -. . . ....... .......
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The SIMOTION programming is fixed (the program will process each of the variables such that the assigned function
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will follow).
The required assignment of commands and feedbacks between concerned drive objects and the Profibus process
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data words (BICO wiring of Profibus PZDs) will be carried out by executing one script-file each for objects VECTOR
and TM15_2.
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page 30
Parameterization via Script-Files
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Change of ramp up time in DDS0 (object VECTOR) to 15s: p1120 [0] = 15
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proj.tos(“VECTOR").parameters(1120,0)=15
proj.tos (“VECTOR") . parameters (1120 ,0) =15
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I I I I
name of drive object in which parameter no. index no. parameter value
p1120 is to be changed
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(not required if script command
applies locally within this object)
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Assignment of AI0 of TM31 (object 3) as source of setpoint in CDS0: p1070 [0] = 4055 [0] of object 3
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proj.tos(“VECTOR").parameters(1070,0)="4055:0:3"
proj.tos (“VECTOR") . parameters (1070 ,0) ="4055 : 0 : 3"
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I I I I I I
as above par. no. index no. connector no. index no. object no.
or bit no.
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SITRAIN
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Have a look at the script-file for object TM15_2 and compare the “wiring” to DO 22 / DO 23 of object TM15_2 before
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and after executing the script-file:
the parameters listed in the script-file have been downloaded.
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Have a look at the “wiring” of “Transmit direction” of object VECTOR, execute the assigned script-file provided in
object VECTOR and compare the resulting “wiring” of “Transmit direction” to the previous one:
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process data words PZD 3 / PZD 4 are now supplied by binector-connector converters and several of the input
binectors are “wired” to DIs of terminal modules.
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PZD 3 of the “Receive direction” of object VECTOR has also been wired by this script-file to read in drive status
messages.
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page 32
Correlation of PROFIBUS Address to SIMOTION Address
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BiCo-Converter wired to:
Bytes of PZD 2 270 271
“object B, PZD 2, transmit”
address 270, 271
Bit in PZD 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
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Bit in Byte 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
“A”
“B”
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SIMOTION address 270.5 271.0
transmit receive
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BiCo-Converter
DI 3 on_off_1
Bit 0
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to VECTOR
ON / OFF 1
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DCC_1
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Transmit
PZD 2
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DI 10 mop_up
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Bit 13
to VECTOR
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P I x.y Periphery Input (to PLC)

PQ a.b Periphery Output (from PLC) Raise MOP
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SITRAIN
Profibus page 33
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Supplement the table by the bit-no. and by the Transmit PZD-no. respectively the Receive PZD-no. which are already
assigned to the DIs / DOs (functions, variables).
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- start by finding the relation “switch no.” (e.g. DI 3) to object name and binector no. (e.g. object TM15-1, r4022.3)
- continue by relating the identified object name and binector no. to the bit and process data word of the BiCo-
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connector of object VECTOR (e.g. bit 0 of PZD 4).

Find out which I/O-addresses are related with the “PZD / bit no.” you identified, enter them into the last column of the
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table and assign these addresses to the variables of the I/O-container.

Writing access to the I/O-container is only given in offline mode. Consider which steps are necessary to have none of
your programming “lost” by “going offline, adapting the I/O-addresses, saving and compiling these changes, going
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online and downloading the modified project”:

1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Now download the modified project and test the function as follows:
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DI 6 = on selection of the SIMOTION program provided for this test

DI 0 = on ALM switches on
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DI 1 = on no OFF3
DI 5 = on inverter is enabled
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DI 3 = on motor switches on
DI 10 raise speed setpoint (via motorpot)
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DI 11 lower speed setpoint (via motorpot)

DI 7 = on change of direction of speed
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DO 12 = on indicates “drive in operation”

DO 13 = on indicates “speed >/= zero”
this programming is also available by project “SL_LV2F.zip”
page 34
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Programming
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in
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Drive Control Chart
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SITRAIN
DCC page 01 © Siemens AG 2011 - all rights reserved
List of Contents
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Workbench of Tool “Drive Control Chart, DCC” …............................................................... 3
Organization of DCC Charts ………………………………………………………..................... 5
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Monitoring Signals in “DCC-Online” (Test Mode, Watch On) …........................................... 7

Searching for Blocks assigned to Variables …..................................................................... 9
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Changing Block Values in “DCC-Online” ….......................................................................... 11

Changing Block Values in “DCC-Offline” ….......................................................................... 13
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Control via PG/PC “in parallel” to SIMOTION …................................................................... 15

“Masking Out” Upstream Bits …............................................................................................ 17
Run-Time Groups in SIMOTION …....................................................................................... 19
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Trace-Tool of SCOUT-SIMOTION ….................................................................................... 21

Assigning DCC-Signals as Pins to the Tracer ….................................................................. 23
Inserting a new Chart in “Object-DCC” …............................................................................. 25
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Engineering DCC-Charts ….................................................................................................. 27

Publishing Parameters …...................................................................................................... 29
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Execution Groups ….............................................................................................................. 31

Structure of the Parameter Number ….................................................................................. 33
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page 02
Workbench of Tool “Drive Control Chart, DCC”
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run sequence reference data
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compile
catalog test mode
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blocks / charts / libraries T2 scan time T2

1 / 4 runtime group 1 / position 4
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Either the position no. of the downstream block has to be larger

or the downstream block has to be in a larger scan time.
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SITRAIN
6 Drive Control Chart m

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For the lab-work on “Drive Control Chart, DCC” project “SL_LV1” will be used again. To be sure to use the “original”
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project, continue as follows:

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- save project “SL_LV1” by the name “SL_LV1T”

- download the project
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- activate mode “RUN” and test the function of the DCC program “DCC_1” via the hand-held operator panel:
1) switch on DI 4 Control command OFF3 is cancelled
2) switch on DI 0 ALM is switched on
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3) switch on DI 1 MoMo is switched on,

but MoMo is not yet enabled for operation
4) switch on DI 2 MoMo is enabled
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5) set the speed via AI 1 (DI 5 = off) values between -1400 rpm and +1400 rpm can be set
6) check the indication of the actual
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speed on LEDs DO12 to DO15

(switches in off position): n = 0 % no indication
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0 % < n < +/- 20 % DO 12

+/- 20 % < n < +/- 40 % DO 13
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+/- 40 % < n < +/- 60 % DO 14

+/- 60 % < n < +/- 80 % DO 15
+/- 80 % < n < +/- 90 % DO 12 to DO 15
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7) Switch on DI 5 the speed changes to zero

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after 2 s the speed changes from 0 to -90 % to 0 to +90 % to 0 etc.

[Switch DI 3 acknowledges faults of all objects.]
page 04
Organization of DCC Charts
sheet number
sheet view screen tiling
overview zooming
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sheet 1
Blocks within one sheet of
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a chart can be defined as
macro; macros can be
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used in other sheets or in
other charts.
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sheet 2
6 DCC sheets define a map.
Connections between sheets
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and maps are listed in the
columns to the left and right;

navigation via double click.
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sheet 3 sheet 6
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one DCC chart may comprise 26 maps

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SITRAIN
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6.1 Basic Handling and Operation of DCC
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Open chart “DCC_1” (double click on “DCC_1” in PROGRAMS) an acquaint yourself with the “organization” of the
sheets used in maps A, B and C:
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- sheet A1 signals coming in via Profibus from object VECTOR

- sheet B1, B2 signal processing
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- sheet C1 signals going out via Profibus to object TM15_1

Navigate from sheet to sheet by double clicking on the identifier (on the left or right side of the sheet) of signals linked
to other sheets or charts.
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page 06
Monitoring Signals in “DCC-Online” (Test Mode, Watch On)
watch off add I/O
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insert connection watch on remove I/O
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connection to
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I/O-variable
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connection to
other sheet or chart bit 15 0
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bit value 0 1 0 1 1 0 1 0 0 0 0 0 1 1 0 1
hex value 5 A 0 D
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“Value-Converters” read “value 1”

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on the “DCC-side” if the “drive-side”

integer float reads the value of the “reference”.
Standard reference values:
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16 bit signals 16 384

32 bit signals 1 073 741 824
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SITRAIN
DCC page 07
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Start on sheet A1 to monitor some signals within DCC:
- select the online view of DCC via button “Test mode”
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- click on the input fed by DI 2 and add this input for monitoring (“right mouse click > Add I/O” or “button Add I/O”)
the logic state is indicated as “0” respectively as “1”
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- check the logic state at the assigned output

- make sure to understand the “conversion” of the logic state of the input bits on the “binary-to-word converter”
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(block 9) to the hex value (16#xxxx) at the output

- think about the results regarding this hex word when changing inputs DI 4 to DI 7 to other logic states;
verify your thinking by observing the variables online
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- monitor the value of variable AI 1 starting on sheet A1 and continuing through the chart to sheet C1
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page 08
Searching for Blocks assigned to Variables
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Chart Reference Data
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SITRAIN
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To easily find the chart, the sheet and the block to which a particular variable in a DCC-programming containing a
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large number of sheets in even several charts is connected, following steps should be used:
- open any of the charts of the project
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- select menu “Chart Reference Data”

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- open the listing of “Cross Reference Chart Elements Address”.

- double-click on the variable in question
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the chart sheet showing this variable and its wiring to a DCC-block is opened automatically
Test this approach for some of the variables of the current project.
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page 10
Changing Block Values in “DCC-Online”
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“refresh rate” via: “Debug > Test Settings”
To add additional blocks, one
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will typically be marked as
“predecessor”; this block is
then marked in “light green”.
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The next block added uses the
same scan time and the next
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position in “sequence of cal-
culation” as the “predecessor”.
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menu to change block values in “DCC-Online” saving data “non-volatile” saving data changed in DCC-online
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(“Test Mode” and “Watch On”) on Compact Flash Card (or DCC-offline) in the offline-project
In
In “DCC-Online”
“DCC-Online” only
only aa number
number of
of “minor”
“minor” changes
changes is
is possible
possible (value
(value assignment,
assignment, chart
chart internal
internal “wiring”)
“wiring”)
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SITRAIN
Open sheet B1 and monitor the output of the sweep generator after switching on DI 5:
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the signal changes (erratically) between 0.09 and 0.11
To monitor signals which change continuously, the refresh rate can be adapted via “Debug > Test Settings”;
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set the refresh rate to 100 ms

the change of the signal can now be observed in its true pattern.
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While still online, change the sweep rate (block connector FW) to “10” and observe the change on the output of the
sweep generator:
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the online change takes immediate effect.

Any change within a chart introduced while in “DCC-Online” becomes effective in the SIMOTION RAM immediately
AND these changes are also saved in the PG-RAM automatically.
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To ensure the project’s consistency, function “Save and Compile” has to be carried out.
Carry out the step required to save the DCC-Online change of the sweep rate on the Compact Flash Card
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......................................................
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page 12
Changing Block Values in “DCC-Offline”
offline
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menu
features a
Comment
line and
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additional
attributes
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menu to change block values in “DCC-Offline”
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once online after compilation
consistency is lost
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consistency is restored
by downloading “D445”
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(possible in mode STOP only)

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SITRAIN
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Changes of the DCC program while in “DCC-Online” are limited to minor modifications. Extensive changes have to be
done in “DCC-Offline” by following the sequence of steps listed:
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1) introduce all changes in “DCC-Offline” (change, delete or add internal or external wiring, add or delete blocks, …)
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2) compile the chart as program (Chart > Compile > Chart as program)
3) download the modified chart by downloading drive device “SIMOTION D445”
(an individual chart cannot be downloaded)
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4) copy RAM to ROM

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page 14
Control via PG/PC “in parallel” to SIMOTION
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bit 0 bit 0
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bit 11
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initial hex value 0 0 0 1
initial binary value 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1

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required binary value 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 1
required OR binary 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0
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required OR word 0 8 0 0
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Bit
Bit 11
11 reads
reads aa logic
logic “0”
“0” upstream
upstream and
and is
is set
set to
to logic
logic “1”
“1” by
by “manual
“manual input”
input” within
within the
the chart
chart
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SITRAIN
st

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Control of the drive is presently executed by the SIMOTION program which responds to commands via switches (the
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switching state is transferred by Profibus from the I/Os to DCC).
Alternatively, control of the drive can also be gained by direct commands entered on DCC-blocks. Such an approach
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is found in many site applications.

In project “SL_LV1”, sheet A1 you find block 11 (OR-gate for words) provided for this purpose.
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Switch on switches DI 2, DI 4, DI 5, DI 0, DI 1 in this sequence (drive performs continuous ramps up / ramp down
movements) and take a note of the hex value at input I1 of block 11 (this hex value is required to have the drive
perform as observed):
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hex value at block 11 DI2 = on 16# . . . . . . . . . . . . . . . . . . . . . .

DI2 + DI4 = on 16# . . . . . . . . . . . . . . . . . . . . . .
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DI2 + DI4 + DI5 = on 16# . . . . . . . . . . . . . . . . . . . . . .

DI2 + DI4 + DI5 + DI0 = on 16# . . . . . . . . . . . . . . . . . . . . . .
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DI2 + DI4 + DI5 + DI0 + DI1 = on 16# . . . . . . . . . . . . . . . . . . . . . .

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Switch off switches DI 1 to DI 4 (drive stops) and assign the OR-word at input I2 of block 11 which is required to have
the drive run again as before:
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1. step 16# . . . . . . . . . . . . . . . . . . . . . .
2. step 16# . . . . . . . . . . . . . . . . . . . . . .
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Assign an OR-word to activate an OFF 3 command ( drive stops); change the OR-word to run the drive again.
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1. step 16# . . . . . . . . . . . . . . . . . . . . . .
2. step 16# . . . . . . . . . . . . . . . . . . . . . .
3. step 16# . . . . . . . . . . . . . . . . . . . . . .
page 16
“Masking Out” Upstream Bits
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l.c
bit 11 = “1” bit 11 = “1”
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tm
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bit 11
bit 11 = “1” bit 11 = “0”
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upstream hex value 0 C 5 F
upstream binary value

88 0 0 0 0 1 1 0 0 0 1 0 1 1 1 1 1
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required binary value 0 0 0 0 0 1 0 0 0 1 0 1 1 1 1 1
required AND binary 1 1 1 1 0 1 1 1 1 1 1 1 1 1 1 1
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required AND word F 7 F F

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Bit
Bit 11
11 reads
reads aa logic
logic “1”
“1” upstream
upstream and
and is
is set
set to
to logic
logic “0”
“0” by
by “manual
“manual input”
input” within
within the
the chart
chart
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SITRAIN
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The control word as processed by the SIMOTION program is transferred to the drive as variable “STW1” (refer to
sheet C1). This SIMOTION-generated control word (output of block 1) is AND-wired (block 2) before being handed on
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as variable “STW1” via Profibus. Such engineering is common site practice to “mask out” fault bits ( an upstream
fault pattern is only handed on if the AND-word permits).
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Run your drive (via switches) as before and assign the AND-word at input I2 of block 2 such that the “OFF 2 enable”
tm
is withdrawn:
16# . . . . . . . . . . . . . . . . . . . . . . ( drive stops)
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Keep all switches (DI 0, …) in the SAME position and restart the drive by assigning the required AND-wiring:
1. step 16# . . . . . . . . . . . . . . . . . . . . . .
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2. step 16# . . . . . . . . . . . . . . . . . . . . . .
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page 18
Run-Time Groups in SIMOTION
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runtime group position =
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sequence of
calculation
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@
For an existing chart blocks can be redefined in their position
( sequence of calculation), in runtime group and scan time.
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T2 scan time T2
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T2
2 / 2 runtime group 2 / position 2 2/2
chart name
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block number Scan times are assigned via “D445 > (rMC) Set system cycle clocks”.
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SITRAIN
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During editing SIMOTION charts, function blocks are assigned to Run-time groups ( cycle time of calculation) in the
sequence as added to the chart ( sequence of calculation).
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The performance of the overall function is influenced both by the sequence and the cycle time; modifications of the
initial setup might therefore be required if extensive changes in the DCC program are carried out.
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A SM150 drive project as you will find it at site is thoroughly engineered. Major adaptations will not be required;
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sequence and the cycle time should therefore not be reorganized.

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page 20
Trace-Tool of SCOUT-SIMOTION
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signal 2 to be traced
chart: DCC_1 / block: 8 / signal: Y
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signal 1 to be traced
chart: DCC_1 / block: 32 / signal: X2
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6.2 Tracing signals of DCC-charts with the tracer of SCOUT-SIMOTION

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Variables at inputs or outputs of DCC blocks can be traced by using the trace tool of SCOUT-SIMOTION; this tracer is
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quite similar to the trace tool of SCOUT-SINAMICS as used previously but not identical.
Apart from a few SIMOTION-specific particularities the SIMOTION tracer is set up the same as the SINAMICS tracer.
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Open menu “SIMOTION tracer” and assign the “recording properties” as suggested in the slide.
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page 22
Assigning DCC-Signals as Pins to the Tracer
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tm
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button OK enters the selected signal into

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the “list of signals selected for recording”

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SITRAIN
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l.c
Assign the input signal of block 32 to channel 1 and the output signal of block 8 to channel 2.
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Record the signals and crosscheck the results as regards amplitude and frequency with the function programmed
in DCC.
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@
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page 24
Inserting a new Chart in “Object-DCC”
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ONLINE
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Technology package “TPdcblib”
might first have to be copied from
SCOUT to the Flash Card (Load to
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target device > Perform actions).
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@
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language for blocks can be selected in this step
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SITRAIN
6.3 Engineering of DCC-charts within objects of SINAMICS drive devices

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DCC-charts are not only available in SIMOTION but can also be assigned to ANY object of the SINAMICS drive
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device. Standard SL150 applications use extensive DCC-programming in SIMOTION but also some DCC-charts in
object VECTOR.
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Disconnect from target system and insert a new DCC-chart by the name “Training_1” for object VECTOR by double
tm
clicking on “Insert DCC-charts” and import library “TPdcblib”:

sheet A1 of chart “Training_1” opens up
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chart “Training_1” is added to object VECTOR
Libraries which have been imported and are to be used by DCC-charts in drive objects have to be “loaded into
target” if the technology package has not been loaded to the CF card any time before (from source SCOUT).
@
If necessary, go online and perform this step via “CU320_2_Drive > Select technology package > TPdcblib > Load into
target device > Perform action > OK” (this download takes about 1o minutes).
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Change to offline mode and carry out the requested “Power OFF / ON”.
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page 26
Engineering DCC-Charts
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DI 6
DI 7
DI 2
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F1
AI 0
AI 1
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additional setpoint, p1075[0]
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Edit the function for chart “Training_1” as shown in above slide:

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- one by one select the blocks from the catalog and insert them into the chart via “drag and drop”
[information to the detailed function of a block is called up by marking the block ( it turns blue) and pressing “F1”]
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- connect the blocks within the chart by first clicking on one end of the “wiring” first and then on the other end
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- connect inputs and outputs of blocks to the respective objects by a right mouse clock on the input (output),
selecting “Interconnection to address” and defining the required connector (parameter)
Compile chart “Training_1” you have engineered:
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you will get a message that several errors have been detected.
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page 28
Publishing Parameters
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compile > chart as program >
connect to target device >
@
download
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connection parameter value parameter

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@ * parameter number parameter name @ parameter number parameter name

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identifier of the type of parameter / parameter number / parameter name

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SITRAIN
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The error message indicates that inputs and outputs have to be published (substitute for I/O-variables in SIMOTION).
l.c
Publish inputs and outputs as suggested:
signal parameter no. parameter name
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DI 6 106 digital input DI 6

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AI 0 200 analog input AI 0
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AI 1 201 analog input AI 1

additional
setpoint 300 additional setpoint
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Publish the input I2 of the multiplier (block 6) by the name “scaling” with parameter number “202”.
Again compile chart “Training_1”; this time the compilation result has to read “0 errors”.
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page 30
Execution Groups
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“Do not calculate run-time group” “T = n * r21002, Free run-time group”
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@
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SITRAIN
Connect to target device:

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chart “Training_1” reads inconsistency
Download drive device “CU320_2_Drive”:
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drive device “CU320_2_Drive” is consistent again

Activate “Test mode” and compare the inputs of the “dummy blocks” to the assigned outputs:
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inputs represent the incoming status or values; outputs read “zero”.

Unlike the DCC-charts of SIMOTION, DCC-charts of SINAMICS don’t automatically become part of a run-time group;
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they have to be assigned to “Execution groups” manually:

- open menu “Set execution groups” (right mouse click on “Training_1” > Set execution groups)
- define a sampling time of 5 ms.
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Again compare the inputs of the “dummy blocks” to the assigned outputs:
now both, inputs and outputs read the same status or values.
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page 32
Structure of the Parameter Number
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@
DCC par. no. + offset 21 500 = expert list par. no. 0300 + 21 500 = 21 800
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SITRAIN
Test the entire function of chart “Training_1” in “Test mode”.

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Open menu “speed setpoint”, set the scaling for the “Main setpoint” to “0 %” and for “Additional setpoint” to “100 %”.
You can observe following:
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- the additional setpoint reads 1 500 rpm for a value of 10 V at the analog input AI 1
tm
- the “Additional setpoint” is connected to parameter r21800

Open the expert list of object VECTOR and scroll to its end:
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parameters p21602 to r21800 are listed with the very names you had assigned when publishing
block inputs and outputs
the parameter numbers are offset by 21 500 versus your entries in DCC.
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Since the multiplier input (block 6) has also been published, its “scaling value” can both be set by parameter p21702
and within the chart.
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Set the speed via analog input to i.e. 750 rpm and compare the “input to block 6”, the “output of block 6”, the “scaling
value” and the “speed setpoint, r60” with each other:
all four readings are logical in their relation to each other
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(DCC setpoint at input = 0.5 / scaling = 1.0 / DCC setpoint at output = 0.5 / speed setpoint = 750 rpm)
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Change the “scaling” in p21702 to 0.1:

the speed drops to 75 rpm as was expected functionally by changing the “scaling”
Again compare the “input to block 6”, the “output of block 6”, the “scaling value” and the “speed setpoint, r60” with
v
each other:
ta
the scaling as shown on the block input still reads “1.0”, but the output reads only 10 % of the input
s
(DCC setpoint at input = 0.5 / scaling = 1.0 / DCC setpoint at output = 0.05 / speed setpoint = 75 rpm)
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Changes of values of “published parameters” made in the expert list take effect BUT the new value is NOT
transferred to the offline value of the DCC-chart!
page 34
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Communication
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with
@
ETHERNET
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SITRAIN
Ethernet page 01 © Siemens AG 2011 - all rights reserved
List of Contents m
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Checking the Active PG/PC-Connection in NetPro …......................................................... 3
Setting the IP-Address on the PG/PC ……………………………………………................... 5
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Testing the Ethernet-Connection via ”Ping” ….................................................................... 7

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Assigning an Ethernet Subnet …......................................................................................... 9

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NetPro View of Subnets ”PROFIBUS” and ”Ethernet” ….................................................... 11

Assigning ”Ethernet” as Active Communication Link …...................................................... 13
Connecting SIMOTION D445 to Ethernet in NetPro …....................................................... 17
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Searching the IP-Address of SIMOTION D445 …............................................................... 19

Using the Project IP-Address of SIMOTION D445 ….......................................................... 21
Online Access to SIMOTION D445 via IT-DIAG (without SCOUT) …................................. 23
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page 02
Checking the Active PG/PC-Connection in NetPro
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In addition to the two PROFIBUS terminals, component SIMOTION D445 also offers two Ethernet terminals IE1 and IE2.
As per factory default following IP-addresses are assigned to these two Ethernet terminals:
- upper socket, IE1/OP 192.168.214.1 - lower socket, IE2/NET 169.254.11.22
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An Ethernet port is defined by its IP-address, by a Subnet mask and (if networked) by the definition of a Standard Gateway.
The definition of the Subnet mask depends on the application class; Subnet mask and IP-address are related as standard.
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For drive applications any Subnet mask can be used with any IP-address.
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Class Subnet mask no. of networks no. of hosts IP-address range network / host bits
A 255.0.0.0 126 16 777 214 1 to 126 7 / 24
B 255.255.0.0 16 384 65 534 128 to 191 14 / 16
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C 255.255.255.0 2 097 152 254 192 to 223 21 / 8
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SITRAIN
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7 Communication with ETHERNET
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7.1 Setting up a communication link “PG/PC D445” via ETHERNET

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Presently the communication between SIMOTION D445 and PG/PC is operating via PROFIBUS. If this fact would be
t
unknown, the currently active communication link would have to be checked in NetPro.
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Open your SIMOTION SCOUT project and verify (the known fact) that the connection of the PG/PC to SIMOTION
D445 is currently activated via PROFIBUS (the active link is highlighted in yellow).
@
Identify the two “IP-addresses” for Ethernet ports IE1/OP and IE2/NET as specified in the project (NetPro) and note
down both the IP-address and Subnet mask [cursor on port IEx > (right mouse click) Object properties]:
IE1/OP IP-address .............................
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Subnet mask .............................

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IE2/NET IP-address .............................
Subnet mask .............................

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If you should not know which IP-address / Subnet mask is defined for the ports of SIMOTION D445, a “search tool” in
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SCOUT can find the assigned address data; please refer to page 19 of this section.
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page 04
Setting the IP-Address on the PG/PC
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l.c
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Start > Einstellungen > Netzwerkverbindungen Start > Settings > Control Panel > Network connections
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Start > Settings > Network connections Start > Einstellungen > Systemsteuerung > Netzwerkverbindungen
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list of available network connections General

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right mouse click

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Properties
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SITRAIN
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l.c
Define the properties of the LAN-connection as “Internetprotocol (TCP/IP)”:
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- open “Network connections” [Netzwerkverbindungen]
- mark “LAN connection” [LAN Verbindung]
tm
- right mouse click on “Properties” [Eigenschaften]

- change to tab “General” [Allgemein]
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- select “Internetprotocol (TCP/IP)”

- press button “Properties” [Eigenschaften]
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page 06
Testing the Ethernet-Connection via ”Ping”
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The IP-address of the PG/PC has to be set in
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accordance with the IP-address of the port used on
SIMOTION D445.
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The IP-address of the PG/PC has to be
tm
- identical in those octets which read “255” on the
Subnet mask and
- it has to differ in at least in one of the octets
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remaining at the end.
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The correct setup of the Ethernet-link 88

can be tested i.e. via the DOS-
emulation menu “Command Prompt“:
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Start > Programme > Zubehör >
Eingabeaufforderung
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…. >ping “IP-address“
Start > Programs > Accessories >

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Command Prompt
…. >ping “IP-address“
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SITRAIN
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Within the given rules of assigning IP-definitions matching the D445 port any IP-address can be set for the PG/PC.
l.c
Decide on an IP-address and on the Subnet mask you want to use for the PG/PC:
PG/PC IP-address .............................
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Subnet mask .............................

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An entry of a Standard gateway is unnecessary for direct communication with a drive.

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Connect the PG/PC to port IE1/OP or IE2/NET of SIMOTION D445 with an Ethernet cable.
“Ping” the IP-address of the port to verify that the Ethernet link between PG/PC and D445 is set up properly.
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page 08
Assigning an Ethernet Subnet
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SITRAIN
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l.c
In any of the projects “SL_LVxx” three communication networks are defined in NetPro:
- Drive PROFIBUS
ai
- Laptop PROFIBUS
- ETHERNET (1)
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To start “at the beginning” in setting up communication with Ethernet, delete the already existing Ethernet network
(click on the green network Ethernet (1) with the right mouse key, delete the Ethernet network).
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To set up an online-link between PG/PC and SIMOTION D445 via Ethernet, a (new) Ethernet interface has to be
added to the PG/PC, the IP-address and Subnet mask of the PG/PC have to be assigned and a new Subnet has to be
added in NetPro.
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Add a new interface of the type “Industrial Ethernet”, define the IP-address and the Subnet mask as valid for the
PG/PC and assign the name “Training” to the new Subnet.
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page 10
NetPro View of Subnets ”PROFIBUS” and ”Ethernet”
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@
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SITRAIN
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Tab “Interfaces” of menu “Properties” of the PG/PC additionally lists an Ethernet port on Subnet “Training”.
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In NetPro an “Industrial Ethernet” by the name “Training” is added and connected to the PG/PC.
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page 12
Assigning ”Ethernet” as Active Communication Link
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Interface assignment in Offline mode only
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Change over to SCOUT and “Disconnect from Target Device” (the assignment of a new interface is possible only if
none of the available interfaces are active).
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Back in NetPro, assign the (now available) Configured Interface “Ethernet port” (on Subnet “Training”) with the
tm
“Interface Parameter Assignments” of the type “TCP/IP Intel(R) 825…” to the list of “Assigned Interfaces”:
in section “Assigned Interfaces” an Ethernet port on Subnet “Training” is listed additionally.
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page 14
Assigning ”Ethernet” as Active Communication Link
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SITRAIN
Ethernet page 15
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Mark “Ethernet port(1)” in section “Assigned Interfaces” and activate the “S7ONLINE Access” via the assigned
checkmark.
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After acknowledging the “change of the PG/PC-interface” the connection from PG/PC to the Ethernet network is
highlighted in yellow; this indicates that the PG/PC is now actively connected to the Ethernet communication network
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“Training”.
The connection from SIMOTION D445 to the Ethernet communication network “Training”, however, has to be added
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as yet.
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page 16
Connecting SIMOTION D445 to Ethernet in NetPro
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IP-address via
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object properties
If the connection of the PG/PC
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Ethernet-port is “not active” (not
highlighted in yellow), communi-
cation to e.g. D445-port IE2/NET
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connect via
is possible, but routing through
“drag & drop”
SIMOTION D445 to e.g. the
PROFIBUS nodes will fail.
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SITRAIN
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Connect port IE2/NET of SIMOTION D445 to the Ethernet communication network “Training”.
(position the cursor on the green block IE2/NET / press the left mouse key and keeping it pressed shift the cursor to
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the Ethernet communication network “Training” / release the mouse key.)
the connection from SIMOTION D445 to the Ethernet communication network “Training” is added.
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To actually activate the communication link as edited in NetPro the NetPro configuration has to be “Saved and
tm
compiled”; carry out this step.

Change back to SCOUT and “Connect to Target Device”: the PG/PC has to communicate via Ethernet.
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Verify that the PG/PC is actually communicating via Ethernet by removing the PROFIBUS cable.
Looking at the navigator section in SCOUT you will notice that SIMOTION D445 indicates “data inconsistency”.
Carry out the required step to create “data consistency”:
@
.......................................
After this step, consistency is restored.
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page 18
Searching the IP-Address of SIMOTION D445
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ETHERNET subnet
@
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An identification of the IP-address of Ethernet ports of

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SIMOTION D445 as shown on this slide requires the

PG/PC to be connected to an Ethernet subnet in NetPro.
The IP-address / Subnet mask initially defined for the
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PG/PC is irrelevant.
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SITRAIN
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7.2 Searching the IP-Address of SIMOTION D445
To have the IP-address of an Ethernet port of SIMOTION D445 identified as shown on above slide, the PG/PC has to
ai
be connected to an Ethernet subnet in NetPro.

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If necessary, set up an Ethernet subnet for the PG/PC as shown on pages 9 to 12 of this section; assign any
IP-address / Subnet mask for the PG/PC (e.g. IP-address = 1.2.3.4 / Subnet mask = 255.0.0.0).
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Connect the PG/PC to the intended Ethernet port of SIMOTION D445.

Start the “search-routine” as follows:
- select “PLC > Ethernet > Edit Ethernet Node”
@
- enter the MAC-address of the Ethernet port you want to identify in menu “Edit Ethernet Node”
(the MAC-addresses of the Ethernet ports are listed on a label behind the cover flap of D445 on the lower end)
- start the search via button “Browse”
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To actually go online with SIMOTION D445, the address of the PG/PC in NetPro has to be the same as the setting of
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the “Internetprotocol (TCP/IP) for the laptop Ethernet port. Furthermore the PG/PC address has to be adapted to the
address of the SIMOTION port within the given rules.
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page 20
Using the Project IP-Address of SIMOTION D445
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via Download of NetPro by means by definition of “Internet
of an existing communication link Protocol (TCP/IP)” on PG/PC
(e.g. PROFIBUS)
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IP-address IP-address
IP “b” IP “a”
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via Download via setting
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@
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IP-address IP-address
via setting IP “b” IP “a” via setting
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7.3 Optional
Take all necessary steps to set up an Ethernet link between PG/PC and port IE1/OP of SIMOTION D445 as follows:
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- IP-address 85.12.17.53
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- Subnet mask 255.0.0.0

- network Training_1.
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page 22
Online Access to SIMOTION D445 via IT-DIAG (without SCOUT)
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Drive device messages and a selection of functions (SIMOTION, Infeed, Motor) can
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be monitored via menus “Diagnostics”, “Messages & Logs” and “Settings”.

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7.4 Online Access to SIMOTION D445 via IT-DIAG (without SCOUT)

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SIMOTION D445 features an integrated Web-function allowing communication (PG/PC SIMOTION D445) via
Ethernet without tool SCOUT.
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Such an online link with SIMOTION D445 and its assigned drive devices (“Infeed” and “Motor”) is possible with any
tm
project and operating state. To access functions and signals used in the steps to come, however, project “SM_LV1”
should be used. If in doubt about the current programming state, perform following steps to use project ”SM_LV1”:
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- close the project you are currently using, retrieve project “SM_LV1.zip” from archive and open project “SM_LV1”
- download drive device “SINAMICS_Integrated”, set SIMOTION D445 to “RUN” and test the operation:
DI 5 = on / DI 2 = on / DI 4 = on / DI0 = on ALM = on / DI 1 = on MoMo = on;
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speed setpoint via sweep generator in SIMOTION DCC.
Take a note of the two “IP-addresses” for Ethernet ports IE1/OP and IE2/NET as currently specified in the project :
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IE1/OP: IP-address = . . . . . . . . . . . . . . . . . . . . . . . . . . IE2/NET: IP-address = . . . . . . . . . . . . . . . . . . . . . . . . . .
In HW-Config, verify that “OPCXML / diagnostic pages” is activated in tab “Ethernet Extended” of “D445 object
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properties”. If you had to activate “OPCXML / diagnostic pages”, “Save and compile” and “Download” the HW-Config.
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Disconnect from target system, close the project and exit tool SCOUT.
Decide which of the two Ethernet ports you want to use and adapt the setting of the “Internetprotocol (TCP/IP) for your
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laptop Ethernet port accordingly. Wire up the Ethernet link and test the communication by “pinging” SIMOTION D445.
Access to variables of SIMOTION D445 and to parameters of the affiliated drive devices is now possible via Web
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Browser and Ethernet (direct link or via Internet).

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Connect to SIMOTION D445 by calling up the IP-address of the Ethernet port of SIMOTION D445 you are using via
“Internet Explorer”: http:// <IP-address>
Have a look at the information provided via menu “Device Info” and menu “Diagnostics”.
page 24
Operating State and Diagnostic Buffer
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RUN
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STOP
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Ethernet page 25
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Open menu “Messages & Logs” and take a note of entry “Nr. 1” in tab “Diag buffer”:
..........................................................
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Open menu “Settings” and enter “simotion” both for “Benutzername” and “Kennwort” (individual definitions for the
tm
access are part of file “WebCfg.xml” on the Compact Flash Card in directory USER > SIMOTION > HMICFG).
In “Time Settings”, set the system time to the currently valid “Day_Month_Date_Hour:Minute:Second_Year” either by
ho
direct entry or by transfer of the “PC time” via button “Transfer PC Time”; activate the setting via button “Set Time”.
Request operating state “STOP” (D445 STOP”) and change back to operating state “RUN” (D445 RUN).
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In menu “Messages & Logs” / tab “Diag buffer”, crosscheck the respective entries with the changes of the operating
state (RUN STOP RUN) you just activated; verify that “time and date” relate to your setting.
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Accessing Parameters of Drive Devices
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I/O-Variables
I/O-Variables and
and Global
Global Variables
Variables
cannot
cannot be
be accessed
accessed !!
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Ethernet page 27
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Open menu “Diagnostics”, select tab “Watch” and continue via button “OK”.
Follow the example in above screen shots and navigate to object VECTOR.
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Enter parameter number p1082 (maximum speed) and assign this parameter to the list via button “Add”.
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Supplement the list by entering following parameters:

object VECTOR p1083 positive speed limit
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r1119 speed setpoint

p1520 positive torque limit
r1526 actual torque limit
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object TM15_ALM r4022 bit 14 switch DI 2 / bit 13 switch DI 1
Save the table you have edited.

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Reading Bit-coded Parameters, Drive Faults and Alarms
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drive device / object / parameter
bit-specific values read in “decimal” notation, e.g. r4022 (digital inputs): shift position
bit r4022.13 = H
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bit r4022.14 = H 16 384 delete line

bit r4022.13 = H AND bit r4022.14 = H 24 576
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download of “New Value”
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Check the indication on r4022 for different switching states of switches DI 1 and DI 2.
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Study the consequences of setting smaller speed limits (p1082 or p1083) as regards the speed setpoint, r1119
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(the speed setpoint is generated in SIMOTION DCC).
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Note down the currently set positive torque limit: p1520 = . . . . . . . . . . Nm

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Set the torque limit to 0 Nm: the drive trips with fault.
Open menu “Messages & Logs” / tab “Alarms drive”: the fault you initiated is indicated (F7900 / motor locked).
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Crosscheck the entry in tab “Diag buffer drive”.

Set the torque limit back to its previous value.
Acknowledge the fault by changing the operating mode from RUN to STOP to RUN.
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Simulate a motor overtemperature alarm (A7910) by setting p0604 to 150C and simulate a motor overtemperature
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fault (F7011) by setting p0605 to 15 0C.

Check the entries in “Messages & Logs”, tab “Alarms drive” and tab “Diag buffer drive”; look for the entry of fault
“F7900 / motor locked” simulated previously.
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Set both temperature limits to 1000C and acknowledge the fault.

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Function “Trace” accesses SIMOTION variables of following types:

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- unit/ interface variables of SIMOTION units

- to/ system variables of SIMOTION technology objects
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- var/ system variables of SIMOTION units

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As none of these variables are used in Medium Voltage Drives, function “Trace” cannot be used for diagnosis.
page 30
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Handling
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Panel OP177
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OP177 page 01 © Siemens AG 2011 - all rights reserved
List of Contents
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Running the Project on the PG/PC ….................................................................................. 3
Communication Network as seen via “NetPro” …................................................................. 5
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Preparing the PG/PC Interface to load the OP177 via MPI ….............................................. 7
Preparing the OP177 to load Data via MPI …....................................................................... 9
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Setting the Properties of the MPI Interface …....................................................................... 11

Verifying the MPI connection between PG/PC and OP177 …............................................... 13
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Defaulting the OP177 (WinCC via SIMATIC Manager) …..................................................... 15

Defining the Communicating Partner …................................................................................ 17
Loading the Project to the OP177 (WinCC via SIMATIC Manager) ….................................. 19
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Running the Drive via OP177 …........................................................................................... 21

Assigning “Global Device Variables” as “Tags” …................................................................. 23
Defining Control Inputs and Monitoring Outputs …............................................................... 25
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Navigating between Screens via Soft-Keys …...................................................................... 29

Navigating between Screens via OP177 Hardware-Keys (F.. / K..) ….................................. 31
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Triggering Drive Functions via OP177 Hardware-Keys (F.. / K..) …...................................... 33

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Running the Project on the PG/PC
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right mouse click >
open object
deletes modifications only
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deletes the old compilation in full
left mouse click
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8 Handling the operator panel OP177
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8.1 Preparing to load the OP177 via MPI

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To gain experience in dealing with steps related to the use of the operating panel OP177, “ready to run” project
“SL_LV4” will be used.
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Open the SIMATIC Manager and delete project “SL_LV4” if it should already exist on the harddisk other than in
directory “C\Temp_Trainee\D445_CFC\0_Training” to which you have copied it one of the previous days.
Retrieve project “SL_LV4.zip” from location “C\Temp_Trainee\D445_CFC\0_Training” into the prompted directory
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(C\Programme\Siemens\Step7\S7Proj).
Select drive device “CU320_2_Drive” and open SCOUT via:
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- left mouse click on the drive device in the “navigator section” and
- right mouse click on the drive device in the “worksheet section” > Open object
In SCOUT start the routine “Save and Recompile all”. For the given project “SL_LV4”, tab “Compile/check output” has
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to read “Create procedure successful” as final line.

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Initiate the routine “Check consistency; the final message has to read “Consistency check successful”.
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page 04
Communication Network as seen via “NetPro”
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The PG/PC can be connected to the D445 via PROFIBUS or via ETHERNET. m
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Open NetPro and find out how to connect to SIMOTION D445 without changing the project definitions; take a note of
the PROFIBUS-, MPI- and ETHERNET-addresses assigned to the nodes of the hardware used (via right mouse click
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on “node connection > Object Properties):

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- D445_DP1: ......................
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- D445_DP2/MPI: ......................
- D445_IE1/OP: IP address: ...................... Subnet mask: . . . . . . . . . . . . . . . . . . . . . .
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- D445_IE2/NET IP address: ...................... Subnet mask: . . . . . . . . . . . . . . . . . . . . . .

- PG/PC_MPI: ......................
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- PG/PC_DP: ......................
- PG/PC_Ethernet: IP address: ...................... Subnet mask: . . . . . . . . . . . . . . . . . . . . . .
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- OP177_MPI/DP: ......................
- OP177_Ethernet: IP address: ...................... Subnet mask: . . . . . . . . . . . . . . . . . . . . . .
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If necessary, adapt your PG/PC connection and properties to connect to SIMOTION D445 via Profibus as defined in
NetPro of project SL_LV4, establish the online connection, download the project, change to operating mode RUN
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(all faults are acknowledged automatically via the implemented DCC-programming) and test the drive’s function:
DI 2 = off off: “remote control” via DIs and AI 1 / on: “local control” via OP177
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DI 0 = on Infeed switches on
DI 1 = on Motor Module switches on
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AI 1 defines the speed of the motor

DI 3 = on/off acknowledges faults (in operating mode RUN)
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page 06
Preparing the PG/PC Interface to load the OP177 via MPI
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Some base programming to run the drive via OP177 is provided via “OP177” within project “SL_LV4”. The OP177-
program, however, still has to be loaded from the project to the OP177.
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To load the OP177 via one of the available interfaces, the interface in question has to be assigned to the PG/PC. In
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this step of training the MPI interface will be used first. Sine the current interface assignment of the PG/PC reads
PROFIBUS, this assignment has to be changed from PROFIBUS to MPI. Since the online connection to the D445 will
no longer be maintained in this situation, disconnect the SCOUT project from the target system (go offline).
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Open NetPro, open the properties of the PG/PC, disconnect the assigned PROFIBUS interface, assign the MPI
interface and activate the assigned MPI interface (in consequence the MPI connection of the PG/PC must be
highlighted in yellow).
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As the change of assignment in NetPro will become effective only after NetPro has been “Saved and Compiled”, carry
out this routine. Close message “no errors” and exit program NetPro by “Network > Exit”.
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Back in SCOUT, verify that the PG/PC is defined the “only master on the bus” (via “Options > Set PG/PC interface >
Properties”).
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page 08
Preparing the OP177 to load Data via MPI
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temporary for 5 s after “power on”
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The selection of the type of interface, the interface settings and the preparation of a data transfer are done in the
menu “Transfer” of the OP177.
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Connect the OP177 to the PG/PC using the available Profibus cable. Connect the separate 24 VDC power supply to
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the OP177 and switch the 24 VDC on (MCB to the right of component TM31).
After the OP177 has been powered up, the “Loader” is displayed for a few seconds and then the defined faceplate
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opens up. Use softbutton “Control Panel” (possibly via “master screen”) to access menu “Control Panel” of the OP177.
Scroll down to menu “Transfer” and double-click on it.
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page 10
Setting the Properties of the MPI Interface
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“click”
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In menu “Transfer Settings” select “MPI/Profibus” for Channel 2 and tick on “Enable Channel” and “Remote Control”
(checkmarks are inserted).
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Call up the “Advanced” settings, select MPI and set the “Properties” as follows:
- panel is the only master on the bus
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- address as defined in NetPro: . . . . . . . .

- time out: 10s
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- baudrate: 187.5 kBaud

- highest station address: 31
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page 12
Verifying the MPI connection between PG/PC and OP177
displayed for 10 s
after
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24 VDC = ON
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Close all windows with OK until the “Control Panel” reappears. Switch off the 24 VDC supply to the OP177 via mcb on
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the right hand side of component TM31, switch it back on again and push softbutton “Transfer” within 5 s after menu
“Loader” pops up.
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Message “Connecting to host” appears, the OP177 is ready for the data download and waits for the data transfer from
the project on PG/PC.
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Test the MPI connection between PG/PC and OP177 using menu “Options > Set PG/PC Interface > Diagnostics”
either in program “SIMATIC Manager” or in program “SCOUT”.
Verify that the nodes as specified in NetPro read “Station active”.
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Defaulting the OP177 (WinCC via SIMATIC Manager)
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“Defaulting” the OP177 has to be carried out using the tool “WinCC flexible”.
In the “navigator-section” of the SIMATIC Manager, doubleclick on “OP177” and then use a right mouse click on
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“WinCC flexible RT > Open Object” to start “WinCC flexible”.

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Before starting the Default routine the station address has to be set. Select “Project > Transfer > Transfer …”, assign
“Mode = MPI/DP”, select “Overwrite user administration” and “Overwrite recipe data records”, assign the MPI node
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number of the OP177 and activate this setting via button “Apply”.
Select “Project > Transfer > OS Update” and start the Default routine via button “Update OS” in the pop-up menu.
After completion of the Default a “power on reset” has to be executed on the OP177 (use the mcb next to TM31):
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the screen indicates “Bootloader, Version, Date …” and automatically changes to “Transfer > Connecting to host”.
Close menu “OS Update”.
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page 16
Defining the Communicating Partner
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Supplement and adapt the ETHERNET communication scheme in NetPro to link the systems mentioned below via
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Ethernet and assign suitable IP-addresses:
- SIMOTION D445, port IE1/OP new IP-address ............................
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- OP177, port HMI/IE new IP-address ............................

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- PG/PC, Ethernet port new IP-address ............................

“Save and Compile” NetPro and download SIMOTION D445.
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The link between OP177 and SIMOTION D445 uses “Global Device Variables” defined in SIMOTION D445 and
assigned to OP177 “panel functions” via “Tags”. These Tags are related to a “Connection” which is to be assigned to
a communicating “Partner” (here: D445) and its node to be used (here: port IE1/OP).
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To be ready for the communication “D445 OP177” via D445-port “IE1/OP”, change to WinCC flexible, open menu
“Communication > Connections”, assign “SIMOTION D445, port IE1/OP” and save the project (Project > Save).
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page 18
Loading the Project to the OP177 (WinCC via SIMATIC Manager)
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8.2 Loading the OP177 via ETHERNET
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Physically connect the PG/PC to the OP177 via Ethernet and assign “TCP/IP Intel(R)82566…, IP-address as set in
NetPro” to the Ethernet port of the PG/PC.
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Adapt the “Transfer Settings” on the OP177 (access via “Control Panel > Transfer Settings”) to enable the
communication with the PG/PC via ETHERNET; when finished, set the OP177 to state “Transfer > Connecting to
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host”.
Test the Ethernet communication between PG/PC and OP177 by “pinging” the OP177.
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In WinCC flexible, select “Project > Transfer > Transfer …”, define “Mode = ETHERNET” and the IP-Address of
the OP177.
Select “Overwrite user administration” and “Overwrite recipe data records” and start the transfer with the assigned
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button.
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page 20
Running the Drive via OP177
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Connect the Ethernet cable (D445, IE1/OP OP177) and the Profibus cable (PG/PC D445, DP1).
Take all necessary steps to establish an online connection
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- between PG/PC and D445 via Profibus and
- between D445 and OP177 via Ethernet
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(if successful, the feedback value “actual speed” reads “0” instead of “####”)
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Select “local control” via OP177 (switch DI 2 = on) and test the operation of the drive via OP177:
- infeed = on ALM is switched on
- motor = on motor is switched on
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- speed command via keypad motor runs at set speed, the “actual speed” is indicated
On closer analysis you will notice that the motor runs at only 50% of the speed command value. Find the reason
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for this behavior and adapt the “wrong setting” to make the motor speed match the command speed:
...........................................................
- switch off the infeed (keep the motor switched on)
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the drive trips with fault “Drive Infeed operation withdrawn”

- acknowledge the fault via OP177, softkey “acknowledge”.
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page 22
Assigning “Global Device Variables” as “Tags”
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8.3 Engineering a basic OP177-program

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Stop your drive and disconnect from target system to continue by engineering a basic OP177 program of your own.
Up to now you have controlled the drive via OP177, screen 1 as part of a “ready to run” project. In the next step you
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will engineer similar faceplates and all related signal connections to run the drive via OP177, screens 2 and 3.
Define following “Global Device Variables” (additionally to the already existing) to carry out the data exchange
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between SIMOTION D445 and OP177:

almon BOOL Init = False
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motoron BOOL Init = False

speedset REAL Init = 0.0
speedact REAL Init = 0.0
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Save and compile the project.

As next step define the same (additional) variables for the OP177 as follows:
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- OP177 > WinCCflexibleRT > Communication > Tags

- right mouse click on “Tags” > Open object
menu “Tags” opens up, already defined Tags are listed
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- click on the left column of the next available line to highlight this line
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- select “Add Tag” (via right mouse click), write “almon” as name and scroll to “almon” in column “Symbol”
(project > SL_LV4_SIMOTION D > D445 > GLOBAL > almon) and click on the checkmark to activate
your assignment.
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- in the bottom section, change the “Acquisition Cycle” to 500 ms.

Follow the same approach to define variables “motoron”, “speedset” and “speedact” as Tags.
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page 24
Defining Control Inputs and Monitoring Outputs
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1 2
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These Tags will now be related to “inputs” and “outputs” defined on screens 2 and 3 of the OP177
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(e.g. to switches, input keypad, feedback message frames etc.).
Open “screen 2” as prepared in your project and insert the following by means of “drag” and “drop” (“pick” & “paste”):
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1) “switch”
- with name INFEED via menu “Switch_1” at bottom; “Label = INFEED”
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- Tag = almon
- background color = yellow via “Property > Appearance”
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2) “switch with text” via menu “Switch_2”; “Type = Switch with text”
- reading “motor is OFF” in “OFF-state”, green color via “General > Text”, “Properties > Backgroundcolor =
- reading “motor is ON” in “ON-state”, red color green”, “Animations > Appearance > Tag = motoron >
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- Tag = motoron Value = 1 > Backgroundcolor = red, Type = Bit”

The programming of above definitions requires several submenus. Call up the online help via Tool Tip Text
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and click on the info-block to read the information.

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Defining Control Inputs and Monitoring Outputs
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OP177 page 27
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Open “screen 3” as prepared and insert an I/O-filed for the speed setpoint with following properties:
- IO Field of the type “input” with blue background
- Tag = speedset
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- decimal “5 digit integer” (reading the value in rpm)

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- name = speed setpoint
To read the actual speed, add a horizontal bar by the name “actual speed” with a range from -1500 rpm to +1500 rpm
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and a spacing of 100 rpm.
Save the current WinCCflexible project and transfer it to the OP177.

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To access menu “Transfer” on the OP177 you can switch the 24 VDC supply off and on or you can restart the OP177
via “Control Panel > OP > Device > Reboot”.
Test the OP177 functions you have engineered.
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Modify chart DCC_1 to run the drive via OP177 with screens 2 and 3 you have engineered instead of using screen 1.
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Test the operation using the OP177 screens you have engineered.
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Navigating between Screens via Soft-Keys
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OP177 page 29
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To operate the drive with your OP177-programming you have to navigate via soft-keys:
- to start and stop Infeed and Motor via “master screen” to “screen 2” and
- to set and monitor the speed value via “master screen” to “screen 3”.
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Supplement your programming to access “screen 3” (values) additionally via a yellow “Button” in “screen 2” by name
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“values” (via “General > Text off = values, Properties > Background color = yellow, Events > Screens >
ActivateScreen > Screen_2”).
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Add another yellow “Button” in “screen 3” by name “commands” to select “screen 2” (commands).
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page 30
Navigating between Screens via OP177 Hardware-Keys (F.. / K..)
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in Template
functional assignments of Hardware-keys valid
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for all screens have to be made in “Template”
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assignment of hardware-keys for individual screens is then blocked in all other screens
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Assign hardware-key F2 to call up “screen 3” out of any screen you are using and assign hardware-key F1 to call up
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“screen 2” out of any screen you are using:
- screen “Template” (assignments in screen “Template” are valid out of any screen unless exempted individually)
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- button “F1”
- in menu “Softkey-F1” continue with “Events > Press”
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- assign function “Screens > ActivateScreen”

- select “Screen_2”
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Verify that menu “Softkey-F1” reads the following in any screen other than in screen “Template”:
- via “Events > Press” “Activate Screen_2”
- via “General” “Use global assignment”
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(if checkmark “Use global assignment” is removed, the assigned button F1 has no
function out of this particular screen)
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Save the current WinCCflexible project, transfer it to the OP177 and test the OP177 functions you have engineered.
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page 32
Triggering Drive Functions via OP177 Hardware-Keys (F.. / K..)
definitions / assignment in DCC
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definitions on OP177
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in Template
if to be valid
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for all screens

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Assign hardware-key K18 (out of any screen you are using) to acknowledge fault messages on SIMOTION D445
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additionally to soft-key “acknowledge” provided in “screen 1”:
1) Steps in SCOUT_DCC
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- open “View > Chart Input/Output” for chart “DCC_1”

- assign variable “killfault”, type BOOL for “Interface > OUT”
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- compile “DCC_1” (ignore the warning message)

- in chart “DCC_1 / A1” connect variable “killfault” to the already existing variable “ack_dump” via the OR-gate
- again compile “DCC_1” (warning message “output … DCC_1<killfault> is not connected …”is irrelevant as
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the connection will be provided via “OP177 hardware-key K18).

2) Steps in WinCC flexible
- supplement menu “Communication > Tags” with a Tag by the name “killfault” and “Symbol = killfault”
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- screen “Template”
- button “K18”
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- in menu “Softkey-K18” continue with “Events > Press”

- assign function “Edit bits > SetBitWhileKeyPressed”
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- select “DCC_1.killfault”
Carry out all steps required to have above programming implemented; test the function by creating a fault (e.g. switch
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the Infeed off while the Motor is still in on-state).

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this programming is also available by project “SL_LV4F.zip”
page 34
Automation and Drives
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Personal Safety
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with
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Medium Voltage Drives
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Personal Safety page 1 © Siemens Industry 2012 - subject to modification
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Table of Contents
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Content Page
Safety Precautions ..................................................................................................................... 3
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Electric Shock Hazards ............................................................................................................. 5

Arc Flash Hazards .................................................................................................................... 6
Areas and Boundaries ............................................................................................................... 7
PPE – Levels ............................................................................................................................. 9
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PPE – Personnel Protective Equipment ...................................................................................... 10

Verifying the De-Energized Condition.......................................................................................... 12
Personnel Safety in Switching Operations................................................................................... 14
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Components carrying Medium Voltage ( > 1000 V )..................................................................... 15

Components carrying Low Voltage ( < 1000 V )........................................................................... 16
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Medium Voltage Circuit Breaker (at Input of VFD)....................................................................... 17

Grounding the VFD and its Environment..................................................................................... 20
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External Main Power Verification................................................................................................. 21

One Source of Isolation for the Medium Voltage.......................................................................... 22
Two Sources of Isolation for the Medium Voltage........................................................................ 23
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Isolating the Output (e.g. for Motors with long Lead Length)........................................................ 24
Isolating the Output (Motor with Bypass Capability)..................................................................... 25
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Isolating the Output (Motor with Parallel Drives).......................................................................... 26

Parallel Drives on Synchronous Motor with Exciter...................................................................... 27
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External Main Power Verification.................................................................................................. 28

General Safety Precautions......................................................................................................... 29
Mechanical Key Interlock (Standard)........................................................................................... 30
Mechanical Key Interlock (System “Areva”)................................................................................. 31
Electromechanical Interlock......................................................................................................... 32

Safety Precautions
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Numerous exposed connections present lethal voltages.
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Only qualified individuals should install, operate,
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troubleshoot and maintain the drive.
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Verify that all power is off before you work on the
equipment.
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Never touch anything within the drive cabinets
until verifying that it is neither thermally hot nor
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electrically alive.

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Never assume that by switching off the circuit
breakers all of the voltage is removed from inside
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the cabinet.
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Voltage is still present on the terminals of the input

www.safetysign.com
circuit breaker.
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There may be voltages present that are applied from other external sources.
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Safety Precautions
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Always follow proper lock-out / tag-out procedures (lock-out / try-out)

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before beginning any maintenance or troubleshooting work on the drive.

According to local regulations, an “Energized Work Permit” may be required.
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Work with one hand, turn away, keep a distance.

Wear insulated or rubber safety shoes.
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Wear safety glasses and hearing protection.

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Use appropriate equipment for checking low voltage, medium voltage

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www.safetysign.com

Electric Shock Hazards
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Voltages may drive a current through your body.
Depending on its amplitude, there may be various effects.
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Arc Flash Hazards
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Released arc flash energy causes following hazards to health or life:

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Thermal
Arc flash temperatures can reach 20.000°C (35.000°F ); the surface of the
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sun is 5000°C (9000°F); skin cell destruction after 1s at 70°C (or 158 °F);
incurable burns will occur after 0.1s at 96 °C (205 °F) for > 1.2 cal/cm 2.
according to NFPA 70E: ArcFlashBoundaryDistance = (2.6 x MVAbf x t)1/2
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e.g. 4MVA transformer at 5% uK ( 80MVAbf) and 0.2s: ArcFlashBoundaryDistance = 2 m (for <1.2 cal/cm2)
The emitted light is very intense and will damage the retina of the
unprotected eye, often permanently.
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Pressure
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Pressure wave up to 14.400 Pa (300lb/ft2) may cause appr. 227kg

(500lbs) thrust onto exposed body surface.
e.g. a 3 phase 20kA short circuit at 100V arc voltage for 0.2sec is equal to about 0.3kg TNT.
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Auditory
Pressure levels can exceed 160dB; a gun blast is only 140dB or 200Pa,
e.g. only 1/10 of that pressure level. Irreversible damage to the ear will
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occur at 120dB or more, which is only 1/100 of that level.
Projectile
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Molten metal and broken parts will be ejected at high speed resulting in
severe burns and cuts.
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Inhalation “Large arc flashes are rare (5-10 per day in the US);
when they happen, they are life-changing events.“
Extremely hot air, molten metal and/or vaporized metal, as well as burning Jim White, Shermco Industries Inc., in: Plant Engineering, April 2010
insulation smoke and fumes will damage lungs and respiratory tract.

Areas and Boundaries
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Boundaries from NFPA70E

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NFPA 70E 2012 Table 130.4(C)(a) shows

approach boundaries for various voltage levels.
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PPE Levels (Personal Protection Equipment)
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Hazard/ Clothing Description Required Minimum
Risk (Typical number of clothing layers in Arc Rating of PPE
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Category parentheses) [J/cm2 (cal/cm2)]
Non-melting, flammable materials
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(i.e. untreated cotton, wool, rayon, silk or
0 N/A
blends of these materials) with a fabric
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weight of at least 4.5 oz/yd2
Arc Rated FR Shirt and FR pants or FR
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1 16.74 (4)
Coverall
Arc rated FR shirt and FR pants or FR
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2 33.47 (8)
Coverall

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3 104.6 (25)
Coverall and Arc Flash Suit
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4 167.36 (40)
Coverall and Arc Flash Suit
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NFPA 70E 2012, table 130.7(C)(16)

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PPE – Personnel Protective Equipment Protective Clothing
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Protective Clothing (Flash Suit Cat. 4, 168J/cm2 or 40cal/cm2 *)

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pants
* Incident energy at 1/10 of a second
jacket causing 2nd-degree burn to bare skin
underneath the PPE. Wear layers of
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other cotton clothing underneath PPE

Flash Hood to reduce heat onto skin (but note that
this does not increase the arc flash
Safety Glasses rating of the PPE).
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Hearing Protection
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Safety Shoes
steel toed, leather upper
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Electrical Hazard (EH shoes)

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Rubber Gloves
class 2 / up to 17,500 VAC
leather gloves as “second layer”

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to protect the rubber gloves

DANGER
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don’t wear rings, watches etc.

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”70% of people who survive a major arc flash event

have to receive long term counseling, almost 60%
of those same people will have failed marriages.“
Jim White, Shermco Industries Inc., in: Plant Engineering, April 2010

PPE – Personnel Protective Equipment Voltage Detector
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Preferably use a type with
“narrow tip” to check the
voltage on individual cable.
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typical medium
voltage cable:
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conductor (Al, Cu)
conductive layer (XLPE) devices shown operate ”capacitive“
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insulation (XLPE)
conductive layer The Voltage detector is used to verify that no voltage

(XLPE) is present on cables, terminals etc. (operating either
88
“on contact” or “capacitive”).
sheath
(Al, Cu)
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Voltage levels to check may be
protection Low Voltage
Medium Voltage.
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XLPE:
cross linked Checking for medium voltage with a “capacitive” device,
low density
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use the “LV-setting” on the probe first to identify voltage

polyethylene
even from some distance.
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Verifying the De-Energized Condition Voltage Detector
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”on contact“
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devices shown operate ”on contact“

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test probe shown:

KP Test 5
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1kV to 36kV, from 10% to 110% of rated voltage at 50Hz

acc. to EN50110-1, IEC61243-1:2003 and IEC61243-1:2005
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Manufacturer:
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Pfisterer Kontaktsysteme GmbH & Co KG

Rosenstraße 44
73650 Winterbach/Germany
www.pfisterer.de

Verifying the De-Energized Condition Voltage Measurement
Depending on local regulations the de-energized
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condition might be allowed to be tested by
capacitive voltage detection devices (Tic Tracer)
or the use of a
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device working “on contact”
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might be mandatory.
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YOU can do better:
• stand on the side of the door (not in front)
• use one hand only to hold the probe
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test probe shown:
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DSP3 HS5 or DSP3 HS11
Manufacturer: Rudolf Tietzsch

Willringhauser Straße 18
85256 Ennepetal/Germany
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www.tietzsch.de
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Basic rules for handling Voltage Detectors

- the Voltage Detector has to be selected for or set to the rated voltage to be checked
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- the function of the Voltage Detector has to be checked on voltage before verifying the de-energized state
- the de-energized condition has to be checked on all three phases
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- if possible, again check the function of the Voltage Detector on voltage

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Personnel Safety in Switching Operations
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“Disconnect”
(typically
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no load isolator)
“Circuit Breaker”
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(switches under load)
Any time you switch on the VFD or a Circuit Breaker a potential risk of malfunction is given.
For maximum safety, stand on the side and turn your head away.
(This precaution is strongly recommended when switching the device for the first time or after major repair work.)

Components carrying Medium Voltage ( > 1000 V )
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Medium Voltage / voltage from the input line: 2.2 kVAC – 33.000 kVAC
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Medium Voltage may be present at e.g.: input-, output terminals, cell connections, bus bars, transformer connections.
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Components carrying Low Voltage ( < 1000 V )
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Low Voltage
control power: 120, 240, 480, 575 VAC (230, 400 VAC)
customer input control: 120, 230 VAC / 24 VAC, VDC / 0-10 VDC / 4-20 mA
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Hazardous Low Voltage (> 50 V) may be present at e.g.: contactors, miniature circuit breakers, power supplies,
terminals, transformers, control boards. Keep in mind to follow appropriate safety rules in Low Voltage circuits as well.

Medium Voltage Circuit Breaker (at Input of VFD)
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HV circuit breaker MV circuit breaker
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PH M
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Hands OFF, other
Customer only ! load
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Schematic of a Circuit Breaker Example of a Circuit Breaker

(racked out test position) (racked in operating position)
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Medium Voltage Circuit Breaker

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1
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1
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2 3
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2
4
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Stationary section Movable section (rear view) Movable section (front view)
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(1) connection to common MV bus bar (1) to common MV bus bar (3) optional fuses
(2) connection to feeder (e.g.: VFD) (2) to feeder (e.g.: VFD) (4) vacuum contactors

Medium Voltage Circuit Breaker
Access to rack the Circuit Breaker in or out without opening the
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front door of the Circuit Breaker compartment (with metering and
protection devices)
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Movable section of Circuit Breaker (shown in operating position;
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test position is given with the Circuit Breaker racked out to front)
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Grounding the VFD and its Environment
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HV circuit breaker MV circuit breaker
PH M
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Hands OFF, other

Customer only ! load
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Transformer Control Room

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VFD M
(HV MV)
Power Input,
Circuit Breaker
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Earth Ground Earth Ground

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Correct grounding of the VFD has to be verified.

The grounding is required for reasons of safety and to ensure correct operation of filtering and protection devices.

External Main Power Verification
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Any work at the Medium Voltage sections of the VFD must be started only
after verification of the de-energized state of the external main power.
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This rule applies both for the input power and for the motor connection.
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The steps required and the sequence to follow depend on site conditions and
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on the configuration of the VFD.
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A choice of typical arrangements will be explained in the following in detail.
In general, the Five Safety Rules apply any time and have to be observed.
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- Switch off the power supply on all poles
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- Verify the de-energized condition
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- Ensure against unauthorized re-energizing (lock-out, tag-out)
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- Ground and short circuit the power terminals on all poles

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- Cover or fence off adjacent live components

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One Source of Isolation for the Medium Voltage

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Step 1 Step 1 - the Vacuum Contactor must be

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Vacuum location (room)

in the de-energized state;
Contactor other than VFD
Step 2 this is the dropped out position.
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Step 2 - the Vacuum Contactor should then

be racked out (with door closed)
and locked in that position.
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Step 3 Step 3 - verify that no power is present

at the VFD
88
Step 4 using an appropriate voltage tester, which

has been tested for functionality itself.
VFD
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Step 4 - install grounding cables.

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GND
GND
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Two Sources of Isolation for the Medium Voltage
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Step 1 - open Vacuum Contactor
Step 1
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Vacuum location (room)
Contactor other than VFD Step 2 - rack out the Vacuum Contactor and
Step 2
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install lock on Vacuum Contactor
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Step 3 - open Disconnect
+ through the viewing glass, verify
that contacts are open
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Step 3
+ open the door and verify
viewing glass that no power is on the output
using an appropriate voltage tester, which
Disconnect
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+ install lock on Disconnect
88 Step 4 - verify that no power is present

Step 4
at the VFD
VFD using an appropriate voltage tester, which
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Step 5 - for additional safety,

install grounding cables
Vacuum Contactor: - manual operation or
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- remote control
Disconnect: - manual operation only
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Isolating the Output (e.g. for Motors with long Lead Length)
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As general rule the input has to be isolated and

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grounded as per information on pages 18 or 19!

VFD VFD
Step 1a.1 - the Vacuum Contactor has to be
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in the de-energized state;

Step 2 Step 3 this is the dropped out position.
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Step 3
Step 1a.2 - rack out the Vacuum Contactor
and lock it in that position.
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Step 1a.1 Step 1b - open Disconnect, verify that contacts

Step 1a.2 Step 1b are open and lock it in that position
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either or
(most have grounding connections)
Vacuum viewing glass
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Contactor Step 2 - verify that no power is present

Disconnect
at the VFD motor terminals
using an appropriate voltage tester, which
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Step 3 - install grounding cables at VFD

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terminals T1, T2, T3 to ground.

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Vacuum Contactor: - manual operation or

Motor Motor - remote control
Disconnect: - manual operation only

Isolating the Output (Motor with Bypass Capability)
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VFD
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Step 1 - the Vacuum Contactor of the VFD
must be in the de-energized state;
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this is the dropped out position.
Step 4 Step 3 Step 2 - rack out the Vacuum Contactor of
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the VFD and lock it in that position.
Step 3 - verify that no power is present
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Step 1 VFD Bypass
at the VFD.
Step 2 Vacuum Vacuum using an appropriate voltage tester, which
Contactor Contactor has been tested for functionality itself.
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Step 4 - install grounding cables at VFD
terminals T1, T2, T3 to ground.
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Motor
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Isolating the Output (Motor with Parallel Drives)

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VFD 1 VFD 2 Step 1 - the Vacuum Contactors of both VFDs

must be in the de-energized state;
this is the dropped out position.
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Step 3
Step 4 Step 2 - rack out both Vacuum Contactors
and lock them in that position.
88
Step 3 - verify that no power is present

VFD 1 Step 1 VFD 2
at the output of either of the VFDs.
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Vacuum Step 2 Vacuum using an appropriate voltage tester, which

Contactor Contactor has been tested for functionality itself.
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Step 4 - install grounding cables at both VFDs

on terminals T1, T2, T3 to ground.
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Motor

Parallel Drives on Synchronous Motor with Exciter
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Power Grid 33.000 kV As general rule the input has to be isolated and
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In this application the common field
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supply is provided by connecting the
Exciter 1 VFD 1 VFD 2 Exciter 2 exciters in parallel with each other.
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If even only one exciter contactor is
AC or DC
AC or DC
closed, power is present on the
Step Step Step Step output of each contactor.
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5–8 1–4 1–4 5–8
To isolate both the stator terminals
VFD 1 (fed via VFDs) and the rotor
Exciter 1 VFD 2 Exciter 2 terminals (fed via exciters) of the
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Contactor Vacuum Vacuum Contactor motor, proceed as follows:
Contactor Contactor
step 1 to 4
88 isolate both VFDs as shown on the

previous slide
step 5 to 8
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isolate both exciter cabinets
(switch off, lock out/tag out, verify
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power is off, ground)
Motor Field Supply

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External Main Power Verification

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Medium Voltage
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Power has been removed on the input and isolated state has been verified
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Wait 10 minutes for the system to discharge capacitors

If a cell is to be handled
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verify that no input voltage is present on the cells

(various cell AC input voltages: 480, 630, 690, 750,1375, 600; measure phase-to-phase only)
verify that no voltage is present on the bus capacitors
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(DC voltages as high as AC voltage x 1.413 can exist: 678, 890, 974, 1060, 1943, 930)
Control Voltage (two sources)

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Verify that the voltmeter operates before shutting the control power off
Shut the control power (“disconnect”) off
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Verify that power has been removed on all three phases on bottom side of “disconnect”
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Shut the power off upstream of the drive

Verify that power has been removed on all three phases on top side of “disconnect”
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Lock out and tag out both sources (in the drive / upstream of the drive)
Customer Input Control

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Before removing or replacing boards

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shut off the customer control input power to the boards

verify that power has been removed and is secure
Be cautious not to short input wires to the control boards

General Safety Precautions
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Always turn the control power on before the medium voltage is applied!
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Always turn the medium voltage off before shutting off the control power!
Never shut off the blower power and leave the main power on. This may cause the drive to
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overheat and cause severe damage to the system.
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Never run the drive with cabinet doors open. This reduces cooling to the drive.
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Never connect or disconnect any meters, wiring or printed circuit boards while the drive
is energized.
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Never store flammable material in, on or near the drive enclosure. This includes equipment
drawings and manuals.

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Always be aware of electrostatic discharge (ESD) when working near or touching
components inside Drives.
(printed circuit boards contain components that are sensitive to static electricity.)
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Mechanical Key Interlock (Standard)

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INPUT MV POWER
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KT 2
K2 K1 INPUT CIRCUIT BREAKER

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K2
L
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K2
Step 1 - de-energize the Medium Voltage

K2
Step 2 - remove K1
88
K1 Step 3 - insert K1 into KT2 assembly block

Step 4 - remove K2 keys and open cabinets
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to be worked on
K2
Step 5 - verify in each cabinet that no voltage
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DOOR INPUT SECTION 2

is present (AC or DC voltages)
K2
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DOOR INPUT SECTION 3D KT 2 assembly block
K2 K2 K2 K2 K1
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DOOR BYPASS SECTION 4B

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K2
DOOR BYPASS SECTION 4D

Mechanical Key Interlock (System “Areva”)
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Step 2 Step 4
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Step 7
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(3)
K2 K1
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(1) K2
Step 5
K2 Step 6
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K2
K1
Step 1 Step 3
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33 kV VFD
switchgear Pre-charge Circuit Breaker (2)
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Step 1 - disengage the 33 kV switchgear

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Step 2 - take out the key (1) and insert it into the Areva key retention
Step 3 - disengage the vacuum contactor
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Step 4 - take out the key (2) and insert it into the grounding assembly
Step 5 - engage the grounding system
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Step 6 - take out the key (3) and insert it into the Areva key retention
Step 7 - take out key K1 and insert it into the VFD KT2 assembly block
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Step 8 - remove K2 keys and open VFD cabinets to be worked on

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Electromechanical Interlock
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3
2
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1
2 3
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(1) “Dummy-Screw” to access the

Bolt of the Solenoid 4
(2) Interlocking Solenoid
8
(3) Cabinet Door Switch

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(4) Control Section Door Switch

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Door interlocking MUST NEVER be bypassed

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with Medium Voltage switched on (C. B. = ON).
Perfect Harmony Drives manufactured in Nuernberg / Germany

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feature an electromechanical interlocking as a standard.

To open any cabinet door of a Medium Voltage section, the
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assigned solenoid (2) has to release the door mechanism by

being energized. The solenoid is energized with control voltage
1
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available and the feedback signal “Circuit Breaker Open”.

If a door should be opened by force, the assigned cabinet door
switch (3) trips the Circuit Breaker.

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Commissioning
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Common Functions
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SITRAIN
Comm_Common page 01 © Siemens AG 2013 - all rights reserved
List of Contents
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1.1 Required Software-Tools …........................................................................................ 6
1.2 Drive Firmware …....................................................................................................... 8
1.3 Structure and contrent of the CF card …..................................................................... 10
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1.4 Getting the PG/PC Installation ready to handle the SL150-project …........................ 12
1.5 Getting the Project ready for the download to the D445-CF card …........................... 16
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1.6 Downloading the Project …......................................................................................... 18

1.7 Exemplary SL150 Application …................................................................................ 20
2.2 Checking the “Communication Network” in “HW-Config” …....................................... 24
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2.3 Rebooting the Controllers …....................................................................................... 26

2.4 Checking the “Communication Network” in “NetPro” ….............................................. 28
2.5 Setting the IP-Address on the PG/PC …..................................................................... 30
2.6 Assigning the PG/PC to ETHERNET in NetPro …...................................................... 32
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2.7 Going Online to D445 and Downloading the Drive Devices ….................................... 34
2.8 Adapting the Hardware Setup ….................................................................................. 36
2.9 Defaulting the DC-Master and setting the Node-Address via PMU …..................... 42
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2.10 Going Online and Downloading the Project Data via Drive Monitor …....................... 42
2.11 Adapting Parameters to particular Plant Conditions …............................................... 50
2.12 Loading the OP177 …................................................................................................. 54
2.13 General Content and Structure of the DCC-charts …................................................. 60
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2.14 Assigning the “Code” to activate DCC-charts …......................................................... 62

2.15 Clearing faults and alarms on behalf of the DC-Master ….......................................... 72
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2.16 Clearing faults and alarms (on behalf of the ET200 stations) …................................. 78
2.17 Forcing a control command via ET200 …................................................................... 86
2.19 Adding field messages to the fault monitoring …........................................................ 98
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2.20 Fault evaluation via N.O., N.C. / Signaling delay / Mode of acknowledging …....... 102
2.21 Defining properties for the ET200 analog modules …................................................ 106
ta
2.22 Controlling the drive’s operation via OP177 …............................................................ 108

2.23 Verifying Essential Settings on the Excitation Unit (DC-Master) …............................ 110
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2.24 Deleting Faults in the ”message buffer” …................................................................. 112

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2.25 Energizing the DC-Master …...................................................................................... 116

2.26 Measuring the Exciter Current …................................................................................ 126
2.27 Substituting the “Automation” via “DCC-Chart, LCOMRG” …................................... 128
2.28 Automatic Optimization and Identification of Current Loop Data (in the DC-Master) 134
2.29 Optimization of the “Exciter Current Controller” (in the DC-Master) …...................... 136
2.30 Tracing Signals at the Input- or Output-Channels of DCC-Blocks …......................... 142
page 02
Training Rack for SINAMICS SL150
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DC-Master for Excitation
ET200-S Mot
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rear view
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Control
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PSA Electronics
ET200-S Aux
SectIon
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rear
view Synchronous
motor
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Phase A
Power
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Motor
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rear Phase B Phase C Output

view reactors
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SITRAIN
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Preface
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This training section covers all essential steps of commissioning the “Common Functions” of a SL150 medium voltage
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converter (downloading the project to D445, basic and technological programming of the exciter unit / DC-Master,
tm
adaptation of the DCC function programming to the plant periphery).

With the inevitable exception of the medium voltage hardware the SL150 training unit is equipped with the same
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components as found in site applications of SINAMICS SL150:

- SCR power sections (4-quadrant design) for phases A to C
- original control electronics (processor boards, option components) including the Power Stack Adapters
@
- DC-Master to provide the excitation current for the synchronous motor

- synchronous motor
The programming within the project used for this training is based on an original site project with some exceptions
8
only; in consequence many steps of commissioning a SL150 converter with synchronous motor can be carried out
d8
on the training unit in quite the same way as at site.

Naturally, the commissioning of the medium voltage hardware cannot be included in this training.
r
Apart from the training for which this material is prepared it can well be used as guideline and reference material for
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plant commissioning. In this case, however, the particular link of the plant periphery to the “drive controllers” (via PLC,
TMxx, …) has to be considered and the plant periphery has to be included in the commissioning sequence as well.
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Wherever you do any commissioning work, please strictly observe the five safety rules.
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page 04
Software Tools and Licenses
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tm
SIMATIC Manager
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SIMOTION SCOUT DRIVE ES WinCC flexible
STARTER integrated DriveMonitor
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Simotion CFC Power Modules DC-Master OP177

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SITRAIN
1 Preparatory Steps
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1.1 Required Software Tools
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To have access to the programming of a SL150-converter as used in mining applications a number of software tools
and their respective licenses have to be installed on the PG/PC. At the PG/PC used for the training these tools and
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licenses are installed already.

Verify that all the required software tools are installed and that the respective licenses are available.
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page 06
Matching the Software Tool to the Firmware
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Content of the Compact Flash Cards
D445
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CU320-2
tm
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Version of the Tool SIMOTION SCOUT

88
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SITRAIN
Comm_Common page 07
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1.2 Drive Firmware
As a general rule, the versions of the software tools have to match the drive’s firmware. This applies in particular to the
ai
version of SIMOTION SCOUT in relation to the firmware of the SL150.

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Create file “directory SCOUT”: > Temp_Trainee; if it should already exist, delete all its content.
Using “Explorer” and a card reader, copy the entire content of the Flash Card of SIMOTION D445 including the
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directory “0_Training” (which contains the zipped projects “8MFSLMIC.zip“ and “8MFSLTRN.zip“) to directory
“SCOUT”\Temp_Trainee\D445_CFC.
Execute the routine “remove hardware safely” (button at the right end of the bottom line) before removing the CF card
@
and the card reader; put the D445 CF card back into controller D445.
Take out the CF card from the CU320-2 DP and copy its entire content to directory
SCOUT”\Temp_Trainee\CU320_CFC.
8
d8
Again execute the routine “remove hardware safely”, remove the CF card and the card reader and put the CU320 CF
card back into controller CU320-2 DP.
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Open tool SCOUT and verify that the version of SIMOTION SCOUT and the firmware of the SL150 are a matching
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pair.
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page 08
Hardware Description Data, Ident-Files and User Data
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ACX-data and Ident-file
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for the Power Stack
of SINAMICS SL150
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CU320-2
user data
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SITRAIN
Comm_Common page 09
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1.3 Structure and Content of the CF card
Check the content of the Compact Flash Card for the CU320-2 to identify the Hardware Description Data, the
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Ident-file for the Motor Module and the User Data:

A) Hardware Description Data (DESCxxxx.ACX) define converter properties such as power section data (voltage,
tm
current) and the actual value monitoring on the PSA

B) Ident files (ident_xx.bin) assign the allocation of the PSA to its application as Motor Module for SL150, Motor
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Module for GM150, Line Module for SM150 etc.

C) User Data (PSxxxxxx.ACX) contain the parameterization of the individual objects of drive device “Motor Module”
(PSxxxx00.ACX to PSxxxx99.ACX).
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page 10
Running the Project on the PG/PC
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l.c
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88 deletes modifications only
right mouse click > open object

deletes the old compilation in full
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left
mouse
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SITRAIN
1.4 Getting the PG/PC Installation ready to handle the SL150 project
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As (typically) found in plant commissioning the SL150-project is provided as a zipped file (project archive) for the
l.c
training as well. Here it is part of the CF card for SIMOTION D445 by the name “8MFSLTRN.zip“ in directory
“0_Training”.
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Open the SIMATIC Manager and delete project 8MFSLTRN if it should already exist (File > Delete > 8MFSLTRN > OK).
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Now retrieve project “8MFSLTRN.zip” from directory “Temp_Trainee > 0_Training” into the prompted directory
(“SCOUT”:\Programme\Siemens\Step7\S7Proj).
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In “sub-project” “Stand R1 Top”, select drive device “U1_A_D445_Stand_6_pulse” and open SCOUT:
- left mouse click on the drive device in the “navigator-section” and
- right mouse click on “SIMOTION SCOUT” in the “worksheet-section” > Open Object
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In SCOUT start the routine “Save project and REcompile all”. You will observe that the compilation output lists a
considerable number of error messages. These error messages indicate that libraries required for the compilation of
88
DCC-charts used in the project are missing. Specifically it is library “TPSIMOTION_DRVMAK(V1.1)” which contains
DCC functions used in mining applications.
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The project for the SL150 can be compiled (and downloaded) only if this library has been imported from tool SCOUT
to the project.
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page 12
Importing required DCC Libraries
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l.c
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mark library TPdcblib library is imported

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SITRAIN
To import DCC libraries, select the required libraries in SCOUT: m

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- right mouse click (RMC) on D445 > Select technology packages
- in addition to already marked technology packages select following:
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“TPdcblib_SIMOTION….”
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“TPdrive_lib….”
“TPSIMOTION_DRVMAK….” > OK
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Now update the DCC libraries in SCOUT > DCC:

- open any of the DCC charts in D445 > PROGRAMS
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- access the import of libraries via “Options > Block Types > OK
- one by one mark above listed libraries, transfer them to “Imported libraries” ( button >>) and “Accept” the request
of the Import of the libraries
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- exit the DCC chart

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page 14
Getting the Project Ready for the Download to the D445 CF card
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l.c
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deletes modifications
right mouse click > open object
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deletes old compilation
left
mouse
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click
> select
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D445
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Comm_Common page 15
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l.c
1.5 Getting the Project ready for the download to the D445 CF card
In SCOUT again start the routine “Save project and REcompile all”. Once finished without errors, initiate the step
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“Check consistency”.
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If no consistency errors are signaled, the project (Simotion programming) is ready to be downloaded to the CF card
either via D445 with the CF card inserted or directly to the CF card via card-reader.
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For either of the two approaches, the CF card has to have a “Simotion specific boot section” (invisible via card-reader)
and the standard firmware for “SIMOTION D4x5”. At this step of training these preconditions are satisfied.
In the given situation the Simotion programming already exists on the CF card; it will subsequently be overwritten by
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the download of the project.

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page 16
Downloading the Project to the D445 CF card
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only for SIMOTION technology,
irrelevant for SL150
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SITRAIN
1.6 Downloading the Project

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Insert the D445 CF card in the card-reader and connect it to one of the USB-ports of the PG/PC; identify which
directory is set up for the Compact Flash Card.
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Directory for “SIMOTION_D”: . . . . . . .

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Download project “8MFSLTRN” to the D445 CF card:

- in SCOUT, RMC on D445 > Load to file system > Save normally
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- button “Select target” > select the drive identified for the CF card > OK
- Acknowledge the request to overwrite the existing user data.
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The routine will finish with the message „Download to file system completed successfully“.
The Download of the project data to the CU320 CF card will be carried out with the CF card inserted in the controller
once online.
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Using the routine “Safely Remove Hardware”, remove the card-reader from the PG/PC and insert the D445 CF card in
the D445 controller.
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Also insert the CU320 CF card in controller CU320-2.

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page 18
Single Line Diagram of a Typical SL150 Sag-Mill Gearless Drive
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IBA-PDA Base Automation
Ethernet Speedmaster (MRG)
OP177B
Profinet
4 x Profinet
color CBE30 Profibus
l.c
2 x Ethernet
2 x Profibus
SIMOTION
SCALANCE
HUB X 005 RUN TIME
optical cable
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D445
commiss.
laptop DRIVE-CLiQ
OBT OBT
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ET200S CBP2 ET200S ET200S ET200S
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auxiliaries control excitation general motor air gap motor differential
CU320-2
and monitoring DC-Master motor monitoring monitoring protection
DRIVE-CLiQ
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88 System 1 System 2
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TMx VSM10 TMx DMC20 SMC30 SMC30 SMC30
terminal terminal sensor sensor sensor
voltage Drive-CLiQ rip-cord
module module module module module
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HUB
TM15 sensing TM15 for for for PSA PSA PSA PSA PSA PSA
or module or one one one
option
TM31 TM31 encoder encoder encoder
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DT DT DT
encoder
DRIVE-CLiQ
option option
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SITRAIN
Comm_Common page 19
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l.c
1.7 Exemplary SL150 Application
The single line diagram above serves as an example for a setup of a SL150 in mining applications :
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- Synchronous motor with external DC-excitation and encoder

- DC-excitation provided by a Simoreg DC-Master
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- Stator winding fed by Sinamics SL150 (Power Module)

- Signal interface to the field via ET200-S (group “Auxiliaries”, group “Motor”)
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- extended motor monitoring “air gap” and “differential protection”

- Local control via OP177
- long term data recorder “IBA-PDA”
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- Process control via “MRG, Basic Automation”

- Data link via Profibus and Profinet
Motors of large power ratings feature two groups of stator windings; the Power Modules are then set up as 2x6-pulse.
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page 20
Voltage Supplies and “Signal Check”
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ET200-S
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Motor Motor
Fan Group Lubrication
SL150 Control
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Cooling System Voltage

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SITRAIN
Comm_Common page 21
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2 Basic Commissioning
2.1 Checking Cabling and Voltage Supplies >only for information<
information<
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Prior to carrying out the wiring and insulation test all circuit breakers and fused switch disconnectors have to be
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opened; sensitive equipment on the plant end of the cables has to be disconnected as well.
Refer to the circuit diagrams to identify the voltage level for which the cables are used to know which voltage to
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choose for the insulation test (100V, 500V, 1000V, 5000V).

Make sure that the cables to the plant feed the equipment as stated in the circuit diagrams. Then one by one
connect each wire at the load side to ground; the measured impedance must be very small (alternatively you can
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measure the impedance between two wires short-circuited at the load).

Continue by measuring the insulation impedance of each wire against ground using an insulation meter (the
impedance must be in the tens of Megaohms).
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Now supply the auxiliary voltage to the busbars in the cabinets and check voltage level and phase sequence.
Then switch on one circuit breaker after the other and one by one check the voltage level and polarity rsp. the
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phase sequence at the load. Equipment which can be damaged by an incorrect voltage level or polarity should be
disconnected until the correct supply has been verified.
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Please observe following warnings:

- Using suitable methods, ensure that no danger can arise for personnel or material before feeding voltage to
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equipment in the plant.

- Before starting the motor fans make sure that the motor pit has been cleaned and painted; otherwise the air
flow might carry foreign bodies into the motor air gap possibly leading to a damage of the insulation once the
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motor rotates.
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Don’t accept any compromises on these points.
page 22
HW-Configuration of the Project for the Training Rack
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CU320-2
SINAMICS_Int
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32
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16
8 PROFIBUS-addresses are set
4 - via switches on the ET200S-stations
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2 address-coding - via switches on controller CU320-2

1 of ET200S; - via parameter on the DC-Master
i.e. address 17
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SITRAIN
2.2 Checking the “Communication Network” in “HW-Config” m

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Open the HW-Configuration (e.g. in SCOUT) and compare the communication network of the project to the actual
connection of the PROFIBUS-nodes: right mouse click on D445 > Open HW configuration.
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Note down the PROFIBUS-addresses assigned to the nodes:

- AUX-ET200: . . . . . . . . . . - MOT-ET200: ..........
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- DC-Master: .......... - SL150/CU320-2: ..........

Verify respectively set these addresses via hardware where possible.
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page 24
Rebooting the Controllers / Connecting the Ethernet Ports
An Ethernet port is defined by its IP-address, by a Subnet mask
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and (if networked) by the definition of a Standardgateway.
The definition of the Subnet mask depends on the application
class; Subnet mask and IP-address range have to match.
S0 F3
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main supply excitation supply Subnet mask IP-address range class networks / hosts
255.0.0.0 1 to 126 A 126 / 1677721
255.255.0.0 128 to 191 B 16384 / 65534
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255.255.255.0 192 to 223 C 2097152 / 254
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X120
IE1/OP
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X130
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IE2/NET
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SITRAIN
Comm_Common page 25
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2.3 Rebooting the Controllers
On the “lower switchbox”, put switches S41 to S44 to their upper position and switches S45 to S56 to their lower
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position. On the “upper switchbox”, put all switches to their lower position.
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Switch on the 24VDC supply to all Simotion and Sinamics components on the SL150 rack by closing the line-side
auxiliary supply breaker S0 (this reboots the controllers of the components). Allow approximately 3 minutes for the
initialization. If the Drive-CLiQ topology of the project which is part of the Flash card content matches the physical
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wiring, the RUN-LEDs of the Drive-CLiQ components will turn green. Else, adapt the Drive-CLiQ connections
according to the topology until the setup is fault-free.
To analyze the nature of fault or alarm messages on the SL150, an online connection with the PG/PC has to be set up
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next.
The PG/PC can be connected to the D445 via PROFIBUS or via ETHERNET; presently the ETHERNET connection to
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port X130, IE2/NET is suggested to be used.

Connect an ETHERNET cable between port IE2/NET of the D445 and an available port of the PG/PC.
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page 26
Communication Network as seen via “NetPro”
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drive device
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(1)
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(1) If component CBE30 is configured, drive device “U1-D-SL-CBE” is

added automatically to the CBE30 ETHERNET (formal reasons).
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No programming is assigned to it.

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2.4 Checking the “Communication Network” in “NetPro”

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l.c
Open the NetPro view (i.e. in SCOUT) and compare the communication network of the project to the actual connection
of the PROFIBUS- and ETHERNET-nodes: Project > Open NetPro.
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In addition to the existing hardware NetPro shows “PDA PC” and “U1-D-SL-CBE” connected to board CBE30 of D445
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via Ethernet. “PDA PC” represents the “master automation” not part of the training rack; “U1-D-SL-CBE” represents
the CU320-2 with its ETHERNET-link on board CBE30 (“U1-D-SL-CBE” is added during configuration; it represents
the very same drive device as “U1_C_SL_CU” and has no programming of any kind implemented.
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Note down the PROFIBUS- and ETHERNET-addresses assigned to the nodes

(via right mouse click on “node connection” > Object Properties):
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- U1_C_SL_CU: ........... - D445_DP1: ...........

- U1-D-SL-CBE: ....................... - D445_DP2/MPI: ...........
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- DC-Master: ........... - D445_IE1/OP: .......................

- PG/PC_DP: ........... - D445_IE2/NET: .......................
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- PG/PC_ETHERNET: ....................... - D445_CBE30: .......................

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- OP177_HMI IE: .......................

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In the next step, the settings of the Ethernet port of the PG/PC have to be adapted as per NetPro to be ready to go
online via Ethernet.
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page 28
Setting the IP-Address on the PG/PC
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Enter
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SITRAIN
2.5 Setting the IP-Address on the PG/PC

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l.c
Follow the sequence “Start > Einstellungen > Netzwerkverbindungen” and doubleclick on “LAN-Verbindung”; open the
properties’ menu via button “Eigenschaften”. Scroll down to “Internetprotokoll (TCP/IP)”, mark it and again continue via
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button “Eigenschaften”.
Now assign the subnet-mask and the IP-address to a setting compatible with the definition of the ETHERNET port
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IE2/NET of the D445 :

Subnet-mask: .......................
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IP-address: .......................
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page 30
Assigning the PG/PC to ETHERNET in NetPro
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Network > Save and Compile

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SITRAIN
2.6 Assigning the PG/PC to ETHERNET in NetPro

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In NetPro the PG/PC is connected both to a PROFIBUS-network and to an ETHERNET-network.
To enable an online connection to the D445, the link to the ETHERNET-network has to be activated:
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- right mouse click (RMC) on PG/PC > Object Properties

- in tab “Assignment” of menu “Properties – PG/PC”, section “Configured Interfaces” select
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”Ethernet Service”
- in section “Interface Parameter Assignments” select ”TCP/IP Intel 825666MC Gigab...”
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(this selection has to match the device type for the “LAN-Verbindung” selected above)
- define this selection as “Assigned” via button “Assign” > OK
- acknowledge the message concerning the change of assignment via button “Yes”
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- mark the assigned interface, verify that the checkmark next to “Active” is inserted and terminate the assignment
by pressing button “OK” > “OK”
The assigned connection of the PG/PC to the D445 is highlighted in yellow.
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Any change of assignment in NetPro will become effective only after NetPro has been “Saved and Compiled”:
Network > Save and Compile.
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Test the communication by “pinging” the D445 in the DOS-prompt: ping “IP-address”.
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Exit program NetPro by “Network > Exit”

Back in Scout, check the access path in menu “Options“ under item “Set PG/PC interface ...“:
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in tab “Access Path“ the selected interface has to be “TCP/IP NameOfAdapter“ (as required).
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Test the communication by “pinging” the D445 in the DOS-prompt:

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ping “IP-address”.
page 32
Going Online to D445 and Downloading the Drive Devices
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connect to download to
target system target system
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if device “U1_B_SL_CU_INT”
should not be check-marked
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depending on
state of CU320-2
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SITRAIN
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2.7 Going Online to D445 and Downloading the Drive Devices
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Return to SCOUT and request the online mode. The consistency plugs have to indicate the online state (“closed
plugs”) for drive devices “D445_Master”, “CU320-2” and “U1_B_SL_CU_INT” (SINAMICS_Integrated, wired to TM31
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components); data consistency has to be signaled by green/green consistency plugs on all devices.
If necessary, download drive devices in question individually to get data consistency.
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page 34
Adapting the Hardware Setup
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SITRAIN
2.8 Adapting the hardware setup

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When checking the Profibus nodes, you will notice that the “AUX ET200S” station indicates “fault” (SF and BF flashing
red). To analyze the reason, open the HW Config in Simatic Manager and switch to online. The station is marked with
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a red bar and can be diagnosed by the function “Module Information“, available via right mouse click.
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Check the messages in tab “DP Slave Diagnostics” and compare the setup in HW Config against the existing ET200S
station setup; note down modules which are part of the HW-Config but are not installed in Hardware:
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Slot Module Periphery address Comment (module name)

..... ...... ......................... .....................
..... ...... ......................... .....................
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page 36
Adapting the Hardware Setup
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SITRAIN
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Adapt the HW Config in offline mode by deleting the extra modules and by moving the remaining modules to their
proper positions (to delete: mark the module > Delete / to shift: mark the module > “drag and drop” to new position).
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“Save and Compile” the HW-Config and download the new hardware configuration to the target system (PLC
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Download; for the Download the D445 is automatically switched to “Stop mode”). Verify that the fault indication on
“AUXET200S” station is cleared.
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Back in Scout, reconnect to the target devices and try to switch to “Run mode” again (Target device Operating
mode). This command will fail because the D445 is inconsistent (red/green). Run a consistency check to find out what
is wrong.
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Identify the variables of the I/O-container which are no longer supported by hardware by checking the message text in
the “Compile/check output“ tab:
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missing addresses:
variable name address
.............................................. .............
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.............................................. .............
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In Offline mode delete the variables in question from the I/O-container and activate the function “Save and Compile”.
You will notice the error message “… error in source U1OUAUXD and U1INAUX”.
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page 38
Finding the Reference “variable / address / chart”
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address references in I/O-container
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any DCC-chart
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SITRAIN
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To easily find the blocks of charts U1OUAUXD and U1INAUX which use the variables “et200_aux_pqb03_x79” and
“et200_aux_pib03_x77_78” (which are no longer existing now), open any DCC chart under “Programs”, select menu
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“Options”, then “Chart Reference Data” and open the listing of “Cross Reference, Chart Elements Address”.
Search for variable “et200_aux_pqb03_x79” and double click on it; the chart page showing this variable and its wiring
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to a DCC-block is opened automatically.

Now delete this connection to block ETA300 (left Mouse Click on input signal line > right Mouse Click: Delete
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Interconnection). Follow the same approach to delete the chart output to variable “et200_aux_pib03_x77_78”.
Compile the modified charts U1OUAUXD and U1INAUX : Chart > Compile > Charts as program > Compile all > OK.
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Once more “Save and Compile” the project and check its consistency.
[If consistency is still not given, follow the above approach once more to delete the offending links to the variables in
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question; again “Save and Compile” the project and check its consistency.]
To restore consistency for SIMOTION D445, connect to target system and download the D445. Be sure to have the
function “Copy RAM to ROM” executed for device “D445_Master”.
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After completion of the download all three drive devices have to indicate data-consistency (green-green).
If a drive device should indicate “disconnected” (red-red) in the sequence of downloading, reconnect it as follows:
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- mark the drive device in question

- open the function menus via “right mouse click”
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- “left mouse click” on “Connect target device”

device changes to “online mode” (green-green)
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Switch SIMOTION D445 to “Run mode” (now this has to be possible).

Open the Alarm-tab in SCOUT and try to acknowledge all faults. You will notice that fault “Excitation group signal fault”
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persists (this fault is quite logical as the DC-Master has not yet been commissioned).
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page 40
Defaulting the DC-Master and Setting the Node-Address via PMU
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Shifting fault or alarm
messages to the background P + ∆ P0623
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F036 o11.0
P0623
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Recalling fault or alarm ∆
messages from the background P + A537
o11.0
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Change from parameter level to
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value indication and vice versa
P234 P 17.20
∆
∆ 88Change from parameter level to
/ index level and vice versa P150 P i 001

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Increasing / decreasing
- the parameter number Change from index level to
i 001 P 56.37
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- the index number value indication and vice versa

- the value
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last
Acknowledging a fault F036 P indication
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SITRAIN
Comm_Motor page 41 © Siemens AG 2011 - all rights reserved
2.9 Defaulting the DC-Master and setting the Node-Address via PMU
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As a standard, the DC-Master for the SL150 synchronous motor application is pre-commissioned at SIEMENS and the
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parameter file provided within the project will require only minor modification at site (i.e. the optimization of the
armature current controller for the synchronous motor excitation).
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Start by defaulting the DC-Master to factory settings using its ParaMeterizing Unit (PMU); the DC-Master for the
tm
exciter is located on the upper left on the rear of the SL150 training rack:
- shift eventual fault and alarm messages to the background
- scroll to parameter P051 (access level) and set the value to P051 = 21 (default request; after execution of this
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routine an internal offset tuning is carried out automatically (indication P051 = 22) and
- after some seconds delay P051 reads P051 = 40 service level for commissioning;
check this state by shifting fault message “F23, fault via Free Function Blocks” to the background
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- scroll to P918 to set the PROFIBUS address as defined in NetPro: P918 = . . . . . . . . .

- scroll to P927 to extend the parameterization authority to “SST1 + PMU + PROFIBUS”: P927 = 7
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Switch the power supply for the DC-Master (single phase m.c.b. F3 / front, top row, right hand side) off and on again to
activate the new PROFIBUS address; acknowledge fault message “F40, control power has been switched off while a
fault was persisting”.
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page 42
Tool “Drive Monitor”
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right mouse click
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left mouse click
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Copy “RAM to ROM”
P971 = 1
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offline online online complete empty online online
RAM EEPROM parameter list parameter list RAM EEPROM
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tracer upload download

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download
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complete
parameter list
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parameter list as used upload

to open Drive Monitor
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SITRAIN
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2.10 Going Online and Downloading the Project Data via Drive Monitor
Within the project view of the SIMATIC Manager the DC-Master is listed as one of the drive devices. Navigate to the
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parameter list (or lists) provided for the DC-Master:

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- in the “navigator-section” successively doubleclick on “DC-Master CBP2”, “SIMOREG DC MASTER” and

“Parameter”
- right mouse click on the parameter list “DC_SL_Trainee_Delta” in the “worksheet-section” > Open Object
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The tool for the DC-Master, Drive Monitor, is opened.

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page 44
Messages: “Differing Firmware” or “Missing Data Base”
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The FW-release of the DC-Master
used in the project differs from the
FW-version of the Control Unit.
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Unless the very latest release of Drive Monitor
is used, a missing data base has to be added.
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SITRAIN
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In Drive Monitor, click on the “list of all offline parameters”: a list of the parameters defined in project parameter list
“DC_SL_Trainee_Delta” opens and indicates the offline values of these parameters.
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Request operating mode “online EEPROM” (to have changes of parameter values saved in non-volatile fashion);
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acknowledge an eventual device identification message by pressing the SW-button “OK”.

(Should Drive Monitor fail to open at all, a program update “sg70v31_des.exe” for Drive Monitor has to be
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installed by copying the file to the disk drive which is used for SCOUT etc. and by starting the installation.)
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page 46
Downloading the Parameter File with Drive Monitor
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SITRAIN
Comm_Motor page 47
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Now download project file “DC_SL_Trainee_Delta” to the EEPROM (the download of a “complete file” takes
considerably longer than the download of a “delta file”, which contains only those parameters whose values are “other
than default values”); close the eventual device identification message with button “Download”.
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If the download is executed with only a very small number “n” of errors (indicated by [OKxxx: E<0: n>]), call up the
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“Details” with the respective button. Analyze the reason for the error; mostly the errors result from different versions of
the tool Drive Monitor and the Firmware of the DC-Master and can be ignored.
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On the DC-Master programming numerous “Free Function Blocks” are used. These “Free Function Blocks” have to be
enabled either temporarily (for test operation with a maximum test time of 500 operating hours) or permanently via
PIN-code.
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For a temporary “enable” parameter U977 is set to U977 = 1500 (the parameterized value “1500” is reset to “0”
automatically). Parameter n978 indicates the remaining hours of test operation in its last three digits
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(e.g. n978 = 1372 372 h of test operation still available).

For a permanent “enable” parameter U977 is set to U977 = PIN-number; in this case n978 indicates n978 = 2000.
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Check whether the training rack’s DC-Master is enabled temporarily or via PIN.
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page 48
Adapting Parameters to particular Plant Conditions
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Comm_Common page 49
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2.11 Adapting Parameters to particular Plant Conditions
You will notice that F021 is signaled and cannot be acknowledged. Using the DC-Master faults list and the plant
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function diagrams for the DC-Master, find out which “plant monitoring” is responsible for this fault (F021):
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...................................
On the training rack this fault condition is simulated by a switch. Navigate within the plant function diagrams for the
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DC-Master to find out which switch is responsible for this fault:

...........................
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Switch on the identified switch and acknowledge fault F021.
Following the same approach, eliminate alarm A021 by assigning a constant “H” instead of the configured evaluation
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of the digital input on the input for the alarm indication A021 (DON’T reassign the wiring on U113 as yet!):
d8
P........... = ...........
PROFIBUS message “Alarm A83” persists because SIMOTION D445 is not sending any PROFIBUS-telegrams as yet.
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page 50
Uploading the Parameterization as “Delta-File”
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Upload the parameterization of the DC-Master as a “delta file” by the name “DC_SL_Trainee_Delta_1”.
Copy file “DC_SL_Trainee_Delta_1” to your listing of DC-Master files in explorer as follows:
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SIMATIC Manager > (right mouse click) DC_SL_Trainee_Delta_1 > Export parameters > Drive Monitor > C: >
Temp_Trainee > 0_Training > DC_Master_Files > Save.
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Go offline with the DC-Master and exit the tool Drive Monitor (View > Offline / File > Exit).
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page 52
Preparing the OP177 to load Data via ETHERNET
displayed for 10 s after 24 VDC = ON
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F7
F7 / System
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2.12 Loading the OP177
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PROFIBUS message “Alarm A083” doesn’t clear as consequence of the still persisting “Excitation group signal fault”
of the Power Modules. To follow up on this fault, SIMOTION messages have to be analyzed which is most comfortably
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done via OP177.

To load the OP177 via one of the available interfaces, the interface in question has to be assigned to the PG/PC. As
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the current interface assignment of the PG/PC reads ETHERNET, the OP177 is suggested to be loaded via
ETHERNET. Since the online connection to the D445 will no longer be maintained in this situation, disconnect the
SCOUT project from the target system (go offline).
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Connect the PG/PC to the OP177 both physically and in NetPro carrying out all steps required. Verify the link by
“pinging” the OP177.
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The selection of the type of interface, the interface settings and the preparation of a data transfer are done in the
menu “Transfer” of the OP177.
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If the OP177 is powered up for the very first time, the “Loader” opens up automatically; in this case press the
SW-button “Control Panel”.
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If the OP177 has been used already, the previously defined faceplate opens up; in this case press HW-button
“F7/System” and then the SW-button “System Control”.
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Scroll down to menu “Transfer”, double-click on it and adapt the “Transfer Settings” on the OP177 to enable the
communication with the PG/PC via ETHERNET.
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page 54
Loading the Project to the OP177 (WinCC via SIMATIC Manager)
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SITRAIN
Set the OP177 to state “Transfer > Connecting to host”.

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In SIMATIC Manager, start “WinCC flexible”, select “Project > Transfer > Transfer”, define “Mode = ETHERNET” and
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the IP-Address of the OP177.
Start the transfer with the assigned button; select the existing password list to be overwritten (else the password list
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has to be overwritten via WinCC flexible by a separate command).

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If the data transfer is finished, close WinCC flexible without saving the changes to the current project.
The faceplate of the OP177 is still incomplete; it will be selected as per project application once SIMOTION D445 is
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online to the OP177.

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page 56
Excitation Group Signal Fault
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PROFIBUS
Communication
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error
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SITRAIN
Both, physically and in NetPro, redefine following ETHERNET connections:

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- D445, port IE1/OP to OP177
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- D445, port IE2/NET to PG/PC
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Assign all addresses as required:

the feedback values for Nact, TQact, etc. on the OP177 screen read 0
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(instead of the #### as before the connection to the D445)

Online mode with SCOUT can be activated
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Alarm “A83” on the DC-Master and “Excitation group signal fault” on drive device VectorSL still persist (for reasons
as stated before).
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page 58
General Content and Structure of the CFC-charts
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IO INAUX Auxiliary inputs via ET200 I/O
internal communication between function charts

INPUT Communication and scaling IO IO COMCBE Communication to other CPU
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LCOMRG Commissioning functions IO IO TMONI Temperature monitoring
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POSIT Spindle spotting IO IO CPU CPU System Functions
IO AUX1 Start-up Sequence Control
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DRVMG Drive Manager IO
OUTPUT Communication and scaling IO IO DOPAR Parameter Read/Write Logic
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IO AUX2 Auxiliaries Control
IO MOPRO Motor protection
IO MSG Messages to OP177
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IO PANEL Communication to OP177
IO OUAUX Auxiliary outputs

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I/O-Container Signals between drive devices and interfaces
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MRG (Basic Automation) DRIVE (Power Units) PDA ET200S (Mot / Aux) DC-Master (Field)
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Comm_Common page 59
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2.13 General Content and Structure of the DCC-charts
Additionally to the control of the Power Modules ( CU320-2) extensive additional functionality is provided in
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D445_SIMOTION via DCC-charts. The diagram above lists the majority of DCC-charts; to view the entire list, refer to
“SIMOTION Program > Pläne”.
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The data exchange between the “DCC-programs”, the “Basic Automation / MRG”, the “Drives Functions / Power
Module, Exciter” and the “Periphery / ET200” is carried out via System Variables which are assigned to the process
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data address codes in the I/O-container.

A detailed list of contents of the individual DCC-charts, each chart containing a large number of sheets (A, B, …) with
six assigned pages is always given on the first page of sheet A.
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page 60
Cross-Reference from OP177-Messages to DC-Charts
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X A reference to the related page of the DCC-
Alarm display OP177
actual messages
charts is shown on the OP177 in column
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Date Time Text “Text” once an alarm or a trip is monitored.
29/03/11 06:12:33 =.WA01/C1 The reference (=.WA01) related to the fault is
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Error Software Protection given in column “Text” and can be identified
as “Comment” in the list of all charts assigned
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to “Charts” of SIMOTION D445.
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via:
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View>Details
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SITRAIN
2.14 Assigning the “Code” to activate DCC-charts

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On the OP177, call up currently identified messages via key “F2 / MSG Actual”; take a note of these messages:
..........................................................................................
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
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If the messages are in German, change the language to English via key “F7/System” and the assigned SW-button.
Return to the main faceplate via key “F1/Start” or [ X ] within the menu.
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You will notice that one of the messages reads “… Error software protection”.
Many of the function blocks used in the DCC-charts are especially designed for mining applications. These blocks are
software-protected and the DCC-charts using these blocks are processed by Simotion only if the correct code is
@
registered (this code is generated by Siemens on the basis of the serial number of the compact flash card).
The code has to be registered in one of the DCC-charts. Use the information on the OP177 / alarm display to find out
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to which chart you have to go to enter the code:

d8
chart: . . . . . . . . . . . . . . . . . . . . . . . . . . .
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page 62
Assigning the “Code” to activate the CFC-charts
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Watch On Watch Off
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Test Mode Overview Sheet View
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Compile Download Chart Reference Data
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SITRAIN
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Open DCC-chart “CPU”, sheet C1 (the project specific name of the chart is U1CPU; U1 is an identifier valid for this
project, CPU is the block name in general).
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Select “Test Mode”, mark block SWP100 and set “Watch On”. Presently the wired output “QKF” respectively
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“BM_ERR_SWP” reads value “1” which means “Error software protection”.

Take a note of the serial numbers SN1 and SN2 (as an example; at site you have to record all serial numbers if the
“Code” still has to be generated by Siemens):
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block U1CPU, serial number SN1: . . . . . . . . . . . . . . . . . . . . . . . . . .

block U1CPU, serial number SN2: . . . . . . . . . . . . . . . . . . . . . . . . . .
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page 64
Customizing I/Os by assigning “Comments”
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SITRAIN
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Inputs and outputs of function blocks are identified by “names” which are factory set and cannot be redefined. To
customize these I/Os, however, self defined “comments” can be assigned. The changeover from “I/O-name” to “I/O-
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comment” is activated via “Options > Customize > Layout”. By positioning the cursor on any I/O a “tool tip text”
providing additional information pops up.
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page 66
Changing Block Values in “DCC-Offline”
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menu to change block values
in “DCC-offline”
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consistency is restored after the download

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Comm_Common page 67
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Set “Watch Off”, discontinue “Test Mode” and assign the code numbers for the CF card you are using (refer to the list
below) after a doubleclick on the individual I/O:
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Possibility 1) internal serial numbers generated for the Compact Flash Card 110422B1 :
SN1: 34303131 SN2: 31423232 SN3: 00000000 SN4: 00000000 SN5: 00000000 SN6: 4F4E5241
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Code numbers to be entered in U1CPU / C1 / SWP100

KW1: 16#E65C7D42 KW2: 16#46154776 KW3: 16#9AAB65D2
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KW4: 16#F08972D5 KW5: 16#B52A76EF KW6: 16#28573B84

Possibility 2) internal serial numbers generated for the Compact Flash Card 11042251 :
SN1: 38423054 SN2: 32323232 SN3: 00000000 SN4: 00000000 SN5: 00000000 SN6: 4F4E5241
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KW1: 16#AC15B40D KW2: 16#FC340A1F KW3: 16#29240982
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KW4: 16#17915EA5 KW5: 16#671D3513 KW6: 16#1981C50C

Possibility 3) internal serial numbers generated for the Compact Flash Card 11041F74 :
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SN1: 34303131 SN2: 34374631 SN3: 00000000 SN4: 00000000 SN5: 00000000 SN6: 4F4E5241
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KW1: 16#233CF308 KW2: 16#2BD246AA KW3: 16#9AAB65D2

KW4: 16#F08972D5 KW5: 16#B52A76EF KW6: 16#28573B84
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To activate these changes, the DCC-chart has to be compiled and downloaded (to download any DCC-chart,
D445_SIMOTION has to be downloaded; the inevitable change from RUN to STOP and back to RUN is requested by
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the system whenever applicable).

A few seconds after the download the output “BM_ERR_SWP” of block SWP100 reads value “0” ( no code error)
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and alarm A83 on the DC-Master clears automatically. The D445 fault “Excitation group signal fault”, however, still
persists.
Additionally a larger number of faults monitored via SIMOTION DCC has popped up both on OP177 and on “SCOUT >
Alarm tab”.
page 68
Changing Block Values in “DCC-Online”
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saving data on Compact Flash Card
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menu to change block values in “DCC-online”
(“Test Mode” and “Watch On”)
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saving data on PG/PC
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close all charts / save and compile the project
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SITRAIN
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Contrary to the sequence just followed, most of the modifications of the CFC-programming you might have to carry out
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during commissioning will typically be done in online mode (“Watch On” state; i.e. changing input values). These
changes become effective in the D445_SIMOTION RAM immediately and they are stored in the PG-RAM
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automatically.
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To save these changes in the “non-volatile” memory (on CF card), the function “Copy RAM to ROM” has to be carried
out for D445_SIMOTION.
To update the PG/PC-project with the modifications introduced while in “DCC-Online”, the function “Compile Chart”
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(saving data of the compiled charts in the PG/PC-project) has to be carried out for all concerned charts.
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page 70
Clearing Faults and Alarms on behalf of the DC-Master
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Some faults within the exciter circuit are monitored both on the DC-Master and on the OP177 (via DCC-charts)
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DC-Master
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OP177
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SITRAIN
Comm_Common page 71
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2.15 Clearing faults and alarms on behalf of the DC-Master
The OP177, which is now indicating the operating state of the hardware components (circuit breakers, exciter unit,
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infeed, motor module, motor and auxiliaries) now indicates a good number of faults or alarms.
These faults and alarms now have to be cleared one by one.
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Start by following up the fault “Trip overvoltage protection excitation DC-side”.

PLEASE NOTE that faults and alarms of the drive hardware such as DC-Master and Power Unit are indicated by the
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respective hardware (“Fxx” messages for the DC-Master, “Alarms” via SCOUT for the Power Unit) but are also sent to
Simotion and are finally displayed on the OP177.
Faults of the exciter hardware are (in part) evaluated by the DC-Master (without being indicated on the DC-Master
@
itself) and then sent on to Simotion where the fault is picked up to trigger the required action and from where the
message is sent to the OP177.
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Refer to the plant function diagrams for the DC-Master and find out which “external monitoring device” generates the
message “Trip overvoltage protection excitation DC-side”:
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.................................
Find out which switch on the training rack is assigned to simulate this condition:
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.................................
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page 72
Measuring Values of Binectors and Connectors (DC-Master)
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selection: P044.4 = K0193
indication on: r043.04 = xx.x%
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measuring Connectors
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(accuracy of 0.1%)
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selection: P046.3 = B0210
indication on: r045.03 = 0 / 1
measuring Binectors
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Comm_Common page 73
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Go online to the DC-Master and check the logic state of the binector which picks up this “external monitoring device”:
P............=............
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If you switch on the assigned simulator switch S4 the logic state of the binector reads “H-state” (on r45).
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Adapt the related BiCo-connections for the “SICROWBAR monitoring” to pick up simulator switch S4 connected to
“CUD2, terminal X161:214”:
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U............. = .............
Clear the (simulated) hardware fault by switching on the assigned switch on the auxiliary rack:
the fault is automatically cleared on the OP177; the overall number of faults is decremented by one.
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Find the source of the fault “Trip overvoltage protection excitation AC-side” by referring to the plant function
diagrams for the DC-Master and identifying the I/O-terminal and the assigned binector:
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....................................................
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Assume the monitoring device in question to be temporarily missing (no simulation switch is wired) and program a
software substitute for the (temporarily) not available binector to the EEPROM:
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U............. = .............
After acknowledging with key ”F8/ACK” fault “Trip overvoltage protection excitation AC-side” is cleared.
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page 74
Clearing Faults and Alarms on behalf of the DC-Master
Some faults within the exciter circuit are monitored ONLY on the OP177 (via DCC-charts)
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OP177
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SITRAIN
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Follow the same approach to clear the alarm “Alarm earth fault monitoring rotor”:
- I/O-terminal and assigned binector: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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- temporary substitute: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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The alarm “Alarm earth fault monitoring rotor” is cleared automatically.

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Again follow this approach to clear the alarms

- “CB earth fault monitoring rotor tripped” U...............
- “CB excitation converter fan 1 tripped” U...............
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Both alarms are cleared automatically.
Assign the fault “Trip earth fault monitoring rotor” to the same I/O-terminal through which the DC-Master fault
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“F021” is generated (simulated via switch S3):

U.........=.........
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Test the function and clear the indicated faults.

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The last message on behalf of the DC-Master reads “Overload overvoltage protection excitation DC-side”. Once
more refer to the plant function diagrams for the DC-Master and follow the message “Overload overvoltage protection
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excitation DC-side”.
Find out which switch on the training rack is assigned to simulate this condition (this switch simultaneously acts as
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“E-Stop” indication “o10.3” on the DC-Master):

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.................................
Switch on the identified simulation switch and verify that a.m. message can be acknowledged on the OP177; also
verify that the operating state of the DC-Master changes from “o10.3/E-Stop” to “o7.1/Waiting for the On command”,
that the D445 fault “Excitation group signal fault” finally clears and that the RDY-LED of CU320-2 turns “green”.
Save the parameterization you have made in the DC-Master as a “delta file” by the name “DC_SL_Trainee_Delta_2”.
page 76
Clearing Faults and Alarms on behalf of the ET200-Stations
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- A11 - X13 module AX13 - A11 – X23 module AX23 - A11 – X18 module AX18
Q.2 Output . Bit 2 I.4 Input . Bit 4 I.0 Input . Bit 0
terminals 2 (signal) terminals 1 (signal) terminals 1 (signal)
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4 (common) 3 (common) 3 (common)
88 ET200S / Auxiliaries (HIB)
slot 01 02 03 …. 10 11 12 13 14 15 16 17 18 …. 31 32 33
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nibble high low high low
bit 4 0 5 1
IM PM DI 8 x DI DI DO DO DO DO DO DI 14 x DI DI TM
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1 5
ET200-
AX 03 04 …. 11 12 13 14 15 16 17 18 19 …. 32 33 terminal
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2 6
nibble L H H L H L L H bit 6 2 7 3
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The first module after a “change of type” starts with the “Low- nibble”.
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SITRAIN
2.16 Clearing faults and alarms (on behalf of the ET200 stations)
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By now the list of fault or alarm messages has been reduced to 8:
- “Enable Circuit Breaker system 1 from PSA missing”
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- “Stator transformer 1 trip oil temperature” - “Stator transformer 1 alarm oil temperature”
- “Stator transformer 1 trip Buchholz” - “Stator transformer 1 alarm Buchholz”
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- “Feedback fault Auxiliaries off”

- “Delayed trip TC7: Quick stop requested”
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- “Delayed trip TC8: Finish Path / Normal Stop requested”

The last two messages listed are “Tripping Combination” messages (…TCxx…). “TCxx”-messages appear with delay
and represent a summary message which will clear only once the individual messages which are part of the summary
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message are cleared.

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page 78
Cross-Reference from OP177-Messages to Circuit Diagrams
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X
Alarm display OP177
actual messages A reference to the related page of the circuit
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diagrams is shown on the OP177 in column
Date Time Text
“Text” once an alarm or a trip is monitored.
29/10/09 08:45:17 =.D01/02.2
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E.g. = D 01 / 02 . 2 the terminal of the
Stator Xformer 1 alarm oil temperature
ET200S for the alarm/trip is shown on
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page D01, sheet 2, column 2.
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SITRAIN
In the next step, message “Stator transformer 1 alarm oil temperature” will be cleared. Use the circuit diagrams for
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the “mill stand” and the information provided on the OP177 to find out by which ET200 module and by which of its
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inputs the message “Stator transformer 1 oil temperature alarm” is picked up (follow “main transformer system 1”).
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information of OP177 . . . . . . . . . . . . . . . . . . . . . . . . . circuit diagram / sheet no . . . . . . . . . . . . . . . . . . . . . . . . . . .

ET200 module no. . . . . . . . . . . . . . . . input terminal .............. Low nibble, bit no. .............
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Use the circuit diagram of the “Auxiliaries’ Rack” to find out which switch is used to simulate the message above:
switch S . . . . . . . . . .
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Switch this switch on to clear message “Stator Xformer 1 alarm oil temperature” ; the message acknowledges
automatically.
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Follow the same procedure to find out which switch simulates message “Stator transformer 1 trip oil temperature ”:
switch S . . . . . . . . . .
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Clear the message “Stator transformer 1 trip oil temperature”; this message has to be acknowledged via OP177
(key “F8/ACK”).
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page 80
Signal Routing from Charts to Field-Hardware
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bit 4 0 5 1
1 5
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ET200-
X terminal
Signal to be followed: 2 6
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e.g. “No-Load contactor open command” (L-byte, H-nibble, bit 4)
bit 6 2 7 3
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SITRAIN
Next, follow up on message “Feedback fault Auxiliaries OFF”.

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Use the information on the OP177 to find the chart, section and sheet processing this message:
information of OP177 . . . . . . . . . . . . . . . . . . . chart . . . . . . . . . . . . section . . . . . . . . . sheet . . . . . . . . .
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Identify the block which outputs this message: . . . . . . . . . . . . . . .

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Identify the nature of the “AND-wired” input signals in the upstream-block SVA150 (follow these signals upstream by
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double-clicking on the signal connection to the left of the block assigned to the signal line):
- input I1 ....................................................
- input I2 ....................................................
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- input I3 ....................................................
Follow the feedback message (I2) upstream to find which auxiliary device issues an ON-feedback despite control
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request “OFF”:
- block / input ......................................
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- device ......................................
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This information can also be found by checking the auxiliaries’ feedback on the OP177 via “F11 / Status” > button
“Status AUX”: “Oil pressure pump DE” reads “ON”.
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Continue to follow the signal upstream until you reach the variable linking this message to the I/O-container:
variable: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Note down which Byte, Nibble and Bit carries this feedback:
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Byte . . . . . . . . . . . . . Nibble . . . . . . . . . . . . . Bit .............
page 82
Relation of DCC-Word to Terminal-No. / “Word – Byte – Nibble”
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Status word
bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
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H-byte
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bit 7 6 5 4 3 2 1 0
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L-byte
bit 7 6 5 4 3 2 1 0
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H-nibble X16 X14
bit 7 6 5 4 7 6 5 4
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L-nibble X15 X13
88bit 3 2 1 0 3 2 1 0
slot 01 02 03 …. 10 11 12 13 14 15 4 5 0 1 4 5 0 1
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1 5 1 5 1 5 1 5
IM PM DI 8 x DI DI DO DO DO DO
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2 6 2 6 2 6 2 6
AX 03 04 …. 11 12 13 14 15 16 6 7 2 3 6 7 2 3
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AX16 AX15 AX14 AX13

nibble L H H L H L H
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SITRAIN
Comm_Common page 83
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Use the information at the input of block DETM200 to find the page of the circuit diagrams of the “mill stand” showing
the ET200 input for the (incorrect) message “Oil Pressure Pump DE = ON”:
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information on block DETM200 ........................................

first page in circuit diagram / sheet ........................................
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second page in circuit diagram / sheet ........................................

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Use this circuit diagram to find out whether the feedback message “Oil Pressure Pump DE = ON” corresponds to the
control command “Oil Pressure Pump DE = ON”.
feedback message at AX26, terminal 6: logic state = . . . . . . .
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control command at module AX . . . . . . . . ., terminal . . . . . . . . ., logic state = . . . . . . .

Check the switching state of contactor K11 in the back of the training rack; please don’t pull any wires!
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Tell your trainer what you think is wrong (he will fix it !): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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page 84
Signal Transfer between ET200 and SIMOTION via I/O-Container
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address references in the I/O-container
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@
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AX13, terminal 2
L-byte, L-nibble, bit 2 PQ 1600.2
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signal from
ET200
1 (3)
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SITRAIN
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2.17 Forcing a control command via ET200

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For a clearly defined condition please select “Local Mode” and “Auxiliaries off” on the OP177 [by pressing key
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“K9/Local” (LED = green) and pressing key “K11/AUX OFF” (LED = green)]; acknowledge faults with key “F8 / ACK”
as far as possible.
tm
Since several alarms and faults still persist, control of the Auxiliaries (i.e. “Oil Pressure Pump DE”) is blocked. To force
“Oil Pressure Pump DE” to ON (e.g. for testing purposes), ET200 module A11-X15, terminal 1 has to be activated.
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To find the chart in which to force “Oil Pressure Pump DE = ON”, follow the procedure as follows.
Open the HW-Config and find out which address is assigned to this ET200
@
(relate AX15 via column “Comment” to -D15):

......................................................
8
Any signal exchange from ET200 to Simotion is carried out via variables. Use the I/O-container to identify the name of
d8
the variable assigned to the address found above:

......................................................
r
Supplement the table below to create a cross reference between “address”, “module number”, “output terminal”, “bit
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number” and “nibble” (refer to the information relating the ET200 terminal numbers to the bit numbers, page 77):
address: 1601. 7 6 5 4 1601. 3 2 1 0 1600.7-4 1600.3-0
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module number: X16 X15 X14 X13

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bit number: … … … … … … … …
nibble (H, L): …………….. ……………..
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output terminal: … … … … … … … …
Which byte (H, L), nibble (H, L) and bit of the assigned variable represents the ON-command “Oil Pressure Pump”?
Byte . . . . . . . . . . . . . Nibble . . . . . . . . . . . . . Bit .............
page 86
Finding the Reference “address / variable / chart”
address references in I/O-container
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any DCC-chart
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1600.0 … 1600.3
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@
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AX13, terminal 2 L-byte, L-nibble, bit 2 PQ 1600.2

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2 (3)
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SITRAIN
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Find out on which DCC-chart and on which page the variable representing “Oil Pressure Pump DE” is processed
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as output:
circuit diagram / page nr. .....................................
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(open “any DCC-chart” > Options > Chart reference data > View > Cross-References…Address > select “variable” >
double-click on this variable to open the “DCC-chart showing the variable”).
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Analyze which bits of the variable in question are on “H”-state:

hex-value: ……. ……. C 0
@
binary-value: … … … … … … … … 1100 0000
The identified ET200 word (for modules X13-X16) is output from block OUP130 (chart OUAUX, sheet C1).
88
Which hex-value has to be OR-wired in input I2/VM_HMEXFC to permanently switch on “Oil Pressure Pump DE”:
current binary-value of output QS: … … … … … … … … 1100 0000
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required binary-value of output QS: … … … … … … … … 1100 0000

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necessary OR-word at input I2: … … … … … … … … 0000 0000

necessary OR-word in hex: ….... ……. 0 0
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Activate the “Test Mode”, set “Watch On” for blocks OUP150 and OUP130, change input I2/VM_HMEXFC of block
OUP130 to the hex-value you have defined and verify that output Q9 of block OUP150 (“Oil Pressure Pump DE”
st
ON command) reads logic “H”.

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Discontinue the forced operation of “Oil Pressure Pump DE” by changing input I2, block OUP130 back to 16#0.
page 88
Control via PG/PC “in parallel” to Base Automation (MRG)
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Correlation of I/Os of ET200 to bits
bit 4 0 5 1
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1 5 ON-command for the anti-condensation heater:
ET200-
terminal via “-X13, terminal 2 = H”
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2 6 via bit 2 (low-nibble) / low-byte
bit 6 2 7 3
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high-byte
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16#3B72 16#3B72 16#3B
@
16#0000 16#72
16#0004 16#76
3 B 7 2
88 low-byte
bit 15-12 11-8 7-4 3-0

low-nibble high-nibble
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X14: high-nibble X13: low-nibble
current hex-value 7 2
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current binary value 0 1 1 1 0 0 1 0

to be set to high to switch on
required binary value 0 1 1 1 0 1 1 0
the anti condensation heater:
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necessary OR-word 0 0 0 0 0 1 0 0
bit 2 (low-nibble) / low-byte
dto. In hex 0 4
st
resulting hex-value 7 6
3 (3)
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SITRAIN
2.18 Clearing faults and alarms (on behalf of the ET200 stations); continued
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As next step of clearing faults and alarms the still indicated individual messages “Stator transformer 1 alarm
Buchholz” and “Stator transformer 1 trip Buchholz” will be followed up.
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Use the information provided on the OP177 and the circuit diagrams for the “mill-stand” to find out by which ET200
module and by which of its inputs “Stator transformer 1 alarm Buchholz” and “Stator transformer 1 trip Buchholz” are
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picked up.
page in circuit diagram / sheet ........................................
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ET200 module nr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

input terminal for “Alarm”: . . . . . . . . . . . . . . for “Trip”: . . . . . . . . . . . . . .
@
Find out whether the related hardware inputs are connected to the “Buchholz relay” (respectively to simulation
switches).
88
Buchholz alarm: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Buchholz trip : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If some components which are part of the evaluation by SIMOTION are temporarily not available, the concerned inputs
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of the ET200 modules can be temporarily connected to P24V simulating an “OK” feedback.
If some components will permanently be missing (i.e. a stator transformer without Buchholz relay is used), an
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adaptation of the related DCC-chart disabling the monitoring of the missing feedbacks is more reasonable.
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page 90
Identification of Fault and Alarm Messages sent to OP177
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16#0
16#8040 16#8040
16#0
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16#0
16#0
16 # 8040 8 0 4 0 16#0
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16#0
1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 16#0
bit number 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
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@
bit
0
1
2
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4
5
6
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7
8
9
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10
11
12
13
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14
15
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SITRAIN
Fault and alarm messages coming in from the plant (via ET200 stations) are evaluated and processed to initiate
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further actions on a larger number of DCC-charts.
In chart MSG, on sheets D4, D5 all messages which are sent to the OP177 are listed; without any fault or
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alarm all inputs of the three related blocks have to read 16#0.
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Find out which inputs on which block read “other than 16#0” and take a note of the value:
block . . . . . . . . . . . . . . . . . . . . . . . . . . input . . . . . . . . . . value 16# . . . . . . . . . .
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Continue by following the identified input with the smallest input number all the way to a sheet showing a table with a
listing of the faultword signals.
@
Analyze output QS of block FWH210 to find out which bits read a logic “H”: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Which messages are identified by these bits: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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........................................................
Note down the contact definition for the bits you are following up:
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contact definition = . . . . . . . . . . . . . . . . . for bits . . . . . . . . . . . . . . . . . .

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page 92
Enabling / Blocking “Groups of Faults”
16#FFFF
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from page 95
16# 7 3 B F 16# 8 0 4 0
*
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1
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enabling
bit 0 - 3
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1
delaying
enabling individual
bit 4 - 7 messages
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0
enabling
bit 8 - 11
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1
enabling
bit 12 - 15
from upstream: 16 # 73BF

88 0 1 1 1 0 0 1 1 1 0 1 1 1 1 1 1
definition NO/NC 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Enabling 1 1 1 1 0 0 0 0 1 1 1 1 1 1 1 1
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message to OP177 1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0
dto. In hex 8 0 4 0
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condition from field contact definition signal to OP177 alarm/fault state

H n.o. H L no message
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H n.c. L H message
L n.o. H H message
L n.c. L L no message
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SITRAIN
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Which field messages are evaluated if the group of messages belonging to “bit 0 to 3” is enabled:
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by bit 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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by bit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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by bit 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by bit 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Exclude all these field messages from being evaluated as messages on the OP177 by blocking the entire group
(nibble) to which they belong by following the respective input of block FWH200.
On block DEN200 (chart AUX1, sheet D2) you can either follow “I1” which will eventually lead you to a selection of “oil
@
transformer” / “dry transformer” or you can follow “I2” which defines the existence of a stator transformer in general.
In the present step please follow the approach via “I2”.
88
Once you have blocked the entire group all messages related to “Stator transformer 1” on the OP177 either reset
automatically or can be acknowledged.
rd
Which field messages are no longer evaluated in addition to the messages “Stator transformer 1 alarm Buchholz” and
“Stator transformer 1 trip Buchholz” by having blocked the entire group:
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..............................................................................
..............................................................................
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st
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page 94
Blocking (Enabling) Individual Faults
16#73BF
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from upstream: 16# 73BF 0 1 1 1 0 0 1 1 1 0 1 1 1 1 1 1
transfer to OP177 1 1 1 1 0 0 1 1 1 1 1 1 1 1 1 1
OR-word binary 1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0
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OR-word in hex 8 0 4 0
to page 93
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messages of bits 10, 11 are blocked downstream via “/enable bit 8-11” 16#73BF
messages of bits 6, 15 have to be blocked individually 16#0
*
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16#F3FF
- blocking (output = H no message) is effected by OR-linking the 16#8040
respective bits with “H” in case of n.o. contacts
- or by AND-linking the respective bits with “L” in case of n.c. contacts
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1 1
@
1 1
1 1
1 1
1 1
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6 1 1 6
0 1
1 1
1 1
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1 1
0 0
0 0
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1 1
1 1
15 1 1 15
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0 1
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SITRAIN
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If these two messages must not be suppressed, the blocking of an entire group is not permissible. In this case the
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messages to be suppressed have to be blocked individually.
To follow this approach, enable the group of messages you have just blocked: messages “Stator transformer alarm /
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trip Buchholz” show up again.

To find the source of the field messages, follow input IS1 of block FWH210 (chart AUX1, sheet E2) upstream all the
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way to a sheet showing a table which lists the individual field messages.
Check the state of the field messages “Stator transformer 1 alarm/trip Buchholz” on block ETA230 (chart INAUX, D2):
@
- Stator transformer Buchholz no alarm . . . . . . . . .

- Stator transformer Buchholz no trip .........
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Please note that a logic “0” represents the “fault state” only if the contact definition (block FWH210) reads “n.o. H”.
Assign a suitable word to the OR-gate (block ETA230, I2) to suppress only the a.m. two messages.
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required word at OR-gate binary … … … … … … … … … … … … … … … …

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hex ……… ……… ……… ………
Again all messages related to “Stator transformer 1” on the OP177 either reset automatically or can be acknowledged.
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Switch on S10 and S11 to disable the simulation of yet other fault conditions.
st
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page 96
Enabling (Groups of) Field Messages
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enabling
bit 0 - 3
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enabling
bit 4 - 7
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enabling
bit 8 - 11
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enabling
bit 12 - 15
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95
st
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SITRAIN
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2.19 Adding field messages to the fault monitoring
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Find out which conditions are simulated by switches S13 and S15 on the auxiliaries’ rack at the input of ET200:
- ET200 module number ...............................
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- terminal number for “S13”: ..................... for “S15”: . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- circuit diagram / page ...............................
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- simulated condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....................................

.................................... .....................................
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In the next step the DCC-programming has to be adapted to have these two messages shown on the OP177 (if the
respective simulation switches are off).
88
Start on chart AUX1, sheet E2 by analyzing the change of “Faultword Hardware 2” at the input of block FWH210 while
simulating the two messages (each message by itself).
d
S13: change from 16 # . . . . . . . . . . to 16 # . . . . . . . . . . S15: change from 16 # . . . . . . . . . . to 16 # . . . . . . . . . .

_r
Which bits are controlled by the switches? S13: ET200-view bit . . . . . . . DCC-fault-word-view bit . . . . . . .
S15: ET200-view bit . . . . . . . DCC-fault-word-view bit . . . . . . .
o
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Follow the signal upstream to a sheet showing a table which lists the individual field messages.
On block ETA250 (chart INAUX, D2) check the state of these two field messages when switching S13 and S15.
st
Which setting is presently blocking these two messages from being indicated on the OP177:
gu
responsible nibble in chart AUX1, E2, block . . . . . . . . . . . . . . for the group of messages belonging to bits . . . . . . . . .
Follow this input upstream and enable the nibble for this group of messages.
- setting in chart . . . . . . . . . . . . sheet . . . . . . . . . . block . . . . . . . . . . . . . to value . . . . . . .
- setting in chart . . . . . . . . . . . . sheet . . . . . . . . . . block . . . . . . . . . . . . . to value . . . . . . .
page 98
Blocking Individual Messages
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tm
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rd
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95
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SITRAIN
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Depending on the sequence you followed in enabling the “nibble” for the group of messages different messages will
have been indicated by the OP177.
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If you acknowledge the OP177-messages now, you will observe that not only the intended messages “Excitation
tm
transformer winding temperature alarm” and “Excitation transformer winding temperature trip” are indicated but
additionally the message “Excitation transformer core temperature trip”.
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Suppress message “Excitation transformer core temperature trip” individually:

- which bit is responsible: bit . . . . . . .
@
- which hex value has to be OR-linked to set above bit by itself:

on chart INAUX, sheet . . . . . . . . in block . . . . . . . . . value 16 # . . . . . . . . . . . . .
- which hex value has to be set to maintain the previous and add the new suppression: 16 # . . . . . . . . . .
88
Verify that message “Excitation transformer core temperature trip” can be acknowledged and that the messages
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“Excitation transformer winding temperature alarm” and “Excitation transformer winding temperature trip” can be
simulated with switches S13 and S15.
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page 100
Fault Evaluation via N.O., N.C. / Mode of Acknowledging
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(1) faultword HW checked
- for events to trip the drive 0100: fault as per bit 8 has
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- acknowledged automatically if cleared to be acknowledged
- set via “L” on “TC1”
(2) faultword HW stored
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- for events to inhibit a “switch on”
- persisting unless cleared AND acknowledged
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- set via “H” on “TC1”
for “NC/NO truth table refer to p. 93
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legend to functional
assignments: sheet A3
@
0102
delaying
88 0102
(1) faultword
messages fault “bit 1” and fault “bit 8” persisting 0100
HW checked
of Tripping only fault “bit 8” persisting 0000
both faults cleared (not acknowledged)
Combination
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0102
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acknowledge (2) faultword

command: 0100
temp. 0000 0100 HW stored
FFFF
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0100
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“latching” for bits as defined in “PM_HM_TC1”

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SITRAIN
2.20 Fault evaluation via N.O., N.C. / Signaling delay / Mode of acknowledging
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Switches S7 and S8 on the motor-ET200 are wired to simulate following messages:
S7 MOT-ET200 MX07, terminal 5 “leakage water in motor DE detected” (=31SF111.H02, sheet 7)
S8 MOT-ET200 MX10, terminal 1 “bearing oil pressure DE too low” (=31SF111.H02, sheet 11)
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First find out which chart reads in these ET200 inputs:

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module MX07 MX10

address ....................... .......................
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I/O-variable ..................................... .....................................

chart / page ................ ................
@
Adapt the logic in block ETM930 to have messages “leakage water” and “bearing oil pressure DE too low” pass
through:
88
value in I2 16# . . . . . . . . . .
Switch the Auxiliaries on (K3 / AUX ON”) to enable the monitoring of these messages.
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page 102
Fault Evaluation via N.O., N.C. / Mode of Acknowledging
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tm
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@
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rd
delaying
individual
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messages
blocking
groups of
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messages
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SITRAIN
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You will notice that the Auxiliaries indicate “Fault” after some delay.
Identify the responsible fault conditions:
ai
..............................................................................
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..............................................................................
Find out which simulation switch is assigned to simulate these faults: . . . . . . . . . . . . . . . . . .

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Starting on chart INAUX / G1 follow “Faultword Hardware 5” downstream to a sheet showing a table with a listing of
the faultword signals.
@
Find out which bits are responsible for these faults:

Bearing oil pressure DE too high, bit . . . . . . . . . .
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Bearing oil pressure NDE too high, bit . . . . . . . . . .

rd
Redefine the feedback evaluation “n.o. / n.c.” for these bits such as to clear these faults:
chart . . . . . . . . . . . . . . . block . . . . . . . . . . . . . . . input . . . . . . . . . . . . . . . value 16 # . . . . . . . . . . . . . . .
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Switch the Auxiliaries on again and verify that messages “leakage water in motor DE detected” and “bearing oil
pressure DE too low” are shown on the OP177 if switches S7 and S8 are switched off.
av
Define a delay time of 5s for “leakage water (S7)” and of 10s for “bearing oil pressure DE too low (S8)”.
If you discontinue the fault simulation by switching off S7 or S8, the respective fault clears automatically.
st
Define “Tripping Combination TC1” such that fault “bearing oil pressure DE too low (S8)” will clear only after it has
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been acknowledged:
chart . . . . . . . . . . . . . . . block . . . . . . . . . . . . . . . input . . . . . . . . . . . . . . . value 16 # . . . . . . . . . . . . . . .
page 104
Defining Properties for the ET200 Analog Modules
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SITRAIN
2.21 Defining properties for the ET200 analog modules

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Check the temperature feedback value on channel 1 in chart INAUX, F2, ETM200, X2 for different temperatures as
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simulated with the assigned pot in the rear of the drive): you will notice that the indication reads “32767” independent
of the simulated temperature.
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Temperature evaluation through analog inputs of the ET200 modules will typically fail if the analog inputs are fed by
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signals other than defined as “object property” for these modules.

Open the HW-Configuration and set the “object properties” of the AI-module (right mouse click on module > Object
Properties > tab “parameters” > click on the right end of line “Measuring type” > select required type > OK). Define
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“Measuring type on channel 1” as “Resistor (4-conductor terminal), value 3 KOhm”.

To activate these changes in the project, start the routine “Save and Compile”,
@
to activate these changes in the D445, download the HW-Configuration: PLC > Download.
After you have followed all steps the system requests you to do, the simulated temperature can be monitored on
“INAUX, F2, ETM200, X2”.
88
Since some changes in the DCC-charts have been carried out in online-mode, they still have to be saved in the
project:
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- exit “test mode”

- compile the DCC-charts (Chart > Compile > Charts as Program > Compile all)
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- close all DCC-charts

- “Save and Compile” the SCOUT-project
v
ta
Save all your modifications on the Flash Card for “U1_A_D445_Stand_6_pulse” (SIMOTION programming).
Save your project by the name SLTRN_1 and archive this project by the name SLTRN_1 as a zip-file.
s
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page 106
Controlling the Drive’s Operation via OP177
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standard “ON“-sequence: 1 5
@
standard “OFF”-sequence: A E
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A
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1 2 3 4 5
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E D C B 5
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SITRAIN
2.22 Controlling the drive’s operation via OP177

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If the Auxiliaries are switched on, the operating state shown on the OP177 indicates “ready to switch on” for the
Exciter C.B., the Exciter Unit (DC-Master), the Main C.B., the Power Uunits, the Motor C.B. and the Motor.
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If the indicated feedback state deviates, some preconditions are not (fully) satisfied as yet.
In the fault free condition an interlocking sequence is predefined for “Local Control”.
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PLEASE NOTE: DON’T FOLLOW THESE STEPS AS YET other than suggested! In a plant side commissioning a
good number of measurements, settings and tests still need to be done before the drive can be switched on in full.
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- Auxiliaries = ready Exciter C.B., Exciter Unit (DC-Master), Power Units, Motor C.B., Motor = ready
Main C.B. = not ready
@
- K3/AUX ON Auxiliaries = ON
Main C.B. = ready
- K4/Power ON Main C.B. = ON
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- K5/Exc. Breaker ON Exciter C.B. = ON

- K6/Excit. ON Motor C.B. = ON
exciter current flowing / pulses of power units still blocked
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- “n.set” via [ /\ ] or [ \/ ] Power Unit pulses enabled / Motor running at defined speed value
feedback on “K7/ENAOP”
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As this “switching-on sequence” shows, the standard routine requires the Main CB to be switched on before the
Excitation C.B. and the Excitation can be switched on. In consequence, the next steps to be carried out will concern
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the preconditions required to switch on the Main C.B. and the Excitation.
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page 108
Essential Settings for the Excitation
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- P100 serves as scaling reference and
as excitation current limit
(along with P171: I.exc.max = P100 * P171).
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- P78 acts as scaling reference for the
line input voltage.
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r072 * P076 p390
P101 p388
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Exciter setpoint from SIMOTION DCC via
PROFIBUS and “Free Blocks” of DC-Master
- p390 defines the HW-rating of the DC-Master and the scaling reference on SIMOTION/SINAMICS.
@
- p388 represents the maximum armature voltage available for a line input voltage as set in P101; P101.max = 1.35 * “P78”).
- p389 acts as exciter current setpoint in no-load condition (i.Sq = 0).
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rd
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P820
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Unless the exciter winding is equipped with temperature

sensors, the I2t-monitoring should not be deactivated.
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SITRAIN
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2.23 Verifying Essential Settings on the Excitation Unit (DC-Master)

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Basic commissioning of the DC-Master has already been carried out by downloading the assigned file (via Drive
Monitor). Furthermore a number of faults which were due to some minor “mismatch” between the required
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parameterization of the DC-Master and the settings assigned to it via download already have been cleared by
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adapting the respective parameters.

Before the DC-Master is switched on for the first time, some essential parameters should be checked to verify that
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the download file which has been used matches with the given set-up:
- P079 = 1, P601.3 = K230 (particular settings, if the DC-Master is used for excitation)
- P171 = 120%, P172 = -10% (current limits; unless required differently)
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- P150 = 100 (training rack: 600), P151 = 1500 (alpha_G limit, alpha_W limit)
The parameters for “Rated excitation voltage” and “Rated excitation current” have to be functionally identical both in
the DC-Master and in the Motor Module; verify that this requirement is given in the current parameterization (refer to
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the information in the slide).

At site applications P076 is typically set to 100%; the setting of 20% is required at the training rack because of
rd
the large armature current rating of the DC-Master in comparison to the small exciter current rating of the
synchronous motor; [requirement: P076 > (P100 * P171) / r072].
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page 110
Excitation-specific Settings of the DC-Master
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2.24 Deleting Faults in the ”message buffer”
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During commissioning a large number of alarm and fault messages have been indicated and acknowledged; all alarm
and fault messages are stored in the “message buffer” and can be viewed on the OP177 via key ”F4/MSG Buffer”.
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Have a look at the “message buffer” and delete its contents as follows:
- HW key “F6/Diagn.”
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- SW button “Delete Old Messages”

- User = ADMIN
- Password = 100
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- SW button “Delete Old Messages”

To block further access to Password protected commands of the OP177, log out of ADMIN:
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- HW key “F7/System”
- SW button “Log Off User”
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page 112
Synchronous Motor Exciter Current Control
θset iSd,set
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in case of
induction
motor
n iSq
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nset iSq,set
- nact - iact, q
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θ iSd
iset, d
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- iact,d
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model
θset IE,set
magnetization
IA
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IE,set IA,set αset
- IA,act
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PROFIBUS
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100%
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model
θact
θact IE,act IE,act IA,act
magnetization
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n iSq
nset iSq,set
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- nact - iact, q
θ iSd
iset, d
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d8
- iact,d
model
θset
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IE,set
operation IMO
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IA
IE,set IA,set αset
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- IA,act
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PROFIBUS
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100%
model
θact operation IMO
SITRAIN
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n iSq
nset iSq,set
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- nact - iact, q
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θ iSd
iset, d
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- iact,d
θset
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IA
IE,set IA,set αset
θ
uS,act model
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- IA,act
θact IE,set operation
iS,act UMO
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UMO; n - θact
PROFIBUS
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IA,act
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SITRAIN
2.25 Energizing the DC-Master

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To test the function of the DC-Master it has to be switched on; In this step of lab, the OP177 will be used.
Via OP177 the sequence of operation implmented in DCC is mandatory: key “K9, Local mode” / key “K3, Auxiliaries
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On” / key “K4, Power ON” / key “K5/Exc. Breaker ON” and finally the ON command to enable its pulses via key
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“K6/Excit. ON”.
At the present step of commissioning, the circuit breaker should only be operated withou feeding voltage to the drive.
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At site, initial operation of Circuit Breakers has to be carried out with the Circuit Breakers in TEST-POSITION !
On the training rack, switch off m.c.b. Q2 to functionally put “Line Side Switch 1” in Test-Position.
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Now select “Local Mode, switch on the Auxiliaries and switch on the Main C.B. via “K4/Power ON”: you will observe
“no function whatsoever”.
To find the very basic reason (indicated on the OP177 by message “Enable Circuit Breaker System 1 from PSA
88
missing”), check the drive’s status via “missing enables” and set the responsible parameter to its required value:
p.......... = ...........
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You will notice that a fault is signaled. Identify the fault message indicated for drive device “VECTOR”:
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current fault: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Open the expert list for object “Vector” and analyze the settings in p405 (this parameter was indicated to have a
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parameterization error) under the aspect of using an HTL-encoder in the given hardware. Crosscheck the respective
settings in p404, adapt them to the requirements of the HTL-encoder and set p10 = 0:
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p.............. = .......... p.............. = ..........

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After some delay the SMC30 reads “RDY = green” and the related LED indicates an encoder supply voltage of >5V.
Upload these changes to the PG/PC, save the changes in the project and save these changes on the CF card.
Again switch on the Main C.B. (“K4/Power ON”): now the Main C.B. will close.
page 116
Source of Excitation Breaker Control
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excitation breaker control via
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DC-Master D445 / ET200
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1 0
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0 1
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Proceed by switching on the “Exciter line breaker”: you will observe that the assigned contactor (exciter breaker K3 on
the training rack) doesn’t respond.
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Checking the function diagrams for the training rack you will find two possible causes: “missing pick up of contactors
K11, K13” and “missing operation of terminal XR109, 110” of the DC-Master.
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The reason could be a true fault in the control of the contactor, but this function will also fail if the exciter breaker is
controlled “from external”, typically via ET200 as true on the training rack.
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Follow up on “terminal XR109,110” using the available circuit diagrams and SIMOTION charts to find the two
responsible settings (hint: exciter control word / HW-Config / I/O-variable …pqw1_err_stw1 / charts OUTPUT, F1 /
OUTPUT, B5 / AUXS, L2 / AUXS, E2 / AUXS, E1 / AUXS, B1):
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setting 1 DCC-block . . . . . . . . . . . . . . . . / Input . . . . . . . . . . . . . . . . / value . . . . . . . . . .

setting 2 DCC-block . . . . . . . . . . . . . . . . / Input . . . . . . . . . . . . . . . . / value . . . . . . . . . .
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The definition “control via DC-Master” respectively “control from external” is set on blocks TPH949 and TPH943 in
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chart AUXS, sheet B1.

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On repeating the test after having assigned the correct definitions, message “Contactor fault excitation breaker” is
indicated temporarily. Switch on switch S16 to clear the simulation of the “contactor feedback fault”.
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page 117
Definition: Continuous Signal or Pulse Signal
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excitation breaker
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control via
continuous pulse
signal signal
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1 0
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Repeating the test once more you will notice that the excitation breaker is still tripping after a short delay with message
“self tripping excitation breaker”. On chart AUXS, sheet E2, block EXB150 the switching characteristic of the exciter
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breaker control has to be defined (“continuous signal” or “pulse signal”).

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Check the wiring scheme of the training rack “Auxiliaries” to find out whether a continuous signal or a pulse signal is
used; adapt the programming of the DCC-chart accordingly.
Verify the success of this modification: the exciter breaker K3 closes and remains closed.
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(A lead to chart AUXS, E2 is given by the temporarily displayed OP177 message “=.WA75/E2, Self tripping excitation
breaker”.)
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Switch on the exciter via “key K6/Excit. ON”. Now you will observe the following:
- the command is accepted but the pulses are not enabled
8
- after elapse of the monitoring time

d8
> the excitation circuit breaker is tripped and

> the Power Units and the Motor signal “Fault” (red symbols on the OP177).
r
Analyze the indication shown on the PMU of the DC-Master “before” and “after” the command “key K6/Excit. ON”.
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Refer to the supplied circuit diagrams of the training rack and to the function diagrams of the DC-Master to find the
reason of the still observed malfunction.
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Take the appropriate action to eliminate this cause:

...........................................
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page 120
Fault Messages of the DC-Master
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SITRAIN
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Again switch on the exciter via “key K5/Ex. Breaker ON” and “key K6/Excit. ON”. You will notice that presently the
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Power Units, the Motor and the Exciter indicate “Fault” immediately.
Find out which fault message and which fault value is shown for the DC-Master:
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................................................................................
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Assign the correct parameter value on the DC-Master ( EEPROM) and again switch on the exciter via
“key K5/Ex. Breaker ON” and “key K6/Excit. ON”.
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Once again, the Motor Module, the Motor and the Exciter indicate “Fault” immediately.
As before, find out which fault message and which fault value is shown for the DC-Master:
................................................................................
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Detailed information about the line voltages of the DC-Master is provided via connectors K301 to K303.
Assign the correct parameter value on the DC-Master ( EEPROM) and again switch on the exciter via
88
“key K5/Ex. Breaker ON” and “key K6/Excit. ON”.

You will notice that:
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- the command is accepted but the pulses are not enabled (the LED assigned to K6 flashes)
- after elapse of the monitoring time, the Power Units and the Motor signal “Fault”
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(red symbols on the OP177).

Again analyze the indication shown on the PMU of the DC-Master “before” and “after” the command “key K6/Excit.
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ON”; refer to the circuit diagrams of the training rack and to the function diagrams of the DC-Master to find the reason.
Take the appropriate action:
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...........................................
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page 122
Cross-Reference from OP177-Messages to Charts to Periphery
=.WA =.WA =.WA
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actual messages >display OP177< X chart chart chart
01 CPU 51 DRVMG 75 AUXS
Date Time Text 03 SIMU 54 ISMON 78 AUX1D
05 POWER 53 MOPRO 81 PANEL
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29/10/10 09:55:45 =.WA11 / I3 (=.DA/1.9) 04 LCOMRG 61 INAUX 82 MSG
Switch on fault excitation converter fan 1 08 DOPAR 62 INAUXD 97 OUAUX
10 COMCBE 71 AUX1 98 OUAUXD
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11 INPUT 72 AUX2 99 OUTPUT
from OP177 chart reference (=.WA xx) to chart, section, page 12 POSIT 73 TMONI
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The assignment of the “message prompt” (e.g. =.WA11) can be found in “object properties” of the DCC-chart as “Author”
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@
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follow the message-relevant signal to the variable / relate variable to process data word / find assigned node and PZD-no.
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follow the connected signal to the responsible origin

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SITRAIN
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Once again switch on the exciter via “key K5/Ex. Breaker ON” and “key K6/Excit. ON”: now the pulses are enabled
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and exciter current is flowing through the synchronous motor; message “exciter converter fan fault” (“spare” by
mistake), however, is signaled.
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Use the information on the OP177 to find chart, section and page which processes this message:
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information of OP177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
chart ............ section ............ page ............
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Analyze the outputs of blocks RLFD300 and RFLD310 to find which input, which variable and which bit represents
message “exciter converter fan fault”:
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input . . . . . . . . . . . . . . . . . variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bit . . . . . . . . . . . .

Hint: via I/O-container relate the variable to the periphery address, via DC-Master function chart find the input
(terminal or substitute).
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Follow this variable and bit to its origin and substitute the binector of the missing input by a constant “H”:
U.......... = ...........
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Upload the parameterization of the DC-Master as “delta file” by the name “DC_SL_Trainee_Delta_3”.
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page 124
Measurement of the Exciter Current in the DC-Master
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G161
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G162
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G121
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SITRAIN
2.26 Measuring the Exciter Current

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Apart from the direct measurement of the exciter current via ammeter the exciter current can be measured via
parameters on the DC-Master and via indication on the OP177 (both as setpoint values and as actual values).
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Read the exciter current on all locations suggested below and crosscheck the readings to verify that they are all
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matching:
OP177 main faceplate IEact = ...............
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F10/Motor FLUX = ...............

F10/Motor IEACT = ...............
K1/Actual values IEact = ...............
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DC-Master diagram G162 r020 = ............... % of . . . . . . . . . . A = .......... A

diagram G162 K115 = ............... % of . . . . . . . . . . A = .......... A
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diagram G161 K133 = ...............

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The last step of commissioning the DC-Master consists of the optimization of the “exciter current circuit” on behalf of
the DC-Master.
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As the exciter current for the synchronous motor is controlled via the armature current of the DC-Master, its “armature
current controller” has to be optimized.
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page 126
Drive Control via DCC-Chart “LCOMRG” Line CoOrdinator Master Ramp Generator
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status feedbacks control commands
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operating modes
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actual values
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setpoints / limits
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SITRAIN
2.27 Substituting the “Automation” via “DCC-Chart, LCOMRG”

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Up to now the required sequence of switching on the Auxiliaries, the Power, the Exciter Breaker and the Excitation has
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been activated via OP177 in mode “Local”. Once the entire system is in operation, control of the SL150 will be in mode
“Remote” via “Base Automation, MRG”.
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An alternative to “Automation” is provided on DCC-chart “LCOMRG, sheet C2”. From this chart the SL150 can be
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switched on in mode “Remote” the same way as from the OP177 (all “DCC-interlocking” for the required sequence
is provided).
Additionally a number of test-signals for the optimization of control loops are ready to be activated.
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page 128
Exciter Control via DCC-Chart “LCOMRG”
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LCO_ACT_STATUS LCO_CONTROL
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2 Auxiliaries = On BM_AUXON
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4 Main C.B. = On POW_ON
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5 Excitation Breaker = On ON
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6 Excitation = On BM_STC_ON
3 Excitation Startup Mode EXC_STARTUP
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Define the current setpoint before switching on the Test Signal
7 Test Signal = On EXC_ENREF
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1 Startup Mode STARTUP
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sequence of operation
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SITRAIN
Change over to mode “Remote” (key “K17/Remote”): all systems switch off. m
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Open DCC-chart “LCOMRG, sheet C2”, select “Test Mode” and set “Watch On” for blocks “LCO_ACT_STATUS”,
“LCO_CONTROL” and “LCO_CTL_010”.
l.
Activate “Startup Mode” on block “LCO_CTL_010” via input STARTUP.

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Verify that the feedback message “BM_AUXONS” corresponds to the control command “BM_AUXON” by switching
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the Auxiliaries “off” and “on” via LCOMRG.

Using “LCOMRG”, switch on the test signal for the optimization of the exciter current as suggested; if relevant, check
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the feedback on the assigned block:

- EXC_STARTUP
- POW_ON Main C.B. switches on
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- ON Exciter C.B. closes

- BM_STC_ON exciter pulses are enabled, current setpoint = 0 (“- -” on PMU)
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Calculate the values for “EXC_SETP1” and “EXC_SETP2” as follows (100% = “p390_Vector”):
- EXC_SETP1 = 50% of the rated exciter current (generally used); at the training rack,
select 50% of the rated armature current of the DC-Master (P100)
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........... A ........... % setting . . . . . . . . . . .

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- EXC_SETP2 = 70% of EXC_SETP1

........... A ........... % setting . . . . . . . . . . .
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- EXC_ENREF current setpoint > 0 (“ I “ on PMU)

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page 130
Definition of the Pulse-Width of the Test Signal
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EXC_SETP1
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EXC_SETP2
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Flashing Flashing
duration duration
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rd
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DANGER ! Please note that DCC-input values of 1.0 represent 100.0% !

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SITRAIN
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Verify your settings by measurement on the DC-Master: r020 = 35% / 50% / 35%, … (100% = “P100_DC-Master”) and
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on the OP177: IEact = 22% / 33% / 22%, …
Follow the signal of the exciter current setpoint in the DCC-charts to find out where to set the pulse-width of the test
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signal:
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....................................................
Change the pulse-width to 1s.
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After a (programmed) delay time of 5 minutes after switching on the excitation (BM_STC_ON), function “Power saving”
reduces the exciter current to (programmed) 20% of the setting (chart AUX2 / B2).
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page 132
Automatic Identification of Current Loop Data
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2 Auxiliaries = On BM_AUXON LCO_CONTROL
4 Power = On POW_ON
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5 Excitation Breaker = On ON
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6 Excitation = Off / On BM_STC_ON
3 Excitation Startup Mode EXC_STARTUP

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7 Test Signal = Off EXC_ENREF

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SITRAIN
Comm_Common page 133
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2.28 Automatic Optimization and Identification of Current Loop Data (in the DC-Master)
The exciter winding resistance and the exciter winding inductivity are typically preset by Siemens in parameters P110
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(armature winding resistance) and P111 (armature winding inductivity). They can, however, also be crosschecked or
identified by an automatic “Optimization and Identification” (manual tuning will not improve the settings beyond the
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result of the “automatic identification”).

First take a note of the presently set values of following parameters (left column):
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- armature resistance P110 = . . . . . . . . . . . . . . . ...............

- armature inductivity P111 = . . . . . . . . . . . . . . . ...............
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- proportional gain P155 = . . . . . . . . . . . . . . . ...............

- integral action time P156 = . . . . . . . . . . . . . . . ...............
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In LCOMRG, switch off the test signal (EXC_ENREF = L) and switch off the excitation (BM_STC_ON = L), set
P51 = 25 (request to auto-tune the pre-control and the current controller) and start the routine by switching the
excitation back on again (BM_STC_ON = H).
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You will notice that the DC-master issues F50. Analyze the prompted fault value, note down the current value of the
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responsible parameter and TEMPORARILY adapt the setting to carry out the identification routine.
P.......... = ............... / ...............
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current setting temporary setting

On completion note down the automatically identified values in the column on the right. Armature resistance and
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armature inductivity have to match fairly well; values for the current controller may differ and will be manually
optimized in the next step.
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Set the parameter you have temporarily adapted back to its original value.
page 134
Trace-Tool of Drive Monitor
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Start of trigger “by command” Start of trigger “as specified”
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Selection of
“signals to
88
be recorded” Sampling rate
and pre-trigger
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recording of signal samples processing of signals transfer of samples to PG/PC
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SITRAIN
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2.29 Optimization of the “Exciter Current Controller” (in the DC-Master)
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To optimize the exciter current controller the “exciter current actual value” has to be recorded and its response to a
step of setpoint has to be evaluated.
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To correctly analyze any optimization, none of the variables of the closed loop in question must be limited; in the given
situation this applies for the firing angle.
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Tracing exciter currents is possible within the DC-Master (Drive Monitor), within the Infeed (SINAMICS Tracer) and
within Simotion D4xx (SIMOTION Tracer). DC-Master connectors (K…) can be traced via Drive Monitor only.
To optimize the PI-controller, the “exciter current actual value”, the step of “exciter current setpoint” and the firing
@
angle will be recorded using the tool Drive Monitor.

Refer to function diagrams G162 and G163 and assign the a.m. signals to be recorded (as close to the current
88
controller as possible):
- “exciter current setpoint” K............
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- “exciter current actual value” K............

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- “firing angle current controller” K............

- “firing angle pre-control” K............
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To be able to identify a limiting of the firing angle, relate the percent reading of K100 representing the currently set
limit of the firing angle to its degree reading (refer to the given characteristic):
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r018 = . . . . . . . . . . . . . . . degrees α [%] (K100)

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K100 = . . . . . . . . . . . . . . . % +100
60 120
α [degr] (r018)
-33.3
page 136
Pre-Control and PI-Controller
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Blocking the PI-controller
(operation on pre-control only)
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P154 = 0 I-controller blocked
1 I-controller active
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* set in P164 = 0 P-controller blocked
relation to
P111 / P110 1 P-controller active
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Blocking the pre-control
is functionally not possible
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P153 = 3 pre-control
for field windings of SYN-motors
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* to minimize mutual influence of Pre-control and PI-controller

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SITRAIN
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(Armature) Current Pre-Control and (armature) current PI-Controller act in parallel.
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Since pre-control cannot functionally be blocked it has to be kept active and the PI-controller will be optimized in
parallel to the pre-control.
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Optimization starts by tuning the proportional gain of the P-controller (either via P154 = 0 or via P156 = 10 s):
beginning with a small proportional gain (P155) its value will be increased such that the current steps up to its setpoint
ho
value without developing noticeable noise (in doubt, select the smaller value rather than the larger).
Optimized “proportional gain”, P155 = . . . . . . . . . . . . . .
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To optimize the integral property the integral component is brought into action starting with a large integral action time
(P156) and then reducing to get a response with an overshoot of close to 15 % (with the pre-control contributing to the
transient); with the PI-controller by itself an overshoot of about 4 % would be expected.
8
Optimized “integral action time”, P156 = . . . . . . . . . . . . . .

r d8
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page 138
Optimization of the Exciter Current Controller (in DC-Master)
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Optimization of the gain (k.P)
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0.2 / 10.0s k.P = 0.4 / 10.0s OPT 1.0 / 10.0s
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Optimization of the integral action time (T.N)
88
damping of the
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overshoot via P191
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0.4 / 50 ms k.P = 0.4 / T.N = 0.01s OPT 0.4 / 0.003s

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SITRAIN
m
Looking at the overall transient (Pre-Control in parallel to the PI-controller) a significant overshoot resulted.
co
Improve the transient response to minimize the overshoot while keeping the dynamic setting of your optimization:
- set the filter time constant (P191) at the setpoint input of the armature current PI-controller to “4-times”
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the time constant defined by the “auto-tuned” values of “Armature circuit inductance, P111” and
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“Armature circuit resistance, P110”

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P191 = . . . . . . . . . . . . .
- check the impact of P191 by again looking at the “Armature current actual value, K115”:
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the transient should read an overshoot of about 8 %.

(Note: P191 is not adjusted by the auto-tune function; it has to be set manually).
@
All settings on the DC-Master have now been completed. Make sure that you have made these settings on the
EEPROM and save the parameterization by uploading the data (i.e. as a delta-file, type “changed parameters only”).
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page 140
Trace-Tool of Scout
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signal to be traced
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chart “OUTPUT” chart “OUTPUT”
block “SFLD20” block “SFLD30”
signal “Y” signal “X”
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SITRAIN
2.30 Tracing Signals at the Input- or Output-Channels of DCC-Blocks

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The “exciter current setpoint” originates from Simotion DCC, the “exciter current actual value” is fed back to Simotion
DCC; therefore both signals can also be traced using the Scout tracer.
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These variables can be picked up in their nature as process data words; equally though they can be recorded at the
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output “Y” or at the input “X” of any block within the DCC-charts.
Open the I/O-container and find out which variables are assigned to the following:
ho
- “exciter current setpoint”: ..........................................

- “exciter current actual value”: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Via “Chart reference data” localize the DCC-chart and sheet where the a.m. signals originate:
@

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Follow both of these values until you come to a block which is referencing the signal; take a note of the name of the
block and of its input / output at the “remote end” of the I/O-variable (select the unscaled value):
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Select the “recording properties” of the Scout tracer as suggested in the slide.
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page 142
Assigning DCC-Signals as Pins to the Tracer
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SITRAIN
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Inputs and outputs of DCC-blocks can be picked up as “Pins” of the DCC-chart.
Define the Scout trace tool to record the two exciter current values.
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page 144
Analyzing the Step Response
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OUTPUT._dcc_instances._output_sfld30.x
INPUT._dcc_instances._input_rfld210.y
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OUTPUT._dcc_instances._output_sfld30.x
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INPUT._dcc_instances._input_rfld210.y
trise = 33ms (typical value 20 … 30ms)
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tdead = 17ms (typical value 10 … 15ms)

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SITRAIN
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Analyze the step response of the exciter actual current as regards:
- overshoot . . . . . . . . . . . . . . % of step (must be no more than 15%)
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- dead time . . . . . . . . . . . . . . ms (typically 10 to 15ms)

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- rise time . . . . . . . . . . . . . . ms (typically 20 to 30ms)
Discontinue the “Excitation Startup Mode” by reversing your steps on LCOMRG:

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- Test Signal = off EXC_ENREF = 0

- Excitation = off BM_STC_ON = 0
- Excitation Breaker = off ON = 0
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- Main C.B. = off POW_ON = 0

- Excitation Startup Mode = off EXC_STARTUP = 0
- Auxiliaries = off BM_AUXON = 0
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page 146
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Commissioning
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the
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Motor Power Section
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List of Contents
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3.1 Ident-file and ACX-data of the Power Stack Adapter …................................................... 6
3.2 Test Modes …................................................................................................................... 8
3.3 Test Mode “Excitation” ….................................................................................................. 14
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3.4 Calibration of the Voltage Measurement …...................................................................... 16

3.5 Calibration of the Current Measurement …...................................................................... 20
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3.6 Phase Shift Measurement / in general ….......................................................................... 24

3.7 Phase Shift Measurement / by comparing “Power Voltage” to “Reference Voltage” ….... 28
3.8 Phase Shift Measurement / by comparing “Power Voltage” to “SCR Gating Pulses” ….. 30
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3.9 Direct Control of the Firing Angle ….................................................................................. 34

3.10 Open Loop Operation in I/f-Mode / f = 0 Hz ….................................................................. 42
3.11 Optimization of the Phase Current Controller in I/f-Mode …............................................. 48
3.12 Open Loop Operation in I/f-Mode / f > 0 Hz ….................................................................. 50
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3.13 I/f-Operation with “Zero Frequency Quantity Controller” ….............................................. 52

3.14 “Zero Frequency Quantity Controller Pre-Control” …....................................................... 54
3.15 Adaptation of the “Intermittent Current” …........................................................................ 56
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3.16 Rotor Position Detection …............................................................................................... 58

3.17 Checking Voltage and Current Waveforms ….................................................................. 64
3.18 Verifying Essential Settings on the Motor Module …........................................................ 68
3.19 Encoder Data …................................................................................................................ 70
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3.20 Operation of the Motor in “Speed Control” …................................................................... 72

3.21 Setting the “Scaling of the Magnetizing Inductance, d-axis” …......................................... 76
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3.22 Setting the Saturation Characteristic …............................................................................ 80

3.23 Excitation Current Adaptation (Balancing-Factor / G-Factor) …....................................... 82
3.24 Transition “Current Model” Voltage Model” ….......................................................... 86
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3.25 Reading “Indexed Variables” …........................................................................................ 88

3.26 Optimization of the Current Controllers via ISq ….............................................................. 90
3.27 Optimization of the Flux Controller …................................................................................ 102
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3.28 Optimization of the Speed Controller via “Step of Setpoint” ….......................................... 108
3.29 Optimization of the Speed Controller via “Step of Load” …............................................... 114
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3.30 Final Steps …..................................................................................................................... 118
page 02
Sag-Mill Gearless Drive, 24 000 kW
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SITRAIN
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Preface
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This training section covers all essential steps of commissioning the Motor Module of a SL150 medium voltage
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converter.
With the inevitable exception of the medium voltage hardware the SL150 training unit is equipped with the same
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components as found in site applications of SINAMICS SL150:

- SCR power sections (4-quadrant design) for phases A to C
- original control electronics (processor boards, option components) including the Power Stack Adapters
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- DC-Master to provide the excitation current for the synchronous motor

- synchronous motor
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The programming within the project used for this training is based on an original site project with some exceptions
only; in consequence many steps of commissioning a SL150 converter with synchronous motor can be carried out
on the training unit in quite the same way as at site.
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Naturally, the commissioning of the medium voltage hardware cannot be included in this training.
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Apart from the training for which this material is prepared it can well be used as guideline and reference material for
plant commissioning. In this case, however, the particular link of the plant periphery to the “drive controllers” (via PLC,
TMxx, …) has to be considered and the plant periphery has to be included in the commissioning sequence as well.
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Wherever you do any commissioning work, please strictly observe the five safety rules.
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page 04
Ident-File and ACX-Data of the Power Stack Adapter
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SINAMICS
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SL150
CU320-2 DP
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Excerpt of the ACX-data
(typically provided by PEP as pdf-file):
Order RACK SL150 --

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Rated power 2 kW
Rated voltage 400 V
Rated current 9.1 A
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AVT-mapping “Current” 9.1 A

AVT-mapping “Voltage” 947 V
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SITRAIN
Comm_Motor page 05
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3 Commissioning the Motor Module
3.1 Ident-file and ACX-data of the Power Stack Adapter
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The measurement of motor voltage and motor current (at the output of the drive) is determined by the respective
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measuring device (voltage attenuators, Hall effect transformers), by the interface (Analog Value Transducer, AVT) and
by the programming (stamping) of the Power Stack Adapter (PSA).
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Power Stack Adapters are identical in hardware for any voltage and power rating of SINAMICS SL150 as well as for
any other SINAMICS medium voltage drive (SM150, GL150, GM150).
The particular function of the PSA as interface for SINAMICS SL150, SM150 etc. is defined by an “Ident-file; the
@
SL150 requires file “ident_23” on the Compact Flash Card as shown in the slide above.
Power unit data (e.g. power, voltage, current) and the “AVT mapping range” (conversion of the optical telegram from
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the AVT to parameter values) are defined via ACX-file “DESC0000.ACX”.

The ACX-file is generated by SIEMENS, has to be on the CF card (refer to above slide) and should be available as a
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pdf-file at site. The “AVT mapping range” currently valid for the PSA can be checked via parameters.
Take a note of the valid “AVT mapping range” for current and voltage using the assigned parameters (AVT mapping
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range parameters define the respective PSA-internal “100%” scaling):

p.......... = .......... current range / r6761: .............A
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voltage range / r6760: .............V

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page 06
Test Modes
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The test has to be initiated by a rising flank (e.g. via switch on a spare digital input).
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SITRAIN
3.2 Test Modes

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Once all auxiliary voltage supplies and field signals have been checked, the cooling unit, the isolator, breakers and the
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excitation circuit can be tested by activating assigned “test modes”.
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In the fault-free state of the drive the preselected test mode is activated by a switchable input as assigned to p6651;
an assignment of a constant “1” is not accepted for the test.
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On the training rack hardware and project programming as installed allow one test mode only:
[33] Test operation excitation exciter unit (DC-master)
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At site, the test of Circuit Breakers has to be carried out with the Circuit Breakers in TEST-POSITION only !
On the training rack, switch off m.c.b. Q2 to functionally put “Line Side Switch 1” in Test-Position.
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page 08
Activating Test Modes via DCC
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SITRAIN
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On the training rack, switch S47 is hardware-wired to activate the “test mode”.
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Using appropriate means, find out which block input of SIMOTION DCC charts provides information of the switching
state of S47:
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- switch S47 is picked up on object . . . . . . . . . . . . . . . . . . . . on terminal . . . . . . . . . . . . . . . . . . . .

- the switching state is transferred via PROFIBUS of object . . . . . . . . . . . . . . . . . . . . with bit . . . . . . .
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of process data word PZD . . . . . . . . using PROFIBUS periphery address PI . . . . . . . . . .

- the link to SIMOTION DCC uses variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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- this variable leads to chart/sheet . . . . . . . . . . . . . . . / . . . . . . . . . . . .

- the switching state of S47 can be monitored on chart/sheet . . . . . . . . . . . . . . . / . . . . . . . . . . . . ,
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block . . . . . . . . . . . . , input . . . . . . . . . . . . . . . . :
S47 = off value 16# . . . . . . . . . . . . ; S47 = on value 16# . . . . . . . . . . . .

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page 10
Activating Test Modes via DCC
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SITRAIN
Comm_Motor page 11
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In the next step find out which block input of SIMOTION DCC has to read in the switching state of S47:
- Binector input p6651 is connected to bit . . . . . . . of process data word PZD . . . . . . . .
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of object . . . . . . . . . . . . . . . . . . . . using PROFIBUS periphery address PQ . . . . . . . . . .

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- the link to SIMOTION DCC uses variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- this variable leads to chart/sheet . . . . . . . . . . . . . . . / . . . . . . . . . . . .
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- the test signal has to be entered on chart/sheet . . . . . . . . . . . . . . . / . . . . . . . . . . . . ,

block . . . . . . . . . . . . , input . . . . . . . . . . . . . . . .
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Change to mode “DCC-Offline” and on block RCU300 set “output, bit 6” to “Visible” (mark block RCU300 > Object
Properties > tab I/Os > remove checkmark “Invisible”).
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“Compile” chart INPUT to extend block RCU300 by this additional output.

d8
Finally connect this new output of block RCU300 to input BM_TST_ON of block INP898 (chart OUTPUT / sheetC3).
“Compile” the changes and download SIMOTION D445 to activate the modifications.
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Verify the switching state of S47 on the link to p6651 (bit 9 of “Connector binector converter” for PZD 16 “Receive”
in object VECTORSL_U1).
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page 12
Test “Excitation”
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Operating status display of the DC-Master / parameter r000
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percentage on p6286 is based on p390

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The rated excitation current (p390) defines the hardware rating of the DC-Master.
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SITRAIN
3.3 Test Mode “Excitation” m

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In mode “operation” the excitation is switched on automatically once an ON-command is given (command at bit 0
of sequence control, p840).
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Pulses of the power section phases A to C are enabled separately via “pulse enable, p852”.
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To test the exciter circuit, test mode “excitation” uses p6286 to define the value of the exciter current.
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Set the OP177 to “Local” (K9/Local), switch on the Auxiliaries (K3/AUX ON), verify that the Main C.B. is in “test
position” at the training rack: Q2 is switched off), switch on the Main C.B. (K4/Power ON) and switch on the
Exciter C.B. (K5/ Exc. Breaker ON).
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Select test mode “excitation” and trigger the test via the assigned switch S47:
the operating state of the exciter (DC-master) changes from “o7.1” (waiting for an ON-command)
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to “- -” (no torque direction requested)

The percentage setting on p6286 is based on the rated exciter current as set in p390.
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Define an exciter current of 0.75 A:

p6286 = . . . . . . . . . . . % exciter current is generated and the feedback in r1641 reads the
actual excitation current to be the same value as set in p6286
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Set the excitation current setpoint to zero, discontinue the test (switch S47 = off) and select “test mode inactive”.
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page 14
Calibration of the Voltage Measurement
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(1)
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power section
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phase A
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AVT
step 1
phase A
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output
K5 disconnector
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U1 U2
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motor step 2b
phase A
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step 2a
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(1) Physical quantities can be shown in “percent” or in “SI-units” ( configuration > units)
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SITRAIN
Comm_Motor page 15
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3.4 Calibration of the Voltage Measurement
The motor voltage (converter output voltage) is measured by the AVTs via voltage attenuators (resistors in series; at
the training rack: 270 kΩ on the converter output / 937.5 Ω inside the AVT).
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The voltage channels for phases A to C have to be calibrated such that a DC-voltage of the value of the “AVT mapping
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range for voltage” reads “this value in Volts” on parameters r6760[0] to r6760[2] as well as on parameters r6911[0] to
r6911[2] respectively a proportional part of either value.
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If the unit system (“Object” > Configuration > Units) is set to “referred”, parameters r6911[x] will indicate the voltage in
percentage of the scaling as per parameter p2001.
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Preparatory steps
Verify that no voltage can be present at the converter output!
- at site: e.g. primary and secondary Circuit Breaker in test position, motor Circuit Breaker in test position or off
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- at training rack: Main C.B. in test position (Q2 = off) and motor disconnected via plugs at the rear X0_A1, X0_A2.
Please note that the test voltage (30 VDC) is injected downstream of the output contactor at the training unit;
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to calibrate the voltage measurement, close the output contactor by switching on the exciter current (K6/Excit. ON).
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To avoid thermal stress on the exciter winding of the synchronous motor, reduce the exciter current setpoint to 10%
while you carry out the voltage calibration: p1625 = 10 %.
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step 1 - at site, short circuit the voltage pick-up for output phases A to C;
at the training rack, short circuit U1-U2, V1-V2 and W1-W2.
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- enable the offset calibration via p6903

step 2 - save the result of the offset calculation via p6903
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- check the calculated value; it has to be less than 1%
page 16
Calibration of the Voltage Measurement
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step 4
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step 5
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step 6
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SITRAIN
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step 3 - remove the short circuit and feed a DC-voltage (motor is disconnected ! ) to the voltage channels
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- at site, connect the positive DC-voltage to the converter output and the negative DC-voltage to the star-
point of the voltage measurement
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at the training rack, connect the positive to U1, V1, W1 and the negative to U2, V2, W2
- increase the DC-voltage to the largest value possible
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step 4 - calculate the percentage of voltage applied versus the value of the “AVT mapping range”
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. . . . . . . . VDC . . . . . . . . . . . %
- the applied voltage has to be indicated correctly on r6911[x] in volts and on r6760[x] in percent;
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if this is not true the phases in question have to be calibrated by setting p6750[x] as follows:
p6750[x] = voltage applied * 100% / voltage indicated
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step 5 - calculate and set the calibration for all (three) phases:
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p6750[0] = . . . . . . . . . . . . . . %
p6750[1] = . . . . . . . . . . . . . . %
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p6750[2] = . . . . . . . . . . . . . . %
step 6 - change the polarity of the applied voltage and verify that the values indicated on r6911 and r6760 read
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values as after the calibration in step 5 but with negative polarity

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step 7 - switch the exciter current off (K14/Excit. OFF)

- switch the DC-voltage off and remove all wiring you have used to carry out this measurement
page 18
Calibration of the Current Measurement
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2000 A / 1 A
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0.4 A
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0.4 A
800 A 200 A
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If the (large) primary current cannot be forced, a secondary current can be
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substituted (e.g. 0.4 A substituting 800 A); this procedure, however, doesn’t
include the function of the Hall-Effect in the testing.
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If several additional turns of wire can be added as shown above, the function
of the Hall-Effect is included in the testing.
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SITRAIN
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3.5 Calibration of the Current Measurement

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The motor current (converter output current) is measured by the AVTs via Hall effect transformers (e.g. 2000/1 A; the
burden resistor in the AVT converts the secondary current to current-proportional voltage).
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At the training rack the burden resistor is part of the special Hall effect transformer and the AVT is fed by current-
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proportional voltage directly.

The current channels for phases A to C have to be calibrated such that a DC-current of the value of the “AVT mapping
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range for current” reads “this value in Amps” on parameters r6761[0] to r6761[2] as well as on parameters r6910[0] to
r6910[2] respectively a proportional part of either value.
If the unit system (“Object” > Configuration > Units) is set to “referred”, parameters r6910[x] will indicate the current in
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percentage of the scaling as per parameter p2002.
Preparatory steps
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Since it will typically not be possible to “force” a large current through the Hall effect transformer at site, its secondary
current is simulated by “forcing” a value representing the primary current (in full or as a percentage). Example:
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Hall effect 2000 A / 1 A (ratio = 2000)

AVT mapping range 800 A
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primary current of 800 A has to read 100% on r6761[x]

this primary current can be substituted by “forcing” a secondary current of 800 A / 2000 (ratio) = 0.4 A
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At the training rack the output current is run through the Hall effect transformer with 3 loops; for simulation of output
current an extra coil with 6 loops is provided. In consequence, the “forced” current acts with twice its actual value
(e.g. to simulate an output current of 2 A a current of 1 A has to be fed to the extra coil).
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Before starting the current calibration, again verify that no voltage can be present at the converter output;
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page 20
Calibration of the Current Measurement
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step 1
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step 2b
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step 2a
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step 3
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step 4
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step 5
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SITRAIN
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The calibration has to be carried out for each phase individually; the procedure is identical for any of the phases.
step 1 - open the current path (to have definitely zero current for the offset calibration)
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and enable the offset calibration via p6902
step 2 - save the result of the offset calculation via p6902
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- check the calculated value; it has to be less than 1%

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step 3 - at site, inject the previously calculated value to verify and set the calibration;
at the training rack, inject a current to read 15% on r6761[x]; calculation:
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r6761[0] = 15% for I.injected = . . . . . . . . . . . A corresponds to a primary current of . . . . . . . . . . A

- inject the calculated current in the extra coil of the Hall effect transformer
- the simulated primary current has to be indicated correctly on r6910[x] in amps and on r6761[x] in percent;
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if this is not true the phase in question has to be calibrated by setting p6751[x] as follows:
p6751[x] = simulated primary current * 100% / current indicated
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step 4 - calculate and set the calibration for the phase in question, e.g. phase A:
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p6751[0] = . . . . . . . . . . . . . . %
step 5 - change the polarity of the injected current and verify that the values indicated on r6910 and r6761 read
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values as after the calibration in step 4 but with negative polarity

step 6 - repeat above steps for the other phases (e.g. B and C) and note down the calibration values:
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p6751[1] = . . . . . . . . . . . . . . %
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p6751[2] = . . . . . . . . . . . . . . %
step 7 - switch the simulated current off and remove all wiring you have used to carry out this measurement
page 22
Measurement of “Phase shift”
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OBSERVER
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L1 L2 L3
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OBSERVER
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L1
88 L2L1 reference measurement:
L2L1 leads L3L2 by 1200

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L3N
L2L1 L1L3 test measurement 1:
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L3L2 L3L2 leads L1L2 by 600
test measurement 2:
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L2 L3 L1L3 lags L3N by 1500

L3L2
L1L2 L1L3
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SITRAIN
3.6 Phase Shift Measurement / in general m

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The “power voltage” at the power section input will typically be phase shifted versus the voltage measured by the
VSM. Value and polarity of the phase displacement (leading, lagging) have to be identified without doubt.
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On the basis of a known voltage system (phases L1 to L3 on the VSM) you should first make a “reference
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measurement” crosschecking the indication on your scope versus “theory” followed by the second step of identifying
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the phase shift between “power voltage at power section input” and “reference voltage at VSM”.
To gain experience use the “transformer box” and carry out the measurements as suggested. Follow the procedure
listed below to make the FIRST MEASUREMENT, then the SECOND MEASUREMENT and finally do the lab work.
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- select the same V/div for both channels, invert channel B, align the two tracks to the zero line with input = GND
- use an appropriate voltage divider to measure voltages outside the range of the scope
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- connect the voltages you want to measure to channels A (L1) and B (L3) of the scope (via voltage divider if large)
- set both channels to DC-measurement and ADD the two channels; you then measure L1 + (-L3) = UL1L3
- follow the same steps to measure the second phase-to-phase voltage (channels A2, B2)
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- if you have to adapt the V/div for any of the measurements, always select the same setting for channels A and B
and verify the zero line alignment
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FIRST MEASUREMENT SECOND MEASUREMENT

make the “reference measurement” to find out make one “test measurement” to verify your scope reading
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how your scope displays voltage UL2L1 versus UL3L2 versus the “theoretical expectation”; i.e. UL1L3 versus UL3N
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UL2L1 UL1L3
UL3L2 UL3N
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reference measurement:
u.L2L1 leads u.L3L2 by 1200
page 24
Measurement of “Phase Shift”
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phase L1 phase L2
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10MOhm 10MOhm
channel 1 channel 2
direct inverted
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100kOhm 100kOhm
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operating mode: channel 1 + channel 2
voltage divider used at the training center
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L1 L2L1
“transformer box” for lab work

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N
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L2 L3
L1
L1
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L2
L2
L1L2 L1L3
L3
L3
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400V 24V
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SITRAIN
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Find out the phase shifts of the voltages suggested in the table below both by “theoretical expectation” and by actual
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measurement.
leads lags by degrees

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UL3L2 UL1L2
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UL1L3 uL2N
UL1L3 uL1N
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UL1L3 uL3N
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UL3L2 UL1L3 UL1L3 UL1L3

UL1L2 uL2N uL1N uL3N
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If you should only have a 2-channel scope available, the voltage UL2L1 has to be measured using channels “A – B” with
e.g. “line trigger”, followed by the measurement of voltage UL3L2 using the same channels “A – B” with identical trigger
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criteria. These two measurements then have to be “mentally” superposed to read the phase displacement.
UL2L1 UL3L2
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page 26
Measurement of the “Line Side Offset Angle”
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phase shift e.g. 300 between primary
and secondary; no phase shift
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between phases A, B and C
Yy0
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100 V power voltage
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VSM
A B C
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UL1L3
CH 1 – 2
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refer to bottom
M
reference voltage CH 3 – 4
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1500
CH 1–2 / CH 1: UL1, CH 2: UL3 either one measurement (4-channel scope)
or two measurements (2-channel scope)
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CH 3–4 / CH 3: UL1, CH 4: UL3 with common trigger, i.e. line trigger
power voltage lags reference voltage by 1500
negative angle (-1500)
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PMK PHV4002-3
20 kV / 1000:1 / 0.5 MHz
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Tektronix P6015A
Mandatory condition: clockwise phase sequence !
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20 kV / 1000:1 / 1.0 MHz

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SITRAIN
3.7 Phase Shift Measurement / by comparing “Power Voltage” to “Reference Voltage”

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Using the equipment available (voltage divider, voltage measurement by two channels in mode “A – B”), measure the
phase angle displacement in test mode “line side switch 1” and the voltage fed to the VSM (with “medium voltage”,
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inverter pulses blocked).

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At the training rack, sockets to pick up all required voltages are located to the right of DC-Master “phase A” as follows:
- power voltage TA_1U1 (phase L1) TA_1W1 (phase L3)
- reference voltage VSM_X522/1 (L1) VSM_X522/3 (L3)
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Phase angle displacement: p6420 = . . . . . . . . . . . . .

Voltage picked up by VSM: p3663 = . . . . . . . . . . . . .
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(Keep in mind that in case of a 12 pulse system phases A to C of system 2 will have a phase shift of their own
other than identified for system 1.)
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page 28
angle of firing pulse angle of firing pulse
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versus UL1L3 = 900 versus UL1L3 = 1200
UL1L3, line UL1L3, line
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power
00 300
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trigger pulse SCR1; trigger pulse SCR1;
firing angle = 900 firing angle = 900
tm
UL1L3, VSM UL1L3, VSM
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reference
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phase angle between phase angle between
Upower and Ureference Upower and Ureference
p6420 = 00 p6420 = +300

88
00 900 00 900
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Clockwise phase sequence required on line- and VSM-voltage! Phase angle p6420 reads positive if Uline leads UVSM
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Using p6069, the “line side offset angle” can be measured via Software (for this measurement line voltage is picked
site routine
up on the TAS-modules line voltage has to be switched through to the power section).
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- offset angle identification is initiated via “p6069 = enabled” PS phase-sequence / -angle ident. [10] Enabled
- offset angle is read on p6068 (index 0 to 5 for phases A to F) PS A / phase-angle measured
PS B / phase-angle measured
- average value as identified has to be manually entered in p6420
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SITRAIN
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3.8 Phase Shift Measurement / by comparing “Power Voltage” to “SCR Gating Pulses”
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Using the “Test operation mode” (for SCRs) individual SCRs can be controlled by shifting the trigger pulses to any
gating angle. The gating angle is referenced versus the phasing detected by the VSM.
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By evaluating the angle between line voltage UL1L3 and the trigger pulse for a known gating angle, the phase shift
tm
between “power voltage” (Uline) and “reference voltage” (UVSM) can be calculated.
Set up the wiring of the measuring leads to scope and drive to display line voltage UL1L3 of phase A on channels 1
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and 2 via voltage divider in mode “channel A – B” and the trigger pulse of SCR 1, phase A on channel 3:
- the line voltage is picked up as in the previous step,
- the trigger pulse of SCR 1 is wired to sockets on the front panel of DC-Master phase A (black = ground).
@
Since the “SCR test modes” require the drive to be switched on (via bit 0 of sequence control), the exciter current will
automatically be switched on as well. To avoid thermal stress on the synchronous motor, keep the exciter current
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setpoint reduced to 10% (as previously set; p1625=10%) for any tests in which the motor will not have to run.
Select test mode “open loop control with VSM, C.B. closed, second pulse is off”: p5950 =............
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Define a firing angle of 1200 for phase A: p5952[0] = . . . . . . . . . . . .

Set “pulse enable” for SCR 1 in torque direction M2: p5951[0] = . . . . . . . . . . . .
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[At the training rack this specific pulse has to be used since only this trigger gate is available for measurement.]
To be able to enable the pulses for the power unit in the currently set “Test operation mode (…C.B. closed, second
av
pulse is on)”, the enable signal has to be “forced” in SIMOTION DCC (an alternative will be explained in a later step).
To find the block where to “force” the enable, follow bit 3 of “Control word sequence control” upstream into SIMOTION
st
DCC until you come to a block where the individual control bits are converted into the control word (hint: bit 3, PZD1 of
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VECTORSL_U1 / PQW 256, 257 / “drv_pqw1_stw1” / chart OUTPUT, E1 / chart OUTPUT, C1 / block INP810).
Switch the drive on (K4/Power ON, K5/Exc.Breaker ON, K6/Exc. ON), verify the flow of exciter current
(r1626, r1641 > 0) and enable the stator pulses by “forcing” command “pulse enable” on the provided input:
input . . . . . . . . . . . . . / value . . . . . . . . . . . . . stator pulses are enabled (noise !).
page 30
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tm
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p5952 = 900 p5952 = 1200
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UL1L3, line 88 UL1L3, line

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SITRAIN
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Note down the phase shift currently programmed in p6420[0]:
lab result other example
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set phase shift, p6420[0] _ old ............ 300

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Change the firing angle for phase A to e.g. 900 (with only one pulse generated, you can set any firing angle between
ho
00 and 1500 <limited by internal software> for testing purposes) and evaluate the trigger angle now observed:
observed trigger angle ............ 2100

@
set trigger angle, p5952[0] 900 900
Calculate the site-specific phase shift according to following formula:

88
p6420[0] _ new = p6420[0] _ old + “observed trigger angle” - “set trigger angle”
p6420[0] _ new ............ 1500 ( 300 + 2100 - 900 )

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Assign the calculated site specific phase shift “p6420[0] _ new”: p6420[0] = . . . . . . . . . . . .
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At the optical outputs of the PSAs the firing of the SCRs can be checked on the assigned sockets as listed below.
M1 _ V1 (X11+X21) M1 _ V2 (X12+X22) M2 _ V1 (X13+X23) M2 _ V2 (X14+X24)
av

st

Check a choice of pulses for SCR 1 to SCR 6, torque direction M1 and M2.
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Block the stator pulses by “forcing” command “pulse disable” on the provided input (value . . . . . . . . . . . . .), disable
the pulses via p5951[x] = “no pulse enable”, deselect the test mode via p5950 = “normal operation” and switch the
drive off via “K14/Excit. OFF”.
page 32
Direct Control of the Firing Angle
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tm
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@
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SITRAIN
3.9 Direct Control of the Firing Angle

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Remove the measuring leads used to measure the line voltage and the firing angle.
Once the phase shift (p6420) is set correctly, all phases can be operated in “direct control”. This step serves to test the
ai
converter, the setting of the phase shift, the current and voltage feedbacks and the “zero current identification” (1).
tm
To analyze stator voltage, stator current and the “zero current identification” (1) you will use a scope.
Set the “software current limit, p6920” to a small value, e.g. p6920 = 20%.
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Note: the software current limit is based on the maximum motor current; if the peak value of the current is exceeded,
stator pulses are blocked and the drive trips with fault “power unit: overcurrent”
(Itrip = p6920 * p323 * sqr 2 / 100%)
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Verify that all actual values for currents and voltages read close to zero.
Set all firing angles for the test mode to 1500: p5952[x] = 1500
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Rack all Circuit Breakers into “operating position” (at the training rack, close Q2).
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(1) at the training rack this last measurement is not possible

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page 34
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tm
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1U2 2U2 1V2 2V2 1W2 2W2 1U2 2U2 1V2 2V2 1W2 2W2
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SITRAIN
st

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Depending on the system used, each phase can be operated individually (open circuit) or two phases have to be used
ai
in combination (star circuit). At the training rack an “open circuit” is engineered. Start by testing phase A:
- select “Open loop controlled operation with VSM, C.B. closed, second pulse is on”: p5950 =............
tm
- enable all pulses for phase A, torque direction M1: p5951[0] = . . . . . . . . . . . .

[in case of a “star circuit”, pulses have to be enabled for two phases; e.g. A, torque dir. 1 and C, torque dir. 2]
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- connect the clamp-on current meter to measure the current in phase A (at the training rack, use the connection
to the external reactor) and connect the meter output to one channel of the scope.
@
- prepare to measure the output voltage of phase A via voltage divider and mode “channel A – B” on the scope.
Switch the drive on (K4/Power ON, K5/Exc. Breaker ON, K6/Excit. ON) and enable the pulses for the power unit in the
88
currently set “Test operation mode (…C.B. closed, second pulse is on)”
- either by “forcing” the “Enable” in SIMOTION DCC or by
- setting any speed setpoint other than zero on the OP177
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(e.g. via “F14/Start up” and assignement of speed setpoint = 1 %).

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page 36
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voltage
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tm
limit of intermittent current
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current
@
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rd
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The “zero current transition signal“
zero current identification (inverted)
av
(I=0) can be picked up optically at

X15 or electrically at X232:3,4
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SITRAIN
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- use parameter p5952[0] to slowly shift the firing angle towards 900 (in steps of 50 for angles > 1000, in steps of 20
for angles < 1000) until the current has reached the limit of “intermittent current”; typically at an angle of about 900.
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[in case of a “star circuit” the firing angle of one phase can directly be set to 900; the current will then be increased
slowly by gradually shifting the firing angle of the other related phase]
tm
- adapt the responsible parameterization if you should trip with overcurrent: p . . . . . . . . . . . = . . . . . . . . . . .

- verify that all six SCRs are firing by analyzing the current waveform; check the waveform of the output voltage.
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- set the firing angle to 1500 and enable all pulses for torque direction M2
- proceed as before until the current reaches the “intermittent limit”; again verify that all six SCRs are firing by
@
checking the waveform of output current and output voltage: both current and voltage have to be of reversed
polarity as per the measurement of torque direction M1.
8
Note: current beyond the limit of “intermittent current” will trip the drive with “Zero sequence component too large”
(since current flows in one phase only, the DC-component cannot be “vector added” with the other two to read 0).
d8
Set the firing angle to 1500, disable the stator pulses via “OR-mask = 16#0”, switch the drive off (K14/Excit. OFF),
block the pulses via p5951, terminate the test via p5950 and remove all connected measuring leads.
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page 38
Current Measurement with “Clamp-on Probe”
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Measuring small currents
(up to 10 A, e.g. gating current of SCRs)
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DC to MHz, typically monitored on scope
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tm
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@
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rd
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Measuring large currents (up to 1000 A).

DC to kHz, monitored on display.
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Measuring moderate currents (up to 100 A)

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DC to kHz, typically monitored on scope

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SITRAIN
m
co
Current Measurement with Rogowski Coil
l.
If necessary, use open coil. Integrator
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With half a turn, just double

the measured values.
tm
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Coil
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rd
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www.sirent.de
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rearch term: “Rogowski”
SITRAIN
Operation in “I/f-Mode” via OP177
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I/f-mode is selected / deselected automatically to force (even large) current
if requested via the Start-up menu of the OP177 (excess current reactive)
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Sequence of OP177 commands to go into operation
K9 K3 K4 K5 - speed setpoint via

Exc.
AUX 88 Power “Start-up” menu
Local Breaker
ON ON ON of the OP177
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- acceleration and
deceleration via
ramps of the
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Sequence of OP177 commands to quit operation

setpoint channel
F1 K11 K12 K13
Exc.
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Start AUX Power Breaker

OFF OFF OFF for details refer to next slide
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SITRAIN
3.10 Open Loop Operation in I/f-Mode / f = 0 Hz

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Trusting that current and voltage evaluation are correct further tests (speed feedback evaluation, transformation angle)
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can be carried out in “I/f-mode”, where the stator current is directly set. In case of doubt about correct current and
voltage evaluation, “V/f-mode” has to be used for analysis. In “V/f-mode” the current is defined via stator voltage, so
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great care has to be used not to have the current shoot up.
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In “I/f-mode the stator current will be “forced” by the direct setting, possibly even to large values (taking all excess
current as reactive current). To tolerate this condition, the “tolerance monitoring of the exciter current” has to be
increased; verify that parameters p3201 and p3202 are both set to 100% (this value should actually be set already).
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The rotor position calculation is not active in “I/f-mode”. As logical consequence, the rotor has to be given ample time
to follow the stator field.
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Due to control via OP177, the ramp settings of the “Vector setpoint channel” now determine the rate of change of
speed unless you exclusively use the [ /\ ] or [ \/ ] buttons to control the speed. In this case ramps set to 60s within the
“OP177 Motorpot” overrule the ramp settings in the setpoint channel.
88
Set the ramp-up and the ramp-down time to 50s each (p1120, p1121).
To operate the drive in “I/f-mode”, Auxiliaries, Main C.B. and Exciter have to be switched on beforehand; these control
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operations can be performed comfortably via OP177.

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page 42
Operation in “I/f-Mode” via OP177
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F14
Speed setpoint for
N_REF_LOCAL
“Local Speed Control”
Start Start up menu
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up pops up F14
Start Changeover to
ON-sequence
I/f-Control is up
“Local Speed Control”
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I/f-Control
preselected
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“Status I/f-control” changes to “ON”, K14
OFF-sequence
Selection Exciter current
I/f-Control is set automatically Excit.
OFF is switched off
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K6
Exciter current builds up
Excit. (OP177: 20%); Stator current is disabled;
ON
Stator current is enabled Selection I/f-control is deselected
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88 one 0.5s pulse
Stator Current Stator Frequency Stator Current

rd
Setpoint (020%) Setpoint (0100) Setpoint (200%)

with ∆=2.5% up to 20% fmax = 10 Hz via DCC with ∆=2.5% down to 0%
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in steps of ∆=1Hz
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SITRAIN
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Please note that the motor might perform a slight movement upon switching on the drive in I/f-mode and take all
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necessary safety precautions.
Block both the “zero frequency quantity controller pre-control” and the controller itself:
m
p5914[0].0 = p5914[0].1 = inhibited

t
(the phase current controller remains active as the only controller in the current loop.)
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Now follow the sequence suggested above to activate the “I/f-mode”:

stator pulses are enabled; with “Stator Current Setpoint = 0” the “Actual Stator Current” reads “near zero”.
@
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page 44
Open Loop Operation in I/f-Mode / f = 0 Hz
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current phase A
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current phase B
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current phase C
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SITRAIN
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Prepare the tracer to record the stator current actual values of phases A to C, r6910[0] to r6910[2] and the phase
current setpoint, r5934[0].
ai
Increase the “Stator Current Setpoint” in steps of 2.5% to initially 20% (the response to the setpoint is noticeably
tm
delayed) and verify the following:

- the “torque generating actual current” (r78) oscillates around 0%
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- the “actual stator current” on the OP177 oscillates around 20% (Stator Current Setpoint)
Start the tracer and compare your recordings with those of the slide above.
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Reduce the current setpoint to 0% and follow the OFF-sequence via OP177 to switch the exciter current off and block
the stator pulses.
88
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page 46
Optimization of the Phase Current Controller (I/f-Mode)
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rd
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p5900 = 0.01 … 0.08 / 0.08 = OPT p5900 = 0.15 p5900 = 0.5

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SITRAIN
3.11 Optimization of the Phase Current Controller in I/f-Mode

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At this time, the phase current controller (control of the phase currents after K/P-conversion) should be optimized
(only by adapting the gain setting; for integral time and droop the default settings will be maintained; the optimization
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of the isd/isq component current controller will be carried out once the drive runs in closed loop control).
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Prepare the tracer to trigger on a step-change of current setpoint (r5934[0] and initiate a step of current setpoint by
changing the value of parameter p6890 from e.g. 10% to 30%.
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Adjust the gain so that the actual current reaches the step value of the setpoint next to immediately but without
overshooting:
gain phase current controller, p5900[0] = . . . . . . . . . . . . . . .
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For the next step please deactivate both the “zero frequency quantity pre-control” (via p5914[0].0) and the
“zero frequency quantity controller” (via p5914[0].1).
88
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page 48
Open Loop Operation in I/f-Mode / f > 0 Hz
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tm
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1200
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1200
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1 revolution
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SITRAIN
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3.12 Open Loop Operation in I/f-Mode / f > 0 Hz
In this step of commissioning the motor will rotate for the first time!
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Verify that all oil pumps for lubrication of the motor bearings are switched on (pressurized oil, oil flow). Also ensure that
tm
no danger can arise to personnel or material by running the motor.

Motor current will be “forced” by setting p6890 as in the previous step; additionally, though, this current vector will now
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be rotated by applying a frequency. The rotating stator field will drag the rotor with it provided the torque created by
the “forced” current is large enough and the frequency is increased at a slow rate (else the rotor will “fall out of
synchronism”).
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In I/f-mode the actual rotor position is not evaluated by the control; at very low speed the rotor will rotate in steps of
600 electrical.
88
Verify that the ramp times are set to a “large” value, e.g. to 50 s each and increase the excitation current setpoint,
p1625 to the rated “no load excitation current”; at the training rack, set the current to 0.9 A:
p1625 = . . . . . . . . . . . . . %
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Follow the ON-sequence via OP177 to switch the exciter current on and to enable the stator pulses.
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In steps, define a stator current of 25 % (via OP177; at site values from 20 % to 30 % will typically be required) and
slowly increase the frequency in steps of 0.2 Hz (about 12 rpm) to 2 Hz (about 120 rpm).
av
Prepare the tracer to record:

- phase currents A, B and C (as in the previous step) and
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- the “pole position angle, r93 ( rotor flux position).

While running at 2 Hz verify the following:
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- phase currents A, B and C represent a clockwise rotating system with phase sequence A, B, C
- the pole position angle increases linearly from -1800 to +1800, then steps down to -1800
- speed setpoint and speed actual value match both in value and sign
(You will notice that percentage-values for current and speed on the OP177 read other than on object Vector; reason
is an as yet incorrect scaling on the responsible Simotion chart).
page 50
I/f-Operation with “Zero Frequency Quantity Controller”
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tm
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p1715 = 0.01
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rd
p1715 = 0.08
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SITRAIN
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3.13 I/f-Operation with “Zero Frequency Quantity Controller”
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The “zero frequency quantity controller” adds voltage to compensate for DC-components in the output current; in
consequence the motor current becomes symmetrical and “more sinusoidal” which results in a more uniform motor
tm
torque.
Initially set the gain to a small value (e.g.: p 1715 = 0.01), activate the “zero frequency quantity controller” via
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p5914[0].1 (this can be done while in operation) and again record the phase currents: the waveform is symmetrical
and “more sinusoidal”.
Optimize the gain, p1715 by recording the current:
@
p1715 = 0.01 the current waveform is unsymmetrical

Increase the gain until the current waveform becomes symmetrical, then double this value to make it the setting:
88
p1715 = . . . . . . . . . . *2 = ...........
Keep parameters p1726 (leakage reactance decoupling) and p1717 (zero frequency current controller integral time) at
d
their default values: p1726 = 100%, p1717 = 2 ms.

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page 52
“Zero Frequency Quantity Controller Pre-Control”
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site recording training rack recording
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top: zero frequency pre-control = disabled / bottom: zero frequency pre-control = enabled
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SITRAIN
3.14 “Zero Frequency Quantity Controller Pre-Control”

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To enable the “Zero Frequency Quantity Controller Pre-Control” the drive has to be stopped (pulses disabled, on-
command cancelled) to avoid step-changes of the firing angle while enabling the pre-control.
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In small steps, reduce the speed to zero, reduce the forced current to zero, block the stator pulses and switch the
drive off.
tm
Activate the “Zero Frequency Quantity Controller Pre-Control”, again operate the drive at 120 rpm and monitor the
phase currents: at this low speed the phase currents will look rather identical to those of operation without pre-
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control; control of the firing angle, however, is now dominated by voltage pre-control.
@
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page 54
Adaptation of the “Intermittent Current”
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zero transition;
e.g. r5925[1].3
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tm
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p5906 = 5 p5907 = 13.5 p5906 = 15 p5907 = 15.5 OPT
@
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p5906 = 5 p5907 = 15.5 OPT p5906 = 25 p5907 = 15.5 OPT
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p5906 = 5 p5907 = 18.5 p5906 = 35…. OPT p5907 = 15.5 OPT

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SITRAIN
Comm_Motor page 55
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3.15 Adaptation of the “Intermittent Current”
Correct intermittent current adaptation minimizes torque pulsations.
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Due to the principle of operation each period of current features two zero current transitions per bridge (per motor
phase two transitions in case of “open circuit”, six in case of “star circuit”). These falsify the ideal sinusoidal shape of
tm
the current, in last consequence resulting in harmonics of the torque.

Start by setting default values for the related parameters:
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p5906 = 5 % (intermittent current limit; value up to which the current is intermittent)

p5907 = 15.5 0 (base value; firing angle for current setpoint “zero Amps” at zero speed, 900 + p5907)
@
Find a setting for “p5907” to get a symmetrical waveform of the torque generating current component iSq, r78:
p5907 = . . . . . . . . . . . degrees
Tune the setting of p5906 to minimize the amplitude of the torque generating current component, r78. Find the
88
smallest setting beyond which no further improvement can be found:

p5906 = . . . . . . . . . . . %
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In order to easily identify the zero transitions of the current, you may use following status bits:
o_
r 5925[0].2 torque direction M1 / enabled phase A

r 5925[0].3 torque direction M2 / enabled phase A
r 5925[1].2 torque direction M1 / enabled phase B
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r 5925[1].3 torque direction M2 / enabled phase B

r 5925[2].2 torque direction M1 / enabled phase C
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r 5925[2].3 torque direction M2 / enabled phase C

etc.
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page 56
Principle of Rotor Position Detection
ϕS
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To achieve maximum torque at a given stator current ( stator flux) the
stator flux vector has to be positioned perpendicular to the rotor flux vector;
l.c
in consequence the rotor position has to be known at any time:
torque
- initially it is identified via “rotor position detection” (after switching on I.E)
- from here on it is calculated by counting the encoder pulses while
ai
in current model operation (low speed)
ϕE
tm
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UL1 Detection of the rotor position by trigonometric evaluation of the voltages
induced in the stator (Ures in direction of UL1 is defined as zero degrees).
@
IE.set UL2
88
IE
UL1 UL3
rd
UL1
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UL2
Ures
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UL3
UL3 UL2
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SITRAIN
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3.16 Rotor Position Detection

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When switching on the exciter current along with the on-command, the diE/dt generates a voltage pulse in the stator
windings; the individual values of the induced voltage depend on the respective angles. The trigonometric evaluation
ai
provides information about the currently valid rotor position.

tm
The phase voltages UL1 to UL3 can be picked up on parameters r089[0] to r089[2], the actual flux is available on
r084[0], parameters r1626[0] / r1641[0] indicate the excitation current setpoint / actual value and the pole position can
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be monitored by parameter r93.

Set up the SINAMICS tracer to record these values for 250ms with a pre-trigger of 50ms.
@
88
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page 58
Rotor Position Identification
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All signals are shown in their true physical relation
i.exc.set
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i.exc.act
tm
u.L1
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u.L2
The “long time” view (1 s) reveals the different
@
voltage values generated by the gradient di.E/dt
88
u.L3
rotor position
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f = 300 Hz (t.P = 3.3 ms)

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The persisting voltage originates from the ripple of

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the exciter current (6 current pulses per 20 ms at

flux line frequency = 50 Hz 3.3 ms per current pulse).
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SITRAIN
Comm_Motor page 59
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l.c
Monitor these values as a result to switching on the exciter current (via OP177).
The “rotor position detection” indicates the identified rotor position after evaluation of the motor voltages
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( unsymmetrical initial values) induced by the di/dt of the exciter current.

tm
Even after the exciter current has reached its steady state value, its ripple still generates motor voltages.
With exception of the first tens of ms the flux increases with PT1-property.
ho
Please note that the signals shown in above slide are shifted on the time axis to represent their true physical
relation.
(For the values one can record, different delay times of the internal algorithms apply. In analyzing these signals
@
relative to each other you would conclude that motor voltages are induced with the exciter current still zero and that
the rotor position is identified directly by switching on the exciter current setpoint; neither of these conclusions is
physically possible!)
8
Note down the identified “Pole position angle”, turn the shaft by a self estimated number of degrees and verify that
d8
the now identified position reads:

“new value” = “previous value” +/- “degrees of movement”.
r
After you have changed the rotor position you will notice that the three motor voltages show a difference of values
o_
and polarity (which of course is the input information for the calculation of the rotor position).
The measured induced motor voltages also serve as input to calculate the actual flux (only “in rough”; since the
av
induced motor voltages are very small, a correct calculation is not possible as yet.)
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page 60
Actual Flux and “Ready for Operation”
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motor model iE exciter setpoint
calibration, p1625 i.exc.act , i.exc.set = 100 %
iµ
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flux setpoint Up
p1570 (100%)
LHd
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iE.set 85 % of p1570 flux.act
- motor magnetizing
tm
LHd inductance, p360 iµ Φact
- scaling factor, p655
ho
motor model iS´ p655 = 135
DC-Master
L.Hd (motor model) = L.Hd ( real motor)
iµ
@
US Up
iS.act
(real)
LHd i.exc.act , i.exc.set = 75 %
motor
88 iE.act
uS.act
LHd motor magnetizing iµ Φact
inductance, p360
rd
flux.act
o_
flux actual Φact

r0084
p655 = 170
av
L.Hd (motor model) >> L.Hd ( real motor)

100%
st
SITRAIN
gu
Trace following signals:

om
l.c
- exciter current setpoint r1626
- exciter current actual value r1641
ai
- actual flux r84

tm
You will observe that the actual flux increases up to 85% and then is substituted by 100%. This changeover to the
substitute value will always occur at 85% (internally set) and acts as an internal “enable” signal inevitably required to
run the motor.
ho
You can monitor this essential response of the flux on the OP177 via key “F13 / Graph”.
If the actual flux doesn’t reach the 85% value, one/several of the motor data or the voltage scaling (parameters p6753
@
to p6755) are likely to be set incorrect.

Motor model data for the motor substitute circuit diagram (“magnetizing inductance”, p360; to minor extent) and its
scaling (p655; dominatingly) define the exciter current setpoint to generate the requested flux.
88
[A large magnetizing inductance (X.Hd) requires only a small exciter current (i.Exc) to generate flux.]
rd
Feeding exciter current to the (real) motor induces motor voltages which serve to calculate the motor flux (via motor
model). Once 85% have been reached the actual flux is defined “100%” until changeover from the current model
o_
(IMO) to the voltage model (UMO).

[If the substitute circuit diagram data are matched to the real motor, a sufficiently large actual flux will be calculated.
av
If, however, the magnetizing inductance of the real motor is smaller than programmed as substitute circuit diagram
value, the measured motor voltages and thus the calculated flux will be rather small and will in consequence not reach
st
the required 85% within the internally set monitoring time.]

gu
page 62
Checking Voltage and Current Waveforms
om
l.c
ai
tm
ho
α
Uα
@
900
88
β
Uβ
rd
o_
av
st
gu
SITRAIN
3.17 Checking Voltage and Current Waveforms

om
l.c
Resume operation in ”I/f-mode at a speed of 240 rpm (about 20%), trace the voltage components (r89[3], r89[4] /
actual phase voltage alpha-component, beta-component) and verify that the “alpha-component” leads the “beta-
ai
component” by 900.
Trace the motor voltages and the motor currents to verify their correct waveform and phase sequence
tm
(currents: r69[0] to r69[2], voltages r89[0] to r89[2]).

At which power factor does the motor operate? power factor = . . . . . . . . . . . .
ho
@
88
rd
o_
av
st
gu
page 64
Checking Voltage Components, Rotor- and Stator Flux
Positions
om
l.c
rotor flux position
stator flux position
ai
tm
900
ho
α
Uα β
Uβ
@
φrotor
88
3600
transformation angle 900
stator flux
1800
rd
φstator
0 cw
0
pole position angle
o_
rotor flux
-1800
900
av
st
gu
SITRAIN
om
Resume operation in ”I/f-mode”, verify that no alarms are signaled and operate the drive at a speed of 10Hz;
trace following signals and verify the indicated relations:
l.c
- r89[3] / 89[4] Actual phase voltage, alpha-component / beta-component
- r93 Pole position angle ( rotor flux position)
ai
- r94 Transformation angle (commutation angle stator flux position)

tm
the “alpha-component” has to lead the “beta-component” by 90 degrees

the transformation angle has to lead the pole position angle by 90 degrees
the 00 (3600) value of the transformation angle has to be positioned with the positive peak value
ho
of the alpha-component
@
88
rd
o_
av
st
gu
page 66
Essential “Siemens-Set” Values for the Motor
om
to be set as per motor rating plate
l.c
ai
tm
to be set in accordance as per site data
ho
to be set as per motor data sheet
or as per Siemens-data
@
to be set as per Siemens-data

88
rd
o_
av
st
SITRAIN
om
gu
l.c
3.18 Verifying Essential Settings on the Motor Module
SL150 drive projects as supplied by Siemens will typically already contain all relevant “Motor Data”. The rating plate
ai
of the motor has to be checked against the data set in the project. If any differences are found, the reason has to be
tm
thoroughly investigated before taking an appropriate action.

“Equivalent Circuit Diagram Data” and “Motor Characteristic” are preset as well and should not have to be modified.
ho
The slide above indicates the parameters involved; the values are relevant for the training unit and will only
coincidentally correspond to site settings.
@
8
r d8
o_
av
st
gu
page 68
Encoder Data
om
track A
l.c
track B
ai
zero
mark
tm
“one-off” position is tolerated;
Alarm- instead of Fault-message
ho
@
zero mark
.........
88
rd
00 position by adding pulses 3620

3600
o_
automatic correction of rotor position

av
st
SITRAIN
Comm_Motor page 69
om
gu

l.c
3.19 Encoder Data
The drive is now ready to be commissioned in speed control mode with encoder. Check some of the essential encoder
ai
data to verify that they are set in accordance with the encoder used as per above slide.
tm
As indicated in the slide above, parameters for the “voltage level” and for the “encoder pulse number” have to be
parameterized to identical settings in two different pairs of parameters.
If fault F31100 or F31101 is signaled, the “zero mark tolerance, p430[0].21” should be set to “Yes”.
ho
The evaluation via SMC30 responds very sensitively to minor changes of the zero-pulse position. If the encoder
feedback reads only minor fluctuations, a.m. faults may appear (in FW version 2.6 the sensitivity of the SMC30
@
will be more reasonably set and this problem will be solved at the source).
If the transition from current model to voltage model (this topic is dealt with later) becomes irregular with time, the
“rotor position adaptation, p430[0].22” should be set to “Yes”.
88
The rotor position is calculated on the basis of the initial rotor position detection (i.e. executed automatically
after switching on the exciter current) by adding the incoming “pulses per revolution”. An erroneous pick-up of
rd
pulses ( long encoder cables) will gradually shift the calculated rotor position to an incorrect value and thus
influence the operation in mode “current model” and the transition from current model to voltage model. If the
o_
rotor position adaptation is activated, the zero pulse readjusts the calculated position with every revolution.
If fault F31118 is signaled, the “dn/dt-monitoring” should be deactivated by setting p492 = 0.

av
At high speed and high encoder resolution the software may detect a (non existing) critical dn/dt which should be
suppressed.
st
gu
page 70
Operation in Speed Control (with Encoder)
om
K9 K3 K4 K5 K6
Exc.
Local AUX Power Breaker Excit.
l.c
ON ON ON ON
ai
ON-sequence K10
Increase of speed
tm
towards positive
K18
ho
Increase of speed
towards negative
F14
@
direct entry of
Start N_REF_LOCAL
88 up speed setpoint
K2
Request of
N*=0
OFF-sequence speed = zero
rd
F1 K11 K12 K13 K14

o_
Exc.
Start AUX Power Breaker Excit.
OFF OFF OFF OFF
av
st
om
SITRAIN
gu
l.c
3.20 Operation of the Motor in “Speed Control”
Please note: at site you must strictly observe all general and local safety rules before accelerating the drive to
ai
noticeable speed!
tm
Verify that operating mode “speed control with encoder” is active (p1300) and set uncritical values for the gain, p1460
and for the integral time, p1462 of the speed controller: p1460 = 1, p1462 = 500 ms
ho
Disable both of the flux controllers: p1600 = 0, p1590 = 0

Switch the drive on (K4/Power ON, K5/Exc. Breaker ON, K6/Excit. ON) and check the exciter current feedback
(about 0.9 A / 22% at r020 on the DC-Master).
@
Using the control keys and buttons of the OP177, run the motor in responsible steps up to its rated speed disregarding
field weakening ( 1057 rpm).
88
If the drive should trip before reaching this speed, evaluate the fault messages and set the responsible parameter to a
sufficiently large value:
rd
p.......... = ...........
o_
Reduce the speed to zero and block the inverter pulses.

av
st
gu
page 72
Equivalent Circuit and Vector Diagram of the Synchronous Motor
om
p0350 p0356
d-axis p0350 p0356
RS LSσσ RS LSσσ
l.c
p0354 p0355
UP RDd UP RDq
US ECD UE US ECD
d-axis p0360 p0358 q-axis q-axis p0361 p0359
ai
LHd LDσσd LHq LDσσq
tm
scaling parameters
iS *
ho
p652 (X
σS +X
) Hd )
p659 d iS * (XσS + X Hd)
p660 +XH
@
(X σ
S
p653 i S*
p657
p658
p655 88 uS emf uP uS emf uP uS emf uP
p656
rd
iS LSσσ LHd
o_
uS emf uP iS
iSq
iS iSq
av
iSq
iS
Φ Φ
st
simplified ECD of synchronous motor iSd iSd

gu
SITRAIN
In the basic example above of the “salient pole machine” the magnetic field is set up by the permanent magnets. The
om
magnetic field is positioned in the d-axis and changes its position once the rotor starts to rotate.
l.c
The stator windings have to generate another magnetic field (in the q-axis) which is perpendicular to the field in the d-
axis to create a maximum of torque for any given current.
ai
Depending on the data of the equivalent circuit components and the counter-emf (which is proportional both to speed
tm
and to magnetic flux) a stator voltage has to be generated such that the motor doesn’t develop a stator current
component i.Sd.
ho
By changing the relation between the values of u.S and emf the stator current i.S can be shifted out of its vertical
position. A positive component i.Sd will increase the flux of the motor, a negative component i.Sd will decrease the flux
of the motor.
@
The data of the equivalent circuit components are defined in parameters p350 to p361. An adaptation of a set “motor
value” is commonly carried out via the assigned scaling parameter.
88
rd
o_
av
st
gu
page 74
Setting the Magnetizing Inductance
om
iS*RS settings for these traces of exciter current (r1626) and actual flux (r84):
p1752 = 211 rpm (20 % of nrated, p1756 = 50% / speed setpoint = 750 rpm
l.c
iS*XσS
ai
100%
tm
iS*XH
uS emf
p655 = 110% p655 = 80%
ho
100%
up
@
88 100%
iS iSq
rd
p655 = 140%
iSd
o_
iµ
100%
av
iE iS´
st
SITRAIN
gu
3.21 Setting the “Scaling of the Magnetizing Inductance, d-axis”

om
l.c
The design and evaluation of the vector diagram shows that a smaller magnetizing inductance (X.H) requires a larger
magnetizing current (the smaller the inductivity the more magnetizing current is required to generate the same flux).
ai
The larger magnetizing current is provided by a near proportional increase of the exciter current.
tm
At the moment of enabling the voltage model (UMO), the flux as calculated by the evaluation of the actual stator
current, stator voltage and magnetizing inductance X.H is output as actual flux (r84).
ho
If the magnetizing inductance is programmed to a value smaller than actually true in the motor, too much exciter
current will result. The evaluation of exciter current and stator current in the vector diagram will conclude a large
magnetizing current and a flux value larger than 100% in consequence.
@
If this value of the actual flux as calculated is other than the setpoint (typically 100 %), the flux controller changes the
exciter current to reach a calculated value of 100% of actual flux if activated; even if X.H is programmed incorrectly).
88
- Deactivate both flux controllers by setting their respective proportional gain to zero: p1590 = p1600 = 0.
- Set the “excitation current setpoint calibration” to 100%: p1625 = 100%.
rd
- Ramp the drive up to e.g. 75% (750 rpm) of speed and read the value for “actual flux” (r84) via expert list.
Find a setting for the “Scaling of the Magnetizing Inductance, p655” such that the actual flux reads 100%.
o_
p655 = . . . . . . . . . . . . . %
If the actual flux reads 100%, the motor voltage (r25) has to be linearly related to the speed (n = 50% Umot = 50%).
av
The “Scaling of the magnetizing Inductance d-axis” (p655) has to be set in the no load condition. The “Scaling of the
magnetizing Inductance q-axis” (p656) is related to load and has to be set once load is available; for now, set p656 to
st
the same value as p655.

gu
page 76
om
θset iSd,set
in case of
induction
motor
n iSq
l.c
nset iSq,set
ai
- nact - iact, q
θ iSd
tm
iset, d
ho
- iact,d
model
θset IE,set
magnetization
IA
@
IE,set IA,set αset
- IA,act
88
PROFIBUS
rd
o_
100%
model
θact
av
magnetization
st
SITRAIN
Comm_Motor page 77
om
gu
l.c
ai
tm
ho
n iSq
nset iSq,set
- nact - iact, q
@
θ iSd
iset, d
88
- iact,d
model
rd
θset IE,set
operation IMO
IA
o_
IE,set IA,set αset
- IA,act
av
PROFIBUS
st
gu
100%
model
θact operation IMO
SITRAIN
om
n iSq
l.c
nset iSq,set
ai
- nact - iact, q
θ iSd
tm
iset, d
ho
- iact,d
θset
IA
@
IE,set IA,set αset
uS,act model UMO θ

θact - IA,act
88
IE,set operation
iS,act UMO

UMO; n - θact
PROFIBUS
rd
o_
IA,act
av
st
SITRAIN
Comm_Motor page 79
om
gu
l.c
3.22 Setting the Saturation Characteristic
Set the parameters for the “Saturation characteristic I_mag” (p366 to p369) to values covering the intended range of
ai
operation. If no special requirements are given, set the default values as follows:
tm
p366 = 50%, p367 = 75%, p368 = 150%, p369 = 200%

Again run your motor at 50% speed.
ho
One by one, set the “Excitation current setpoint calibration” (p1625) to the values assigned to p366, p367, p368
and p369.
Read the actual flux (r84) for each of these settings and set the parameters of the “Saturation characteristic flux”
@
(p362 to p365) to the percentage of the identified actual flux:

p362 = . . . . . . . . . . . . . %
88
p363 = . . . . . . . . . . . . . %
p364 = . . . . . . . . . . . . . %
rd
p365 = . . . . . . . . . . . . . %
o_
Note: to carry out this test, it might be required to temporarily set “Flux outside the tolerance threshold value” (p3204)
to e.g. 50%. Don’t forget to set p3204 back to its previous value (e.g. p3204 = 10%) after having finished the test.
Set the “Excitation current setpoint calibration” (p1625) back to 100%: p1625 = 100%.
av
st
gu
page 80
Verification of the “Setting of the Balancing-Factor”
om
flux increases with - reduction of p655
Interaction between “stator flux current” and “rotor exciter current”
- increase of p1625
l.c
Φ p655
rated flux
(100%)
ai
at iSd = 0
p1625
tm
ideal
response
ho
field generating stator
change of the current comp. / r76
-iSd +iSd
“stator flux current”
@
from 0% to -25% in
flux increases for negative iSd when increasing p1625 steps of -5%
excitation current
Φ DC-Master / r1641
p1625
88
rd
ideal
response
o_
-iSd +iSd
av
p0655 scaling magnetizing inductance d-axis actual flux / r84

p1625 excitation current setpoint calibration
st
gu
SITRAIN
3.23 Excitation Current Adaptation (Balancing-Factor / G-Factor)

om
l.c
The flux of the synchronous motor is defined both by the “magnetizing stator current component, isd” and by the
“excitation current in the exciter winding, iExc”.
ai
Since the physical influence on the flux is different for each of the two currents, their relative effects are taken into
account by the implied algorithms of Vector Control.
tm
As you can see in the diagrams above, the two parameters used in the definition of the flux setpoint (p1625, via DC-
Master exciter current) and in the calculation of the actual flux (p655) both influence the value of the flux at iSd = 0.
ho
The example in the above slide shows variables “r76, current actual value field-generating”, “r1641, excitation current
actual value” and “r84, flux actual value” as response to a testing sequence commonly applied.
@
The settings of a.m. parameters have to match statically (parameters set such as to get 100 % flux). Additionally,
however, these parameters have to be set such as to have the flux increase slightly if the stator operates with a
negative field generating current component (negative iSd).
88
The mutual influence of these parameters has to be balanced (balancing-factor / G-factor).

rd
Note down the currently set values for the parameters listed below:
p1625 [%] = . . . . . . . . . . p655 [%] = . . . . . . . . . . r84 [%] = . . . . . . . . . .
o_
step 1 increase the field generating current component iSd (p1620) in steps of -5 % to -25 %
observing the flux which must not change its value by more than +/- 10 %
av
step 2 adapt p1625 to get a flux of about 102 %

st
step 3 in steps of 5%, set p1620 to zero the flux should drop to 100 %
step 4 if required, adapt p655 to get an actual flux (r84) of 100% (at iSd = 0)
gu
Note down the values finally set: p1625 [%] = . . . . . . . . . .

p0655 [%] = . . . . . . . . . .
page 82
Transition “Current Model Voltage Model”
Current Model (IMO) rotor angle iE.act
om
flux angle via rotor angle; iE motor model iS´ motor model
actual flux via current

evaluation, on success iµ iµ iS.act
substituted by 100% Up Up
l.c
US
LHd LHd
Voltage Model (UMO) uS.act
ai
flux angle and actual flux
flux angle Φact IMO 100% Φact UMO
via actual values of iS, uS
tm
and substitute circuit data
flux value
ho
r84
Φ maximum deflection : 5%
@
flux
p1752 * p1756 p1752

speed
88
hysteresis
rd
enable voltage model

o_
and flux controller

voltage model (UMO)
av
current model (IMO)
om
SITRAIN
st

gu
l.c
Verify the correct settings by studying the expected interaction between ISd (r76), Iexc (r1641) and flux (r84) by carrying
ai
out a test as follows (e.g. at 750 rpm):
- assign r76, r1641 and r84 to be recorded by the tracer (suggested recording: endless trace)
tm
- start the tracer and set ISd via p1620 successively to following values (in A):
0 / -0.1 / -0.2 / -0.3 / -0.4 / -0.5 / -0.4 / -0.3 / -0.2 / -0.1 / 0 (steps are 5% of the rated motor current; p323 = 2.2 A)
ho
- stop the tracer and verify that the exciter current (r1641) increases whenever the field generating stator current
(r76) decreases and that the flux increases slightly (up to 105 % at p1625 = -25 %).
Please note: the exciter current (r1641) must never become “zero” since this corresponds to an “open exciter circuit”
@
and bears the risk of resulting in “high voltage” on the exciter circuit.
To allow the ISd controller a fair margin of positive control, define a “minimum stator current”:
p1620 = -0.2 Arms (ISd = -10%).
88
As observed in the previous test, this setting increases the exciter current of the DC-Master but keeps the flux
constant.
rd
o_
av
st
gu
page 84
Transition “Current Model Voltage Model”
om
p1752 * p1756 p1752
l.c
ai
current model (IMO) voltage model (UMO)
tm
ho
@
p1756 = 99.9 p1752 = 30 p1756 = 99.9 p1752 = 20 p1756 = 99.9 p1752 = 10

88
rd
o_
p1756 = 95 p1752 = 20 p1756 = 90 p1752 = 20 p1756 = 80 p1752 = 20

av
om
st
SITRAIN
gu
l.c
3.24 Transition “Current Model” Voltage Model”
ai
In “Vector Control Modes” the position of the rotor flux is permanently available on the basis of following relations:
- on enabling the excitation current, the rotor position is identified by trigonometric evaluation of the stator voltages
tm
- up to the next zero pulse the position is calculated by evaluation of the A/B-track pulses
- at the next zero pulse the A/B-track pulse counter is reset and starts a new count
ho
(the number of A/B pulses to the next zero pulse is monitored).

This flux angle is calculated by a “Current Model” (IMO) at lower frequencies and by a “Voltage Model” (UMO) at
higher frequencies.
@
While the current model calculates the flux angle initially on the basis of the rotor position and the flux value on the
basis of exciter current and flux characteristic, the voltage model uses the actual values of stator current components,
88
stator voltage and the substitute circuit diagram data of the motor to determine both the flux angle and the flux value.
Using actual values for the calculation gives more accurate results once a certain minimum frequency with sufficiently
rd
large motor voltages is reached (typically: 10 – 20% of the rated frequency).

The transition between the models is set by parameters “changeover speed, p1752” and “changeover hysteresis,
o_
p1756” (refer to above slide). If the substitute circuit diagram data of the motor are known, the transition parameters
are preset by Siemens.
av
To set these parameters, proceed as follows:

- activate both flux-controllers by setting their proportional gain
st
(if available to the pre-set project values, else to default values: p1590 = 0.5, p1600 = 1.0)
gu
- set p1752 to 50% and set p1756 to 99.9% ( the transition UMO IMO is very close to p1752)
- ramp up the drive from 1% to 50% speed and trace the actual flux
- reduce p1752 to just short of oscillation p1752 = . . . . . . . . . . . .
- increase the hysteresis by reducing p1756 to get
the least deflection once the voltage model sets in p1756 = . . . . . . . . . . . .
page 86
Indexed Variables
om
l.c
Orientation Angle Voltage Model

ai
measurement
or recording
tm
ho
@
excerpt of: Abbrev Index Description
USER > SINAMICS > DATA, RhoUm

88 327 Orientation Angle Voltage Model (WUM)
file “DrvAdd2.txt” opened via Excel RhoIm 341 Orientation Angle Current Model (WIM)
RhoSm 354 Effective Orientation Angle
dAngle 355 Angle Differential WUM / WIM
rd
dAngleSM 356 Angle Differential Smoothed (p1754)
udInt 472 Integral Component zero-freq contr d-axis
o_
uqInt 473 Integral Component zero-freq contr q-axis

udCtrl 474 d-component (Controller + Pre-Control)
uqCtrl 475 q-component (Controller + Pre-Control)
av
fuCtrl 477 Voltage Vector Frequency

buCtrl 478 Voltage Vector Absolute Value
Index wuCtrl 479 Voltage Vector Angle
st
gu
SITRAIN
3.25 Reading “Indexed Variables”

om
l.c
As stated already, the flux angle is calculated both by the current model (IMO) and by the voltage model (UMO).
Neither of these angles, however, can be picked up by “published” parameters.
ai
Apart from the flux angle, a considerable number of physical quantities are not directly available. By assigning up to
tm
eight of the many internally defined physical quantities to parameter p4862, index [0] to [7], these “Indexed Variables”
can be measured via r4863[0] to r4863[7].
ho
All “Indexed Variables” are listed in “User Folder”, file “DrvAdd2.txt” with their assigned Index numbers.
The parameters defining the transition of the models (IMO UMO) are either preset by Siemens in accordance
with the motor used or have been set at site as in the previous step.
@
Standard values read p1752 = 40 % (changeover speed), p1756 = 35% to 50% (hysteresis).
[ flux controller enabled at p1752 * p1756 = 14% to 20%, UMO fully in control at p1752 = 40%.]
In any case, the validity of these settings should be checked by reading the “angle deviation ωUM / ωIM” at constant
88
speed; the value must not exceed 5 degrees: ∆ [0] = ∆ [%] * 1800 / π
rd
Run the drive at a speed somewhat larger than required to enable the flux controller and note down the
value ωUM / ωIM:
o_
angle deviation (ωUM / ωIM)max =..............% = . . . . . . . . . . . . . . degrees.

Double the speed and again note down the value ωUM / ωIM:.
v
angle deviation (ωUM / ωIM)max =..............% = . . . . . . . . . . . . . . degrees.

ta
Both values have to be roughly the same.

s
gu
page 88
Principle of Generating a Step of ISq-Setpoint / Torque Limit
om
A small step of speed setpoint will force the speed controller to its internal limit (200%).
The step of ISq current setpoint is defined by the torque limit and acts until the speed has increased up to the setpoint value.
l.c
ai
tm
speed controller
ho
nset .
.
@
torque
nact
limit
Φ
88
Integrated
Profibus
rd
p1520
o_
av
N_SET = steady state speed
torque limit (from SIMOTION) TQ_LIM = torque limit (pos + neg)

st
gu
SITRAIN
3.26 Optimization of the Current Controllers via ISq

om
l.c
In this step the response of the “ISq-Controller” to a step of ISq-setpoint will serve to optimize the current controllers.
The optimization of one of the current controllers (“ISq-Controller” and “ISd-Controller”) is sufficient since both current
ai
controllers use the same setting of gain and integral action time.
tm
A common practical procedure to generate an “ISq-setpoint step” is to step up the speed setpoint by a fairly large value
(i.e. 20%) but limit the torque setpoint to the value intended as “ISq-setpoint step” (e.g. 20%; this step acts temporarily
only until the actual speed has reached the speed setpoint; for the short rise time of the actual current, however, this
ho
time is more than required).

Even though the torque limit could be set at the output of the speed controller directly (by “parameter”) a preferred
@
approach is to manipulate the torque limit as it is requested from Simotion-DCC via Profibus.
Alternatively to the “technological limit” a “manual limit” can be set in LCOMRG, sheet C2, block SETPOINTS_010.
The value at the input TQ_LIM is used to define the effective torque limit.
88
(Please remember: a value of “1.0” in DCC represents “100%”.)

Follow the torque limit TQ_LIM downstream through the charts to find out which PZD word transfers the torque limit to
rd
object “Vector”:
o_
- PZD word for “torque limit”: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

In Starter, follow this PZD word to the menu where the torque is limited and find which parameter could be used
alternatively:
av
- parameter for “torque limit”: . . . . . . . . . . . . . . . . . . . . . .

st
The optimization of the stator current controller has to be carried out in a range of speed where the voltage model will
be fully active; determine the speed where the voltage model becomes fully active:
gu
speed_voltage_model = . . . . . . . . . . . . . rpm
Set the base speed for the current controller optimization to about 120% of the value identified above:
base speed = . . . . . . . . . . . . . rpm
page 90
Generating a Step of ISq-Setpoint via LCOMRG
om
l.c
steady state
speed
ai
general
torque limit control of
(pos + neg)
tm
the drive
ho
@
request for
* p.85
88
continuous steps
rd
o_
av
st
SITRAIN
om
gu
l.c
To operate the drive via LCOMRG, set the operating mode to “Remote” (“K17/Remote”).
For the current test the drive will be run at a base speed (set via block SETPOINTS_010, input N_SET) to which an
ai
additional step of speed will be added.

tm
For this purpose LCOMRG offers a “continuous step” generator which is activated on block LCO_CTL_010 via input
CONT_STEP_RE.
ho
@
8
r d8
o_
av
st
gu
page 92
Continuous Step Generator
om
* request: continuous steps
l.c
p.83
a (ms)
ai
tm
ho
2*c
@
a, b
88
0.5 * cycle time c (ms)
rd
cycle time adjustment
o_
b
av
step value Inevitable requirement: c > a / the settings of a and b define the symmetry of the generated signal
st
gu
SITRAIN
om
Activate the “continuous step” generator and follow the request to the next chart. Use input “Factor” of block OPTI_050
to define a (symmetrical) signal with a sweep time of 5s.
l.c
Define a step of speed of 10% (setting: 0.1 !) and roughly estimate the result of your settings on output
ai
STEP_RESONSE of block OPTI_100.

If satisfied, deactivate the “continuous step” generator.
tm
Now define the intended “ISq-setpoint step” by setting the torque limit TQ_LIM to 10% (setting: 0.1 !), assign a base
speed of 30% (setting: 0.3 !) and start the drive via LCOMRG (after each command wait for the feedback information):
ho
STARTUP / BM_AUXON / POW_ON / ON / BM_STC_ON / CNTR_EN

The drive will run up to a steady speed of 30%.
Activate the “continuous step generator” and verify that the speed is changing between 30% and 40%.
@
88
rd
o_
av
st
gu
page 94
General View of the Step-Response of ISq
om
+20%
l.c
+4%
ai
ISq-setpoint
-5%
r77
tm
ho
ISq-actual
short sampling time recording
for analysis and optimization r78
@
750rpm
nsetpoint
88 r1170
250rpm
rd
nactual
o_
r63
av
st
SITRAIN
gu
Prepare the tracer to record following variables:

om
l.c
- ISq-setpoint, r77 - ISq-actual value, r78
- speed setpoint, r1170 - actual speed, r63
ai
Suggested trigger settings

tm
- initially, to get a general view: “endless trace, recording time = 10s” (you can “zoom in” to read details)
- for the optimization: “sampling rate = 0.5ms / pre-trigger = 50ms / recording duration = 255ms /
trigger condition = current setpoint > 0.2A
ho
Study the trace as result to a step of speed from e.g. 0 to 500 rpm / 500 to 0 rpm.
You will observe that the torque generating current component steps from an average of +4% to the set value of +20%
@
respectively -20% (the base torque of 4% is required to overcome friction).

88
rd
o_
av
st
gu
page 96
Optimization of the Current Controller via ISq-setpoint
om
l.c
ai
tm
ho
0.04 / 1000ms 0.8 / 1000ms 1.0 / 1000ms
@
88
rd
o_
av
0.8 / 10ms 0.8 / 2.25ms OPT 0.8 / 1.8ms

st
SITRAIN
Comm_Motor page 97
gu
om
l.c
SINAMICS SL150 uses three current controllers for following requirements:
- control of the flux generating stator current component (vector iSd)
- control of the torque generating stator current component (vector iSq)
ai
- control of the overall phase current (after the K/P-conversion)

tm
The phase current controller has already been optimized in I/f-mode at f = 0 Hz. In the current step, the controllers for
the stator current components will be optimized.
ho
To optimize the iSq current controller, follow the standard procedure of optimizing a PI-controller :
- start with a large “integral action time” ( P-controller) to optimize the “gain” (e.g. 1000ms)
- start with a small gain (e.g. 0.04) and set the gain to get a fast response but no overshoot
@
- reduce the “integral action time” to again get a fast response but no overshoot
Find the optimum values for the current controller settings:
88
“gain, p1715” = . . . . . . . . . . . . . . and “integral action time, p1717” = . . . . . . . . . . . . . .

Analyze the resulting rise time; you should find a value in the range of 5ms – 10ms. If in doubt as to the correct setting,
rd
the “less dynamic” setting should be preferred.

(Since the iSd current controller is defined by the same parameters an individual optimization is neither required nor
o_
possible.)
av
st
gu
page 98
Step Response of the ISq-Current Controller
om
l.c
ai
tm
site recording
ho
@
rise time: 6ms

88
rise time: 3.7ms
rd
o_
av
st
SITRAIN
gu
om
To give you a feeling of a site-recording, the above slide also shows the signals as they are found at site using the
l.c
PDA recording system.
ai
tm
ho
@
88
rd
o_
av
st
gu
page 100
Flux Control Loop [6726, 6728]
om
p1590[D] (0.5) p1592[D] (200)
[%]
l.c
ai
main control
of the flux
tm
[%]
ho
via EMF; on basis of actual values
of iS, uS and substitute circuit data
@
dynamic
100% support
Φset
88 about zero in
example for
“rolling mill” p1643[D] (0.40)
steady state
application for correct X.H
rd
base speed max speed to verify the “G”-factor

o_
typ. 60% 100%

r1624
av
st
gu
SITRAIN
3.27 Optimization of the Flux Controller

om
l.c
Within the motor the flux is generated mainly by the excitation winding (via DC-Master, IExc) but additionally by the flux
generating current component (ISd) of the stator.
ai
Flux control is accordingly assigned to two flux controllers, a PI-controller defining the setpoint for “IExc“ and a
tm
P-controller for the setpoint of “ISd”.

For the optimization of the two flux controllers a step of flux setpoint acting simultaneously on both controllers will be
ho
used. By alternatively assigning a value of 0% respectively 10% as “supplementary flux setpoint” (parameter p1572) a
setpoint step is generated. The controller settings will be adapted to obtain an optimized step response.
Since the “actual flux” is calculated on the basis of the EMF, the drive has to be run at a speed where the voltage
@
model is active (for the given situation: n > 30%).

Prepare the tracer to record following values:
88
- actual flux, r84

- IExc-actual value, r1641
Suggested trigger settings:
rd
sampling rate = 0.625ms / pre-trigger = 400ms / recording duration = 1700ms / trigger condition = actual flux > 104%
o_
av
st
gu
page 102
Optimization of the PI-Flux Controller
om
IExc, actual (r1641)
l.c
ai
actual flux (r84)
tm
ho
0.2 / 10000ms 0.4 / 10000ms 0.8 / 10000ms
@
88
rd
o_
100 ms / div
OPTIMUM
av
0.4 / 250ms 0.4 / 180ms 0.4 / 100ms

st
SITRAIN
gu
om
The optimization of the the two controllers has to be done one by one (one controller is deactivated while the other
l.c
controller is optimized).
To carry out the optimization of the PI-controller, the P-controller has to be deactivated by setting p1600 = 0.
ai
Run the drive at a speed of 500 rpm.

tm
As for other PI-controllers, follow the standard procedure to optimize the “PI flux controller”:
- start with an “integral action time” of 10 000ms ( P-controller) to optimize the “gain”
ho
- set the gain to get a fast response but no overshoot

- reduce the “integral action time” to get “next to none” overshoot
Find optimized values for the flux controller settings:
@
“gain, p1590” = . . . . . . . . . . . . . . and “integral action time, p1592” = . . . . . . . . . . . . . .

88
rd
o_
av
st
gu
page 104
Optimization of the P-Flux Controller / Final Result
om
ISd, actual (r76)
l.c
actual flux (r84)
ai
tm
OPTIMUM
0.2 0.5 0.8
ho
@
88
rd
rise time: 120ms

o_
OPTIMUM
PI-controller: 0.4 / 180ms
av
P-controller 0.25
st
SITRAIN
Comm_Motor page 105
gu
om
l.c
To optimize the P-controller, deactivate the PI-controller by assigning the gain to p1590 = 0 and optimize the gain of
the P-controller to again get a “next to none” overshoot:
ai
“gain, p1600” = . . . . . . . . . . . . . .
Set p1590 back to its optimized value (previous page) and analyze the resulting transient of the actual flux.
tm
You will notice that the added influence of both flux controllers results in a too large overshoot.
ho
Reduce the gain of the P-controller to half of its current setting: gain P-controller, p1600 = . . . . . . . . . .
The transient should now show only a slight overshoot. Analyze the rise time; you should find a value in the range
of 100ms to 150ms.
@
When running the drive at constant speed also verify that the flux setpoint at the output of the PI-flux controller (r1593)
reads “about zero”. Any noticeable deviation results from either an incorrect setting of the magnetizing inductance;
i.e. its scaling parameter p655 or an incorrect evaluation of the actual values of motor voltage or motor current.
88
rd
o_
av
st
gu
page 106
Speed Controller
om
reference model
off
l.c
on
ai
same rise time
tm
t
ho
Kp
@
Tn
natural frequency
damping
88
dead time
rd
o_
av
st
gu
SITRAIN
3.28 Optimization of the Speed Controller via “Step of Setpoint”

om
l.c
Any controller optimization is based on the consideration of the “system properties” of the respective control loops.
Unlike all the other controllers where the “system properties” are (at least to a very large extent) constant for any kind
ai
of load or speed, the “system properties” of the speed control loop may change considerably with a “change of speed”
or with a “change of dynamic load” (moment of inertia).
tm
For this reason the optimization of the speed controller should not be based on one single operating point but it has to
be valid for the entire range of operation. If the “system properties” change considerably (i.e. proportional to the speed
ho
or in relation to the “number of revs of the shaft” like for a winding stand) the speed controller settings have to be
(automatically) adapted as necessary ( menu “Adaptation”).
@
DCC-chart LCOMRG, sheet C2 offers essentially following functionality to optimize the speed controller or to test
speed control loop properties:
1) ramping the speed up to a constant value with subsequent setpoint steps
88
(step up, step down at regular intervals)

2) performing reversing runs with defined ramp times within defined speed limits
3) “stepping” the speed up to maximum speed (preset step: 2%)
rd
4) simulating a “step of load” (adding a step of torque)

o_
Adaptation: if the moment of inertia changes along with the speed or with time, the controller properties have to be
adapted to the change of the controlled system.
av
Reference model: the reference model converts a step of setpoint to a signal comparable to the actual speed
feedback value. In consequence the set-actual deviation is nearly zero; the Integral-controller channel is not
st
contributing to the PI-controller output which makes the PI-controller functionally a P-controller with “Value Optimum”
Properties no overshoot.
gu
Steps of load are controlled with the high dynamic property of the PI-controller.
page 108
Functionalities to Optimize the Speed Controller
om
CONT_STEP_RE continuous step response generator
activated additionally to N_SET
HIN und HER the speed setpoint is ramped from
l.c
plus N_SET to minus N_SET
ENABLE_OPT I steps the speed up to maximum speed
ai
with a fixed step value
ENABLE TOPT provides for steps of torque
tm
downstream of the speed controller
ho
nactual
nset (r1438)
@
nactual (r61)
88 speed is ramping up;

controller properties
cannot be analyzed!
rd
must not be limited !
o_
ISq,set
av
ISq, actual (r77)

st
gu
SITRAIN
om
Functionality “Cont_Step_Re” will be used first to optimize the speed controller at a constant base speed which is
l.c
preferably selected to correspond to the dominating operating speed (or at a speed at which basic controller settings
apply which will be adapted in operation i.e. with the change of speed).
ai
At the training rack the “system properties” of the speed loop are the same at any speed.
tm
Select a base speed of initially 60% (N_SET = 0.6 !) and define the step of speed to be 2% (LCOMRG, sheet D1,
block OPTI_100, input X2 = 0.02).
[The step value has to be small enough not to have torque or current limited; so start with a really small value initially.]
ho
Switch on the drive via LCOMRG, have it run up to the set speed of 60% and activate “continuous setpoint steps”
(CONT_STEP_RE).
@
Prepare the tracer to record following values:

- speed setpoint, r1438
- actual speed, r61
88
- ISq-setpoint, r77
Suggested trigger settings:
rd
sampling rate = 1.0ms / pre-trigger = 200ms / recording duration = 2000ms / trigger condition = speed setpoint > 61%
Analyze the recorded signals.
o_
In particular have a look at the peak value of the torque generating stator current component (r77):
peak value of r77: . . . . . . . . . . . . . .
av
This peak value has to be noticeably smaller the set torque limit (p1520) to allow for the optimization
(when the gain is optimized it may be increased well beyond its initial value; the larger the gain, the larger the ISq peak
st
value for the same value of step).

gu
page 110
Optimization of the Speed Controller via Step of Setpoint
om
l.c
ai
3 / 1000ms 6 / 1000ms 12 / 1000ms
tm
ho
@
88
rd
OPTIMUM
6 / 200ms 6 / 80ms 6 / 30ms
o_
t.rise = 55ms
av
st
gu
SITRAIN
om
To optimize the “PI speed controller” follow the same sequence as has been used for other PI-controllers. The typical
l.c
aim of the optimization, however, is to find a step response featuring a considerable overshoot (details will follow).
Start the optimization by following the standard procedure:
ai
- set an “integral action time” of 1000ms ( P-controller) to optimize the “gain”

- set the gain to get a fast response but no overshoot
tm
- reduce the “integral action time” to get “only one” undershoot of the actual speed (the resulting overshoot will
range within 20% to 50%; the value depends on the mechanical properties of the load).
ho
[The noise of the actual speed may make it difficult to identify the undershoot; looking at the current setpoint in
comparison an identification of the correct setting will be successful.]
@
Note down the optimized values for the speed controller settings and the resulting “rise time”:
“proportional gain, p1460” =.............. “rise time” =..............
88
“integral action time, p1462” =..............
Please note that the settings and the results you have found in this step are valid for the small synchronous
rd
motor with the very small moment of inertia.

At site all “time values” will typically differ: “integral action time = 100ms – 200ms”, “rise time = 80ms – 100ms”.
o_
It is suggested to optimize the speed controller somewhat less dynamic than proposed above to ensure an
uncritical and stable operation of the complete drive system (once all the related motors are interacting by the
coupling of the load).
v
s ta
gu
page 112
Optimization via “Simulated Step of Load”
om
simulated
load
l.c
-
i.Sq.set
current
ai
controller
-
tm
i.Sq.act
ho
@
88
rd
o_
Profibus
negative torque limiting symmetrical

av
om
SITRAIN
st

gu
l.c
3.29 Optimization of the Speed Controller via “Step of Load”
ai
In actual operation steps of setpoint as used in the previous approach of optimization will rarely occur because any
request to change the speed will pass a ramp function generator (either the one within the drive’s setpoint channel or
m
some other implemented in the “higher level control” like “Automation”.

t
In practical operation the motor will have to handle steps of load. Since real steps of load can hardly be generated “on
ho
demand”, simulated steps of load are used to test the response of the drive to a “step of disturbance variable”.
Set the “commissioning torque limit” in LCOMRG, block SETPOINTS_010, input TQ_LIM to 75% and verify via Starter
@
that this value is active.

This setting limits the maximum torque the drive will accept on request from the speed controller to 75%. In
consequence a simulated load of more than 75% cannot be counteracted by the speed controller; the drive would
88
accelerate up to the voltage limit!

rd
o_
av
st
gu
page 114
Optimization of the Speed Controller via Step of Load
cycle time “c” c
om
a, b
a
l.c
step value - inevitable requirement: c > a
- the settings of a and b
ai
define the symmetry of
the generated signal
tm
b
dynamic speed controller setting: Impact Speed Drop (ISD) < 0.25 %s
ho
∆t
ISD = ISD = ISD =
@
1.25 %s 0.55 %s 0.15 %s
∆n
88
n: 1div=0.5% i: 1div=20% t: 1div=0.1s
∆ load = 50%
rd
o_
av
∆ load =20% 40% 60% 8 / 200ms 18 / 200ms 18 / 40ms

st
SITRAIN
om
gu
l.c
Go to chart LCOMRG, sheet D5, block OPTI_101, input X2 and set the “disturbance variable” to simulate a “10% load”
for 1s with a “1s zero load” interval (remember that a setting of 1 acts as 100% ! ).
ai
Switch on the drive via LCOMRG, have it run up to a speed of 60% and activate the simulated “disturbance variable”
(ENABLE_TOPT).
tm
Trace the same signals as before for a “step of load” of 20%, 40% and 50%: you will notice that the maximum loss of
speed is proportional to the step of load.
ho
If your drive should trip with “overcurrent, fault 30001” while simulating steps of load, check your current controller
settings; at the “TC-stand” they should read p1715 = 0.15, p1717 = 6ms (in particular your gain might be set too
@
large). If necessary, adapt your settings.

If you compare the step response for a constant step of load but for different controller settings you will notice that the
“area” made up by the loss of actual speed versus the constant speed setpoint decreases the more dynamically the
88
speed controller is set.

This area defines the quality of the speed controller setup. It is known by the name “Impact Speed Drop” and should
rd
be less than “0.25%s” for a step of load of 50% according to following equation
(you might want to substitute your signal by an approximated triangle):
o_
ISD = 0.5 * ∆t * ∆n [∆t in s, ∆n in % (nmax = 100%), ISD in %s]

Take one of your traces for the optimized speed controller and calculate the ISD:
av
ISD = . . . . . . . . . . . . %s
st
Once you terminate this test, set the value of the “disturbance variable to 0% and disable the “additional step of
torque”.
gu
To continue, be sure that the speed controller data are set to your optimized values.
page 116
Saving all Settings in “Non Volatile Memories”
om
Offline Online
l.c
RAM
V02.02.03
ai
D445
tm
Reboot
PG-RAM D445-RAM
ho
for: for:
SIM_D445 SIN_Int. SIMOTION_D445
SIN_Int. (SIM_D445)
@
Load to
target
Open project 88
HD RAM
rd
RAM
V02.02.03
o_
CU320
Save project
Reboot
Load
av
to PG
not for
PG / PC SIM_D445 SINAMICS_CU320-2
st
gu
SITRAIN
3.30 Final Steps

om
l.c
In operation a more moderate ramping than currently valid will be preferred; please set the ramp times (p1120, p1121)
to 5s each.
ai
At site the ramp times of the internal ramp function generator (p1120, p1121) are typically set to 1 s. The ramp
tm
times needed for operation are always larger; they are set via “Automation” as required in the individual
operating stages (superposed on the internal ramps).
ho
At the very end of commissioning, don’t forget following steps:

- verify that “Control via LCOMRG” is disabled (all control inputs read “zero”) and define N_SET = 0
- download “Simotion D445” and save the changes on the CF card (Copy RAM to ROM)
@
- upload the online changes you have made on the Power Module (…Vector)
- save the changes on the CF card (Copy RAM to ROM)
- save the uploaded data in your project (Save project)
88
- archive your project

rd
o_
av
st
gu
page 118
om
l.c
ai
tm
Miscellaneous
ho
@
88
rd
o_
av
om
SITRAIN
st
Miscellaneous page 01 © Siemens AG 2013 - all rights reserved

gu
l.c
ai
List of Contents
m
Assignment of Switches, LEDs and Pots of the Control Box …………….......................... 3

Navigation from OP177-Message to Circuit Diagram / DCC …………….......................... 4
t
ho
@
88
rd
o_
av
st
gu
page 02
Assignment of Switches, LEDs and Pots of the Control Box
om
control box component designation
l.c
DI 0 TM15-1 X520: 2 DI/O 0
DI 1 X521: 7 DI/O 13
ai
DI 2 X521: 8 DI/O 14
DI 3 X520: 5 DI/O 3
tm
DI 4 TM15-2 X520: 2 DI/O 0
DI 5 X521: 3 DI/O 9 analog indication I/O
ho
DI 6 X521: 5 DI/O 11
DI 7 X520: 5 DI/O 3 indication changeover TM15-1
DI/DO 8 D445 X122: 2 DI 1
DI/DO 9 X122: 3 DI 2
@
TM15-2
DI/DO 10 TM31 X541: 4 DI/O 10 TM31: analog input 0
DI/DO 11 X541: 5 DI/O 11 D445 / TM31
X541: 1 (P24) TM31: analog input 1
88
DI/DO 12 TM15-2 X522: 8 DI/O 22 TM15-2 / TM15-1

DI/DO 13 X522: 9 DI/O 23
DI/DO 14 TM15-1 X522: 6 DI/O 20
rd
DI/DO 15 X522: 7 DI/O 21
AI 0 TM31 X521: 1 AI 0
o_
AI 1 X521: 3 AI 1
X521: 2+4+6 (M24)
av
AO 0 TM31 X522: 1 AO 0
AO 1 X522: 4 AO 1
X522: 2+5 (M24)
st
gu
SITRAIN
Navigation from OP177-Message to Circuit Diagram / DCC

om
l.c
Project
ai
tm
Circuit Simatic Manager

Diagrams
ho
HW Simotion SCOUT
Config
D445
@
I/O DCC
List Cross Reference
88
rd
o_
Terminal / I/O- Block /

=.Xnn Variable =.WAnn
Device Address Pin
v
s ta
gu
SITRAIN

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SINAMICS SM150 Service and Commissioning

Commissioning 8 Control Circuits

Course DR-SL150 9 PROFIBUS

10 Drive Control Chart

12 Operating Panel OP 177

Course from: to:

15 Commissioning the Power Section

This document was produced for training purposes. 16 Miscellaneous

SIEMENS assumes no responsibility for its contents. The

reproduction, transmission, communication or use exploitation

damages. Non-compliances with this prohibition make the

Copyright © Siemens AG 2011. All rights, including

particularly the rights created by to file a by patent and/or 18

patent and/or other industrial property right to be granted

SITRAIN courses on the internet: www.siemens.com/sitrain

Course folder Version: V6.0 20

Operating Type “SERVO” and “VECTOR” …....................................................................... 6

Design “6-pulse, Star” and “6-pulse, Open” …..................................................................... 7

Resulting Motor Voltage ….................................................................................................. 13

Generating Voltage at a Frequency of 25 Hz ….................................................................. 17

IGBT air depending on type, 1.0 to 12.0 kV

0.5 1 10 100 MVA

… for every power range

G110 G120 S120 G130 S120 S120 G150/S150 GM/GL/SM/SL150

Sophisticated Drives X M 150 / X L 150 medium voltage

… for every application

G110/120 G130 G150 S150 GM/GL/SM/SL150 S120 S120

partly in conjunction with technology controllers

pumps compressors hot rolling mills sag mill

• operating type SERVO for fast response, motion control (positioning),

typically: Torque Torque typically:

overall moment of inertia overall moment of inertia

rated motor torque rated motor torque

Function page 07 © Siemens AG 2011 - all rights reserved

Design “2*6-pulse, Star”

line side voltage

* depending on the power rating,

on the three phase input

attenuation operational principle

1U2 2U2 1U2 2U2

The 12 SCRs of one motor phase (two anti-

L1L2 L1L3 L2L3 L2L1 L3L1 L3L2

Function page 11 © Siemens AG 2011 - all rights reserved

L1L2 L1L3 L2L3 L2L1 L3L1 L3L2 L1L2 L1L3 L2L3

Voltage [%] 0 26 50 71 86 96 100 96 86 71 50 26 0

0 3.3 6.6 10.0 13.3 16.6 20.0 ms

1U2 1V2 1W2 2U2 2V2 2W2 D C

system 1 system 1 system 1 system 2 system 2 system 2

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to Xformer 1 to Xformer 2 to Xformer 3

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to system 1 / phase A to system 2 / phase A

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to motor side current monitoring

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Control Power Module Power Module Power Module

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SCR rack SCR rack