Control Boards

DriveAutomation
Technologies
andDivision
Drives
Tasks and Function
of
Control Boards
10_Controls page 1 © Siemens Industry 2013 - subject to modification
DriveAutomation
Technologies
andDivision
Drives
Table of Contents
Content Page
Control Cabinet........................................................................................................................... 4
Perfect Harmony Control Boards / NXG I, NXG II....................................................................... 5
Control Boards of the Electronic Rack / NXG IA.......................................................................... 6
Control Boards Interconnection / NXG IA.................................................................................... 7
Control Boards of the Electronic Rack / NXG IB, NXG II............................................................. 8
Control Boards Interconnection / NXG IB.................................................................................... 9
Control Boards Interconnection / NXG II..................................................................................... 10
“Microprocessor Board“ und “Keypad Interface“ / NXG IB........................................................... 11
Current and Voltage Evaluation / Line Side, MV-Section............................................................. 12
“Signal Conditioning Board“......................................................................................................... 13
Parameters representing Power Section Hardware Data............................................................. 14
Current- and Voltage Evaluation / NXG IB, NXG II...................................................................... 15
Tuning Input- and Output-Quantities (Voltage, Current).............................................................. 16
“System I/O-Board“...................................................................................................................... 17
Diagnosis of Internal and External Signals on Test-Points.......................................................... 18
Purpose of Feedbacks from the Line and Motor Side.................................................................. 19
“Modulator, Fiber Optic Board” / NXG IA..................................................................................... 20
Function of “Modulator, Fiber Optic Board“................................................................................. 21
continued next page

DriveAutomation
Technologies
andDivision
Drives
Table of Contents, continued
Content Page
Pulse-Width Control / e.g. LV-VFD.............................................................................................. 22
Generation of the Power Cell Output Voltage............................................................................. 24
Resulting Motor Voltage.............................................................................................................. 26
Generation of the Output Voltage / Perfect Harmony.................................................................. 27
Response of Controls to “one Cell bypassed”.............................................................................. 28
Data Exchange with the “Cell Control Board“ (all cells except LNG, WC III)............................... 29
Fault Identification on Basis of the “Cell Control Board“.............................................................. 31
“Cell Control Board“.................................................................................................................... 32
“Mechanical Bypass Board“........................................................................................................ 33
Customer Interface “Break-out Board“........................................................................................ 34
Customer Interface “Wago“......................................................................................................... 35
Assignment of SOP Variables to Terminals of Wago Modules.................................................... 36
“Communication Board“.............................................................................................................. 37
DriveAutomation
Technologies
andDivision
Drives
Control Cabinet
Control Cell
Cabinet Cabinet
1
2 4
3 5
8
7
In
In the
the example
example of of the
the shown
shown Perfect
Perfect Harmony
Harmony Drive
Drive the
the
Control
Control Cabinet
Cabinet isis located
located in
in between
between the
the Transformer
Transformer
Transformer Cabinet
Cabinet (left
(left side)
side) and
and the
the Cell
Cell Cabinet
Cabinet (right
(right side).
side).
Cabinet
Keypad
Keypad // Oper.
Oper. panel
panel (1),
(1), Auxiliary
Auxiliary Supply
Supply Control
Control (2),
(2),
Local
Local Safety
Safety Trip
Trip (3),
(3), Local
Local Remote
Remote Selection
Selection (4)
(4) and
and
Laptop 8
Laptop Port
Port (5)
(5) can
can be
be accessed
accessed on on the
the cabinet
cabinet front.
front.
A
A key
key operated
operated Acknowledge
Acknowledge Switch
Switch (6)
(6) for
for selected
selected
The location of components installed “Fatal
“Fatal Faults”
Faults” is
is found
found inside
inside along
along with
with the
the Control
Control
differs with type and power rating. Rack
Rack (7)
(7) and
and required
required Interface
Interface Boards
Boards (8).
(8).

DriveAutomation
Technologies
andDivision
Drives
Perfect Harmony Control Boards / NXG I, NXG II
Perfect Harmony Control Boards are mostly located within the Control Cabinet (low voltage compartment). Several boards,
though, are connected to devices installed in medium voltage sections; some boards are inside medium voltage sections.
The type and number of boards installed depends on the generation of drive (e.g. Gen III, IV, …), on the type of control
(e.g. Legacy, NXG, …) and on options built in.
Following boards can be found in the Digital Control Rack (DCR):

NXG IA NXG IB, II
Motherboard / ISA Bus x x
Keypad Interface x x
CPU x x
Modulator Board x Signal
Signal conditioning
conditioning board
board
Fiber Optic Interface (for up to 12 cells) x
Modulator / Fiber Optic Interface (12 cells) x
Fiber Optic Board (additionally for > 12 cells) x x
System Interface x
Analog to Digital Board x
System I/O-Board x
Communication (Base Board) x x
Communication Add-on Board x x Input/Output
Input/Output Breakout
Breakout board
board
Boards within the control cabinet but outside the DCR:
Signal Conditioning Board
Input/Output Breakout Board
Wago Input/Output Interface System
Boards installed in medium voltage sections:

Cell Control Boards Wago
Wago Interface
Interface modules
modules
Mechanical Bypass Board (option)
The migration from NXG IB to NXG II included: - Smaller Rack, - Smaller Motherboard, - Singular PS, - Break Out Board
DriveAutomation
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Drives
Control Boards of the Electronic Rack / NXG IA
Keypad Interface
CPU
Fiber Optic Interface
Simulator Board
(Analog to Digital)
Modulator
System Interface
Communication

DriveAutomation
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Drives
Control Boards Interconnection / NXG IA
Line Voltage Line Current Motor Voltage Motor Current +15/-15

Attenuation Circuit CT Circuit Attenuation Circuit Hall Effect
vL1 vL2 vL3 iL2 iL3 vT1 vT2 vT3 iT2 iT3
Signal Conditioning Board PS
line-
line-side feedback signals motor-
motor-side feedback signals
HW E-Stop
System Int.
Cell Bypass
FO
A/D Board Control
Fiber Optic Interface

Modulator Board
Power
Fiber Optic Supply
Keypad
Keypad Board
Interface CPU for DCR-
(>12 cells) Boards
+5/-5
Wago +12/-12
CF Card Power
Communication - drive SW Cell
Board - SOP FO
Control
- current par.
I /O Profibus - default par.
+24 Wago
laptop Wago
PS
TOOL SUITE
120 VAC
FO = Fiber Optic I/O = analog and digital, inputs and outputs
DriveAutomation
Technologies
andDivision
Drives
Control Boards of the Electronic Rack / NXG IB, NXG II
Optical cables to Cells A B F C D E

Communication, e.g.Profibus
Supply
Power Supply
Rack
Control Rack
Control
Power
IfIf the
the converter
converter features
features
more
more than than 12
12 cells
cells an
an
additional
additional Fiber
Fiber Optic
Optic Board
Board
Control rack is
is installed
installed in
in position
position ”F”.
”F”.
A Communication D CPU Any

Any further
further modules
modules are
are
A Communication D CPU installed
installed outside
outside the
the
electronic
electronic module
module rack.
rack.
B
B System
System I/O-Board
I/O-Board E
E Interface
Interface
to keypad
C
C Modulator
Modulator // Fiber
Fiber Optic
Optic

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Drives
Control Boards Interconnection / NXG IB
Line Voltage Line Current Motor Voltage Motor Current +15/-15

Signal Conditioning Board PS
line-
HW E-Stop
System
Modulator /
I/O - Board Cell Bypass
Fiber Optic FO
Control
Power
Fiber Optic Supply
Keypad
Keypad Board
(>12 cells) Boards
+5/-5
Wago +12/-12
CF Card Power
Board - SOP FO
Control
- current par.
+24 Wago
laptop Wago
PS
TOOL SUITE
120 VAC
DriveAutomation
Technologies
andDivision
Drives
Control Boards Interconnection / NXG II
Line Voltage Line Current Motor Voltage Motor Current

line-
HW E-Stop
+24 +15/-15
DI/DO System
Breakout Modulator /
I/O - Board Cell Bypass
Board AI/AO Fiber Optic FO
I /O Control
Power
Supply
Fiber Optic
Keypad
Keypad Board
(>12 cells) Boards
+5/-5
Wago +12/-12
optional
CF Card Power
Board - SOP FO
Control +24
- current par.
+24
Wago
laptop
120 VAC
TOOL SUITE

DriveAutomation
Technologies
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Drives
“Microprocessor Board“ und “Keypad Interface“ / NXG IB
11
11 Keyboard
Keyboard port
port (CTRL
(CTRL H
H selects
selects help
help menu)
menu)
44
22 Ethernet
Ethernet to
to laptop
laptop // Modbus
Modbus // WCIII
WCIII screen
screen
22 33 User
User I/O
I/O ”Wago”
”Wago” (serial
(serial port)
port)
>2009 1GB
33 44 VGA
VGA Monitor
Monitor port
port (for
(for debugging
debugging monitor)
64 MB
monitor)
Compact Flash Card can be read with card reader (PCMCIA, USB)
via Explorer. Always switch off control power before pulling CFcard!

Eagle
Eagle Code
Code (Firmware)
(Firmware)

Boot
Boot up
up Program
Program

System
System Operational
Operational Program
Program (SOP)
(SOP)

Parameter
Parameter files
files (Current.cfg
(Current.cfg // Default.cfg)
Default.cfg)

Min/Max
Min/Max values
values parameters
parameters

Event
Event logger
logger
With the hardware redesign for NXG II the size of the CPU
(from left to right) is only about half the size shown above.
The “old” CPU cannot be used for FW “V5.0” and ”V5.1”.
DriveAutomation
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Drives
Current and Voltage Evaluation / Line Side, MV-Section
“low voltage”
proportional vW1
Signal
Conditioning
Board
“low voltage”
proportional iW1
5/1
Voltages Signal
Voltages and
and currents
currents are
are picked
picked up
up in
in the
the
medium
medium voltage
voltage section
section and
and processed
processed in in Conditioning
to signal evaluation (burden
the
the control
control cabinet
cabinet (signal
(signal conditioning).
conditioning). Board
resistor, Signal Conditioning)

DriveAutomation
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Drives
“Signal Conditioning Board“
Tasks
Tasks of
of the
the “Signal
“Signal Conditioning
Conditioning Board”
Board”
to ”System Interface Board”
Providing feedback values of

- input voltage - input current
- output voltage - output current
burden resistors
Picking up voltage values to monitor power supply of
CT iline. L2, L3 - Hall Effect transformers - control power
Picking up the HW E-Stop (CR3, Current Relay 3)
CTs for current measurement of option “output filter”
CT ioutput filter. T1, T2, T3
connection of analog feedback signals v, i
The ”Signal Conditioning Board” converts current and voltage

measured on the line- und motor-side to analog ”10V-values”.
As result of the combination of the signal measurement in the MV
section and the signal evaluation via ”Signal Conditioning Board”
(burden resistors, voltage attenuator) a uniform scaling is reached:
in the feedback, power data of the value ”100%” correspond to the
power data as parameterized (e.g. output data):
vrated,HW = 4000V vmotor,act = 3600V

a) ID2030 = 4000V feedback to controls = 3600V CORRECT These parameters are set in the factory as per VFD
b) ID2030 = 3600V feedback to controls = 3240V WRONG !! hardware (nameplate) and must NOT be changed at site.
DriveAutomation
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Parameters representing Power Section Hardware Data
As shown for the example of output voltage on the previous slide a number of other “hardware related” parameters are set
in factory and must not be changed at site; the functional assignment of these parameters is explained on the next page.
Parameter ID Units Description Parameter ID Units Description
Parameter ID Units Description

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Current- and Voltage Evaluation / NXG IB, NXG II
6.0 kV ID2010 = 6000 V rated drive output voltage

rated drive ID2030 = 4160 V
input voltage ID3045 = 5700 kΩ attenuation resistor input voltage attenuation resistor output voltage
ID3455 = 4200 kΩ
5.7 MΩ ID3040 = 1.0 scaling of input voltage
scaling of output voltage
ID3450 = 1.0
A VAvail
D 100% = “ID2010”
x V 1.91 V
“Incorrect“ settings of the hardware-

MV cabinet Signal Conditioning System Interface related parameters shown on this page
result in incorrect operation of the drive!
(Wrong monitoring and tripping levels, wrong
90 A ID2020 = 90 A ID3030 = 1.0 scaling of input current magnetizing current, wrong torque limiting etc.)
rated drive
input current
A ITotal Out
D 100%=“ID2020” rated drive output current
ID2040 = 140 A
5 1 x V 1.77 V
scaling of output current
ID3440 = 1.0
On the motor side Hall-effect trans-

current transformer 100 / 5 :
former and Burden resistor are
ID3035 = 100 windings (100 / 5 and 5 / 1 results to 100 / 1 ID3035 = 100)
always adapted to result in a value
If the conversion ratio of the line side current transformer is different of 1.77 V (NXG IB, NXG II) for the
(other nameplate data), ID 3035 will be set to different values. rated drive output current.
DriveAutomation
Technologies
andDivision
Drives
Tuning Input- and Output-Quantities (Voltage, Current)
Scaling parameters as listed on the previous page (input voltage, ID 3040 / input current, ID 3030 / output voltage, ID 3450
and output current, ID 3440) indicate only 1 after-comma digit (1.x).
Since the values of the attenuation resistors as stamped and programmed (input resistor, ID 3045 / sum of output resistors
in series, ID 3455) are correct within 1 % only, fine tuning via the assigned scaling parameter may become necessary.
The scaling value, however, will have to be set to a higher resolution than the visible “1 after-comma digit”.
Fine tuning may also be required for the current measurements; here as well the parameters read only “1 after-comma digit”.
Even if values are rounded (e.g. to 1 digit) on the display and in the parameter dump file, they can be set to and act internally
with a total of 7 digits.
Example: required scaler setting 1.0739
entered value ID 3040 = 1.0739
displayed value ID 3040 = 1.1
internally acting value 1.0739
You can verify the internally acting value by checking this parameter in file “current.cfg”: 3040, 55, 1.073900e+001
Practical procedure of fine tuning the scaling parameters

The example shows the tuning the scaling for output voltage, but by logic adaptation it equally applies for input voltage or
input/output current.
- Operate the drive at a constant (large) speed to get a constant (large) output voltage displayed; note down the value of
the output voltage as “vD”. [To tune the current scaling, operate the drive at constant (large) current; value as “iD”]
- Note down the output voltage programmed in ID 2030 as “vP”. [For current use “iP”].
- Voltage scaling calculate the rms-voltage you have to get at the assigned test point as “vTP”: vTP, rms = 1.91 * vD / vP
- Current scaling calculate the rms voltage you have to get at the assigned test point as “vTP”: vTP, rms = 1.77 * iD / iP
- Adjust scaling parameter ID 3450 until the actual voltage measured on the test point matches the calculated value “vTP”.

DriveAutomation
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Drives
“System I/O-Board“
”ISA Bus” power supply only to ”Modulator / Fiber Optic” to ”Break-out Board” / DI, DO
to ”Signal Conditioning Board”
to ”Break-out Board” / AI, AO
test-points
Tasks
Tasks of
of the
the “System
“System Interface
Interface Board”
Board”
Condtioning of feedback measurements from SCB

- line voltages - line currents
- motor voltages - motor currents - output filter currents
IOC monitoring (Instantaneous Over Current)
Power supply failure detection for
- Control power - Hall Effect power
A–D conversion (of feedbacks for monitoring by CPU and Modulator Board)
DriveAutomation
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Drives
Diagnosis of Internal and External Signals on Test-Points
Voltages and currents at the converter input and at the inverter output are scaled as follows:
voltages NXG IB, II 1.91 Vrms [ 5.39 Vpp] if the actual input (output) voltage corresponds to the input (output)
NXG IA 3.82 Vrms [10.78 Vpp] voltage which is specified on the nameplate of the particular drive:
vrated,HW,in = 6600V vline,act = 6600V value = 1.91V
vrated,HW,out = 6000V vout,act = 5000V value = 1.60V
currents NXG IB, II 1.77 Vrms [ 5.0 Vpp] if the actual input (output) current corresponds to the input (output)
NXG IA 3.54 Vrms [10.0 Vpp] current which is specified on the nameplate of the particular drive:
irated,HW,in = 195A iline,act = 195A value = 1.77V
irated,HW,out = 172A iout,act = 85A value = 0.87V
measuring
measuring points
points input
input voltages
voltages output
output voltages
voltages input
input currents
currents output
output currents
currents
physical quantity Vin,L1 Vin,L2 Vin,L3 Vout,T1 Vout,T2 Vout,T3 Iin,L2 Iin,L3 Iout,T1 Iout,T2 Iout,T3
name of test-point V1A V1B V1C VMA VMB VMC IIB IIC IMA IMB IMC
no. of test-point TP1 TP2 TP3 TP5 TP6 TP7 TP12 TP13 TP21 TP22 TP23
TP 4, 9, 11, 14, 18, 20 ground connections TP 47, 48 analog output (in Volts) TP 52 analog input break-out board
TP 15, 16, 17 output filter currents TP 49, 50, 51 analog inputs (no. 3, 2, 1) TP 19 IOC feedback
TP 24 - 26, 28, 29, 31 programmable ( 4-26; 4-82) TP 35, 36, 37 motor voltage TP 10 AI/O (non-isolated input SCB)
TP 44, 45 encoder feedback (track A, B) TP 31, 32 analog output (in Amps) TP 8 not used

DriveAutomation
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Purpose of Feedbacks from the Line and Motor Side
line-
feedback
feedback quantity
quantity identified
identified fault
fault // alarm
alarm // condition
condition feedback
feedback quantity
quantity identified
identified fault
fault // alarm
alarm // condition
condition
- line voltage - under voltage alarm/fault - motor voltage - to regulate the motor voltage
- over voltage alarm/fault - over voltage alarm/fault
- single phase condition - ground alarm/fault
- ground alarm/fault
- phase mismatch (SYNC Transfer)
- line current - high reactive current - motor current - to regulate the motor current
- over current (IOC)
- thermal overload
- torque limiting
identified
identified fault
fault // alarm
alarm // condition
condition
- magnetizing failure
- power factor - drive loss failure
- harmonics
Evaluation of line voltage, line current, motor voltage and motor current identifies “energy loss (Pin – Pout)”.
Additional feedbacks
Hall Effect Power Supply is monitored for +15/-15 VDC to ensure current feedback
DCR Power Supply is monitored to ensure function of control boards for VFD operation
Emergency Stop Input is fed through SCB for direct HW shut-down; the signal is also sent to CPU for control
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“Modulator, Fiber Optic Board” / NXG IA

transmit
receive
Fiber Optic connections to up to 12 “Cell Control Boards” (per cell: transmit, receive)
optical link to ”Mechanical Bypass Board”
FO output enable via “Modulator“ to prevent false pulses
underneath flat-cable
connection to 2nd “Fiber Optic
Interface Board” for >12 cells
x to ”System Interface”
x connection to the
FO output enable via “Modulator“ to prevent false pulses “Modulator Board“
(only for NXG IA)
to “Modulator / Fiber Optic Board“

DriveAutomation
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Function of “Modulator, Fiber Optic Board“
fcommand
Reference- 1 x per cell
Key
Key function
function of
of the
the “Modulator
“Modulator // Fiber
Fiber Optic
Optic Board”
Board”
sine per
interpolator
phase optical link;
In its key function the “Modulator” comprises a Carrier
micro- generator and comparators to control up to 24 cells.
comparator transmit,
processor
receive A “Reference Sine per phase” true to motor frequency
and value (scaled down) is superposed to a triangular
carrier signal of 200 – 1200 Hz generated for each cell.
MODULATOR
1 “Carrier“ Frequency and phase shift of the carrier signals are
Carrier per cell defined by the CPU
- frequency - phase shift: 3600 / no. of cells per leg
- phase shift - frequency: as set by parameter
factory-set, related to power rating and number of
cells (high power, many cells smaller frequency)
Carrier
generator The output of each comparator provides information
for the pulse-width control of the four IGBTs of the
particular cell.
System timing
Interface The telegram-coded optical signal to each cell is
engine
updated in intervals of about 10µs and transferred to
100kHz the “Cell Control Boards” via optical link (Transmit).
Interrupt (synchronize) The Receive channel reads in the cell status feedback.
Digital Modulator System Protection

“Modulator Board” inhibits “Output Enable” to all power cells immediately upon detection of any of the following conditions:
- Power Cell fault (any cell) - Inhibit signal CR3
- IOC (Instantaneous Over Current) - Mechanical Bypass fault
- CPU or Hall Effect Power Loss - CPU watchdog fault (3 consecutive unacknowledged system interrupts)
Each of these signal conditions are latched to ensure that the CPU can properly determine fault conditions.
DriveAutomation
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Pulse-Width Control / e.g. LV-VFD
Every type of AC motor requires its stator voltage to be adapted to the stator frequency (in roughly linear relation;
details depend on the type of motor: induction motor, synchronous motor, …).
The inverter of a voltage source drive can only switch the DC-link voltage to its output “in full” or “not at all”. To
provide an output voltage of values other than “0” or “maximum”, the output voltage is pulse-width modulated.
DC-link voltage (positive towards output) DC-link voltage (positive towards output)
resulting
output voltage resulting output voltage
f 0.5 f
DC-link voltage (negative towards output) DC-link voltage (negative towards output)
Essentially, pulse-width control switches the DC-link voltage to the output “in blocks” of differing length (e.g. tens to
hundreds of µs) combined with “no voltage” intervals.
Mathematically the output voltage corresponds to the “area” covered by “blocks” and “no voltage” intervals; on the
motor itself the resulting “average voltage” is true if there are many “switching operations” per period ( high pulse
frequency).
The resulting output voltage can be varied in amplitude (and frequency) but maintains its block shape character
which in consequence results in non sinusoidal voltage, current and motor torque ( torque pulsations).

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Pulse-Width Control / e.g. LV-VFD
A first approach to achieve a smooth “sinusoidal” output voltage is to adapt the “length of the block” and the “no voltage”
interval to the “instantaneous” value of the intended sinusoidal output voltage.
DC-link voltage (positive towards output)
resulting output voltage
DC-link voltage (negative towards output)
To make the voltage still more sinusoidal, the pulse frequency can be increased: This, however, will result in larger
thermal losses on the IGBTs (during the switching which takes about 100 ns, the IGBT is subjected to noticeable
current and voltage at the same time which creates considerable switching losses).
Perfect Harmony drives utilize these methods to generate the individual cell voltages. By generating the cell voltages
with defined “phase shift” versus each other, the overall voltage of the cells in series (phase-to-star-point N) already
shows a good sinusoidal character (refer to page 24).
The geometrical addition of the phase-to-star-point voltage into the output voltage (output voltage vT1T2 = vT1 - vT2)
makes it still more sinusoidal. With the motor connected, the motor inductivity “smoothens” the voltage additionally
leaving but negligible noise (very smooth sinusoidal voltage, very uniform torque; refer to page 25).
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Generation of the Power Cell Output Voltage
Calculation of the pulse width modulated IGBT-control-signals for up to 24 cells in accordance with the request of frequency
and voltage (via ”reference sine” from the CPU and superposition with a triangular signal ”Carrier”, 200 - 1200 Hz)
reference sine phase L1 “original-Carrier“ inverted “original-Carrier“
reference sine is
shown for “over-
modulation”
(additional 3rd
order harmonic)
L1
R1
A1
signal L1 is generated if: signal R1 is generated if: signal A1 (of cell A1)
reference sine > “original-Carrier“ reference sine < inverted “original-Carrier“ results via “ L1 – R1 “
+
A1 = positive control of IGBT Q1 + Q4 in cell A1 positive cell voltage Q1 Q3
A1 = negative control of IGBT Q2 + Q3 in cell A1 negative cell voltage

A1 = zero control of IGBT Q1 + Q3 rsp. Q2 + Q4 cell voltage zero Q2 Q4
–

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Generation of the Power Cell Output Voltage
The control of cells A2 and A3 follows the same procedure but with two additional phase-shifted “Carriers“. The phase
shift between the “Carriers“ is defined as: “3600 / number of active cells per leg“ (e.g. 1200 for 3 active cells per leg).
“original-Carrier“ 1200 shifted “Carrier“ 2400 shifted “Carrier“
A1
A2
A3
AN
AN = A1 + A2 + A3 AN = terminal A towards the
floating N of the inverter;
NOT towards N of the motor!
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Resulting Motor Voltage
Using two reference sine waves which

are shifted by 1200 (2400) for phases L2
phase to neutral (L3), voltages BN (CN) are generated
voltages with 3rd again by interaction with “Carriers” of
order harmonic corresponding phase shifts.
In consequence the phase to phase

motor voltages originate from voltages
phase to phase voltage; 3rd order AN, BN and CN:
harmonic cancelled
vL1-L2 = AB = AN - BN
vL1-L3 = AC = AN - CN
vL2-L3 = BC = BN - CN
motor current
phase T1 motor voltage
phase T1-T2
motor voltage motor current

phase T1-N phase T3

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Generation of the Output Voltage / Perfect Harmony
Each cell is modulated according to the principle of “instantaneous value control” to achieve a best possible approach
to the sinusoidal voltage (resulting in an extremely smooth AC-current and uniform torque).
The “instantaneous value control” is applied within the levels of voltage possible for the given number of cells per leg.
cell A1 N
cell A2
cell A3
phase A A1 B1 C1
vs. N
Small IGBT switching frequency causes:
few switching losses high efficiency
A2 B2 C2
phase B
vs. N A3 B3 C3
phase A
vs.
phase B M
Large switching frequency of the motor
voltage causes small current harmonics
Since the phase to phase output voltage always includes two phases the resulting switching frequency is twice
the frequency of the carrier; the number of cells per leg acts as additional multiplier.
In
In consequence
consequence the
the resulting
resulting modulation
modulation frequency
frequency reads:
reads: 22 ** carrier
carrier frequency
frequency ** number
number of
of cells
cells // leg
leg
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Response of Controls to “one Cell bypassed”

If one cell of e.g. “three cells per leg” is bypassed, the phase shift between the “Carriers“ changes from 1200 to 1800. Trigger
signals are now generated for only two remaining cells. In the affected phase, pulses are extended and no-voltage intervals
are shortened to reach the maximum voltage possible. The two intact phases increase their output voltage according to the
requirement of the neutral point shift to maintain the phase to phase voltage of the fault-free condition.
phase A: “standard-modulation” / all cells available phase A: “standard-modulation” / one cell lost
A1 B1 C1 A1 B1 C1
AN AN
A2 B2 C2 A2 B2 C2
A3 B3 C3 A3 B3 C3
M M
AN AN
AN = A1 + A2 + A3 AN = A1 + A3

DriveAutomation
Technologies
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Drives
Data Exchange with the “Cell Control Board“ (all cells except LNG, WC III)
The communication between the “Modulator / Fiber Optic Board” and the “Cell Control Board” is carried out
by exchanging telegram-coded optical signals (serial strings). Transmit Data send the control request to the
“Cell Control Boards”, Receive Data transfer the cell status information to “Modulator Board” and “CPU”.
Each
Each serial
serial string
string contains
contains 11
11 bit:
bit: 22 start
start bits
bits (have
(have toto read
read “H,
“H, H”
H” to
to have
have the
the telegram
telegram accepted),
accepted), 88 data
data bits
bits
(B0
(B0 to
to B7)
B7) and
and 11 stop
stop bit
bit (“H”:
(“H”: received
received data
data bits
bits are
are executed
executed // “L”:
“L”: corrupted telegram
corrupted telegram communication
communication fault).
fault).
run request power on

Transmit
Transmit data
data Bit mode 00 mode 10 mode 01 mode 11
the transmission modes are specified B0 0 1 0 1
with data bits B0 and B1 : B1 0 0 1 1
the functional request is coded within B2 /enable reset reset TstEn
data bits B2 to B5 B3 left pole test a
(B6 and B7 have no function): B4 right pole test b
B5 /TstEn
With each ON-command a cell test is carried out via mode 11; following is requested:
for HV-cells these two
- test a) Blocking state: “UCE >> 0“ without triggering the IGBT; fault if UCE = 0
tests are not carried out
- test b) Switching state: “UCE = 0“ while triggering the IGBT; fault if UCE > 50V
Prior to starting the inverter operation of the IGBTs, “/enable“ is cancelled ( inverter enabled). For operation
the control of the IGBTs (Q1 to Q4) is handled via data bits B3 “left pole“ and B4 “right pole“ as follows:
B3 B4 triggered IGBT B3 B4 triggered IGBTs generated voltage

Q1 Q3
L Q1 L L Q1 + Q3 zero
H Q2 L H Q1 + Q4 positive
L Q3 H L Q2 + Q3 negative Q2 Q4
H Q4 H H Q2 + Q4 zero
DriveAutomation
Technologies
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Drives
Data Exchange with the “Cell Control Board“ (all cells except LNG, WC III)
Receive
Receive data
data Bit mode 00 mode 10 mode 01 mode 11
bit B0 signals “communication error“ B0 link fault link fault link fault link fault
receive modes defined with data bits B1 B1 0 1 0 1
and B2 specify fault groups B2 0 0 1 1
within the fault groups bits B3 to B7 B3 Gen. fault Out Of Sat /Q1OOS * VQ1>50 **
identify the detailed faults of the “Cell B4 Vavailable Overvoltage /Q2OOS VQ2>50
Control Board“ B5 Overtemp(1) Undervolts /Q3OOS VQ3>50
B6 Pwr Okay Cap share /Q4OOS VQ4>50
B7 Comm. fault Blown fuse
(1) Depending on the cell temperature bit B5 is set “H” at varying intervals. In the CPU these bits are “counted” for
a fixed time and converted to a temperature value; eagle code then issues “temperature alarm” or “temp. fault”.
IfIf the
the “Cell
“Cell Control
Control Board“
Board“ identifies
identifies any
any fault,
fault, message
message “General
“General fault“
fault“ is
is immediately
immediately transmitted
transmitted to
to the
the CPU.
CPU.
In consequence all cells are blocked via “/enable“ (transmit data, mode00, bit B2) and the CPU reads the detailed
fault message from the “Cell Control Board”.
* Out Of Saturation (OOS) Fault
The same reaction is also triggered for following faults: IGBT is triggered, but
- IOC (Instantaneous Over Current) UCE >50 V (has to be = 0)
- Mechanical Bypass Fault
- Hall Effect Power Loss ** Blocking Failure
- CPU Watchdog Fault IGBT is not triggered, but
- Operation Inhibit Signal (CR3) UCE = 0 (has to be >> 0)

DriveAutomation
Technologies
andDivision
Drives
Fault Identification on Basis of the “Cell Control Board“
The
The “Cell
“Cell Control
Control Board“
Board“ monitors
monitors the
the function
function of
of the
the power
power cell
cell and
and identifies
identifies following
following warnings
warnings (A)
(A) and
and faults
faults (F):
(F):
Power Fuse Blown Failure of fuse between converter and inverter of the power cell (Gen I, II / WC I, II) F
Voltage Available Supply voltage of the power cell is less than the monitoring limit F
Control Power Control voltage of the ”Cell Control Board” is missing or outside tolerance F
Over Temp Warning Feedback bit Q5 triggers the alarm limit value (defined in eagle code) A
Over Temperature Feedback bit Q5 triggers the fault limit value (defined in eagle code) F
DC Bus Over Voltage DC-link voltage exceeds the fixed limit (>800/1200 VDC for 460/630,690 VAC) F
DC Bus Low Warning DC-link voltage is < 65 % rated A
DC Bus Under Voltage DC-link voltage is < 55 % rated F
IGBT OOS 1, 2, 3, 4 Device failed to turn on while in “operation” F
(UCE > 50V in case of an IGBT being triggered; has to be = 0V)
Blocking Q1, 2, 3, 4 Device failed to assume blocking state when requested in “cell diagnostics” F
(UCE = 0 in case of an IGBT not being triggered; has to be >> 0V)
Switching Q1, 2, 3, 4 Device failed to turn on when requested in “cell diagnostics” (refer to “IGBT OOS”) F
Cap Share * Voltage on one of the DC-link caps in series is larger than 425 VDC F
Communication Transmission of telegrams is faulty F

Link Transmission of telegrams is missing all together F
* only for cells with capacitors in series all of the above warnings and faults are set by software (eagle code)
DriveAutomation
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“Cell Control Board“
The ”Cell Control Board” communicates with the “Modulator / Fiber Optic Board:
- receiving optical control signals for the IGBTs and converting these on its Gate Driver Board into firing signals
- transmitting identified faults which result from monitoring the function of the power cell
Each Cell Control Board is self-powered by switch mode PS connected to DC-bus (operational from 250 VAC up).
WC I, WC II
access
access for
for cell power section
board
board and
and cell
cell
test
test (factory
(factory
use)
use) gate gate
board board
cell control board
gate
gate board
board cell
cell control
control board
board
Gen III, IIIe, IV
cell power section
gate
board
cell control board

DriveAutomation
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“Mechanical Bypass Board“
Activating the ”Bypass”- contactor in case of loss of a cell.

Pre-conditions: - Bypass Type / ID2590 = Mechanical
- Fast Bypass / ID2600 = Enable
optical link to
sequence: - ”cell fault” via ”Modulator” to ”CPU” “Modulator Board“
- inverter (all cells) = OFF via ”Modulator”
- Bypass = ON via ”Modulator” / ”Bypass Board”
- monitoring of current flow to Bypass selenoid
- adaptation of carrier phase shift
- automatic acknowledgement of fault message
- automatic execution of “Spinning Load”
(even if disabled by parameter)
- inverter (working cells) = ON via ”Modulator”
After identification of a ”cell fault” the motor is re-energized within
300ms to 350ms or once vEMF,current,motor < vINV,max is true. connections to the
“Bypass“-contactors
FO
Modulator / Fiber Optic Board
FO
M
FO
interruption
disables
power supply of the
Bypass Mechanical PS from “Mechanical Bypass Board“
FO Bypass Board Cell C1
DriveAutomation
Technologies
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Drives
Customer Interface “Break-out Board“
The customer interface ”Break-out Board” serves to connect digital and

analog inputs, digital and analog outputs and one incremental encoder.
System
CPU Interface Break-out Board
Board
20 digital inputs (24VDC / 120VAC) 16 digital outputs (250VAC, 1A)

terminal digital input no. terminal digital output
J 8:1-4 0a / 1a / 2a / 3a J2:1-12 0– 3
J 9:1-4 0b / 1b / 2b / 3b J3:1-12 4– 7
J10:1-4 0c / 1c / 2c / 3c J4:1-12 8 – 11
J21:1-4 0d / 1d / 2d / 3d J5:1-12 12 – 15
J11:1, 3, 5, 7 0e / 1e / 2e / 3e (DOs as no/nc contacts)
3 analog inputs 2 analog outputs Encoder

terminal analog input terminal analog out terminal track
J13:3-4 1 “mA” J14:7-8 1 “V” J7:1 A+
J13:5-8 2 “mA / V” J14:9-10 2 “V” J7:2 A–
J14:1-4 3 “mA / V” J7:3 B+
J7:4 B–
SOP variable names (e.g. for DI J10:3 / DO J4:4-6)
InternalDigitalInput2c_I / InternalDigitalOutput9_O

DriveAutomation
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Drives
Customer Interface “Wago“
The customer interface ”Wago” serves to connect digital and analog inputs, digital and analog outputs.
Modules for the types of signals are selected as required; the necessary number of channels is obtained by
adding an appropriate number of modules.
Modbus
CPU Wago DI DO AI
Available types of interfaces (modules):

- digital inputs (yellow) - analog inputs (green)
- digital outputs (red) - analog outputs (blue)
Modbus-coupling to CPU
Digital inputs and outputs can be 24VDC or 120VAC.
power supply to Wago

The combination of modules of different voltage is
termination module
possible with a separator module in between.
power 120VAC
RO – 120 / 2RO
power 24VDC
DO – 24 / 2DO
AO – 24 / 2AO
DI – 120 / 2DI
DI – 120 / 2DI
DI – 24 / 4DI
AI – 24 / 2AI
termination
separation
MODBUS
24 VDC 120 VAC
DriveAutomation
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Drives
Assignment of SOP Variables to Terminals of Wago Modules
MODBUS Digital inputs and digital outputs always count in groups of 8 starting with A (to H).
The count starts on the left with “DI 01” or “DO 01”. If the module type changes
power 24VDC the count is interrupted; the count for the new type of module again starts with A.
Once the module type is the same as before interruption the count is picked up.
AI – 24 / 2 AI
AO – 24 / 2 AO SOP variable names
DI – 24 / 4 DI A–D ExternalDigitalInput 01a_I .. Input 01d_I

DI 01
DI – 24 / 4 DI E–H ExternalDigitalInput 01e_I .. Input 01h_I
DI 02 DI – 24 / 4 DI A–D ExternalDigitalInput 02a_I .. Input 02d_I
DO – 24 / 2DO A–B ExternalDigitalOutput 01a_O .. Output 01b_O
DO 01 DO – 24 / 2DO C–D ExternalDigitalOutput 01c_O .. Output 01d_O
DO – 24 / 2DO E–F ExternalDigitalOutput 01e_O .. Output 01f_O
separation
power 120VAC
DI – 120 / 2DI E–F ExternalDigitalInput 02e_I .. Input 02f_I

DI 02
DI – 120 / 2DI G-H ExternalDigitalInput 02g_I .. Input 02h_I
DI 03 DI – 120 / 2DI A–B ExternalDigitalInput 03a_I .. Input 03b_I
DO 01 RO – 120 / 2RO G–H ExternalDigitalOutput 01g_O .. Output 01h_O
DO 02 RO – 120 / 2RO A–B ExternalDigitalOutput 02a_O .. Output 02b_O
termination

DriveAutomation
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“Communication Board“
The ”Communication Board” serves as hardware interface for the installation of different bus systems.
The communication interface “Modbus” is available directly on the basic board. Additionally two more bus modules can be
selected and mounted on the “Communication Board“.
Presently available: Modbus Plus / Ethernet Modbus / Allen Bradley Data Highway Plus /
Device Net / Drive Profile / Profibus
connector to
communication
board
Modbus
RS485 port
PROFIBUS
Debug
module
port
Profibus connection

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DriveAutomation

Tasks and Function

10_Controls page 1 © Siemens Industry 2013 - subject to modification

continued next page

10_Controls page 2 © Siemens Industry 2013 - subject to modification

Table of Contents, continued

10_Controls page 3 © Siemens Industry 2013 - subject to modification

10_Controls page 4 © Siemens Industry 2013 - subject to modification

Perfect Harmony Control Boards / NXG I, NXG II

Following boards can be found in the Digital Control Rack (DCR):

Boards installed in medium voltage sections:

10_Controls page 5 © Siemens Industry 2013 - subject to modification

Control Boards of the Electronic Rack / NXG IA

Fiber Optic Interface

10_Controls page 6 © Siemens Industry 2013 - subject to modification

Control Boards Interconnection / NXG IA

Line Voltage Line Current Motor Voltage Motor Current +15/-15

Fiber Optic Interface

10_Controls page 7 © Siemens Industry 2013 - subject to modification

Control Boards of the Electronic Rack / NXG IB, NXG II

Optical cables to Cells A B F C D E

A Communication D CPU Any

10_Controls page 8 © Siemens Industry 2013 - subject to modification

Control Boards Interconnection / NXG IB

Line Voltage Line Current Motor Voltage Motor Current +15/-15

10_Controls page 9 © Siemens Industry 2013 - subject to modification

Control Boards Interconnection / NXG II

Line Voltage Line Current Motor Voltage Motor Current

10_Controls page 10 © Siemens Industry 2013 - subject to modification

“Microprocessor Board“ und “Keypad Interface“ / NXG IB

10_Controls page 11 © Siemens Industry 2013 - subject to modification

Current and Voltage Evaluation / Line Side, MV-Section

10_Controls page 12 © Siemens Industry 2013 - subject to modification

“Signal Conditioning Board“

Providing feedback values of

connection of analog feedback signals v, i

The ”Signal Conditioning Board” converts current and voltage

vrated,HW = 4000V vmotor,act = 3600V

10_Controls page 13 © Siemens Industry 2013 - subject to modification

Parameters representing Power Section Hardware Data

Parameter ID Units Description Parameter ID Units Description

Parameter ID Units Description

10_Controls page 14 © Siemens Industry 2013 - subject to modification

Current- and Voltage Evaluation / NXG IB, NXG II

6.0 kV ID2010 = 6000 V rated drive output voltage

“Incorrect“ settings of the hardware-

On the motor side Hall-effect trans-

10_Controls page 15 © Siemens Industry 2013 - subject to modification

Tuning Input- and Output-Quantities (Voltage, Current)

Practical procedure of fine tuning the scaling parameters

10_Controls page 16 © Siemens Industry 2013 - subject to modification

to ”Break-out Board” / AI, AO

Condtioning of feedback measurements from SCB

10_Controls page 17 © Siemens Industry 2013 - subject to modification

Diagnosis of Internal and External Signals on Test-Points

10_Controls page 18 © Siemens Industry 2013 - subject to modification

Purpose of Feedbacks from the Line and Motor Side

10_Controls page 19 © Siemens Industry 2013 - subject to modification

“Modulator, Fiber Optic Board” / NXG IA

optical link to ”Mechanical Bypass Board”

FO output enable via “Modulator“ to prevent false pulses

to “Modulator / Fiber Optic Board“

10_Controls page 20 © Siemens Industry 2013 - subject to modification

Function of “Modulator, Fiber Optic Board“