DriveAutomation

Technologies
andDivision
Drives

Commissioning

the

Laboratory Converter “GEN IV”

19_Commissioning LAB page 1 © Siemens Industry 2013 - subject to modification

 DriveAutomation
Technologies
andDivision
Drives

Table of Contents

Contents Page
1 Observing the Safety Measures…………………………………………………………..….…. 3
2 First Commissioning without Motor…………………………………………………………...… 4
3 Testing the "Cell Bypass" Option……………………………………………………….…....….. 7
4 First Commissioning with Induction Motor in OLTM…………………………...………….…… 8
5 Commissioning with Induction Motor in CLVC…………………………………………….…… 10
6 Optimizing the Drive………………………………………………………………………….…… 15
7 Setting up the function “Spinning load”………………………………………………….….….. 16
8 Fault Detection and Replacement of Components………………….…………………….…... 17
Diagnosing a Power Cell with Diode Tester / Ohmmeter…………………………..……….... 18

19_Commissioning LAB page 2 © Siemens Industry 2013 - subject to modification

 DriveAutomation
Technologies
andDivision
Drives

Observing the Safety Measures

1 Introduction
This section contains all of the steps for the basic commissioning of the medium-voltage lab-converter of the series “Perfect Harmony
Gen IV” (air cooled) .
As starting condition you find an already commissioned converter with an induction motor already connected to it.
For this reason, steps which are required for a regular first commissioning, such as
- visual inspection of converter, motor and plant periphery,
- verification of the connection of the converter to the plant via customer terminal strip,
- analysis of the “System Operational Program” and
- operation of the converter without motor
are not dealt with in this part of practical training.
You will find suggestions of how to carry out these steps in addition to this section of lab work in the respective factory documentation.

If you want to open one of the doors to one of the compartments with medium voltage
equipment, kindly observe the five safety rules at any time:
- Switch off the power supply on all poles
- Interlock against unauthorized re-energizing
- Verify the de-energized condition
- Ground and short circuit the power terminals on all poles
- Cover or fence off adjacent live components

Ensure that the auxiliary voltage is switched on via the switch on the control cabinet of the converter BEFORE
switching on the medium voltage and that it is only switched off AFTER the medium voltage is switched off.

19_Commissioning LAB page 3 © Siemens Industry 2013 - subject to modification

 DriveAutomation
Technologies
andDivision
Drives

First Commissioning “without Motor” 1(3)

2 First commissioning “without motor” (on the lab-converter with motor)

In this commissioning step, the most essential converter and motor parameters are set, the function of the power cells is verified and
the actual values of the line- and motor-side voltage detection are checked.
To do this, proceed according to the following recommendations.
The steps must be carried out in sequence; each step may only be carried out after the preceding step has been completed
(
checkbox ).
In particular, observe the warning information specified for some steps before carrying them out ( ! ).

Note down the rated data for the converter on the rating plate (on the inside of the door to the control compartment):

rated input voltage = 400 V rated input current = 1040 A

rated output voltage = ............... rated output current = ...............

Connect your PG/PC via the Ethernet connection (“crossover" cable) to the RJ-45 socket on the operator panel of the converter.

! Do NOT connect the Ethernet connection "PG/PC – converter" “ when the drive is switched on (energized motor), if your PG/PC
is grounded during operation (your PG/PC or the processor module could be damaged).

Switch on the auxiliary power supply at the plant end and via the switch on the converter.

Parameterize parameters ID2010 to ID2040 according to the converter data; select “OLTM” as type of control (ID2050).

Ensure that the scaling for the input current (ID3030) and input voltage (ID3040) is each parameterized to the value "1.0“.
[ via: Stability > Input Processing ]

Parameterize the "transformer tapping" (ID7050) according to the actual existing connection.

19_Commissioning LAB page 4 © Siemens Industry 2013 - subject to modification

 DriveAutomation
Technologies
andDivision
Drives

First Commissioning “without Motor” 2(3)

With the exception of some converters of smaller power ratings, a pre-charging routine is run through prior to EVERY switching-on of the
medium voltage. The respective pre-charging routine is type-dependent (Gen IIIE, WC III, Harmony HV, etc.) and is explained in the
corresponding manuals. The pre-charging is carried out in conjunction with the SOP; observe the relevant programming.

! If the converter to be commissioned is subject to a pre-charging routine, the pre-charging must be thoroughly tested in
accordance with the specifications in the manual (this step is omitted for the "Gen IV, Micro Harmony" training unit).

Configure the operator panel for displaying the input voltage (VAVI), input frequency (FRIN) and motor voltage (VLTS).

Parameterize the motor voltage (ID1040) according to the converter output voltage and the motor frequency (ID1020) to 50Hz
[ via: Motor > Motor Parameters ].

If existing, block the "Fast Bypass" option (ID2600) [ via: Drive > Cells > Fast Bypass ].

Switch on the medium voltage power supply of the converter and acknowledge all of the error messages and alarms.

! Check the supply voltage and supply frequency displayed on the operator panel or via Tool Suite. If the supply frequency display
is negative, the incoming supply is counterclockwise and the rotating field of the infeed should be changed.

If the drive is operated in an application with " synchronous transfer", both the input and output phase sequence have to be
clockwise.

When supplying the converter with rated voltage, a voltage of 1.91 [3.82] Vrms or 5.4 [10.8] Vpp has to be measured at the
voltage measuring points VIA, VIB and VIC of the "System Interface Board" ( NXG II [NXG] ); if the converter is supplied with a
reduced line voltage, the voltage at the measuring points has to be reduced proportionally.

If the voltage is noticeably too high or two low, the tapping of the transformer must be adjusted (observe all necessary safety
measures!). A voltage which is somewhat too high is generally not critical. If the voltage is too low, the tapping should be
changed.

19_Commissioning LAB page 5 © Siemens Industry 2013 - subject to modification

 DriveAutomation
Technologies
andDivision
Drives

First Commissioning “without Motor” 3(3)

Set a speed setpoint of 25% and switch on the drive ("Run Command").

At the voltage measuring points VMA, VMB and VMC of the "System Interface Board", the measurement must show the
approximate value of 0.48 [0.96] +/- 0.1Vrms or 1.35 [2.7] +/- 0.14Vpp ( NXG II [NXG] ); for the waveform of the signal, refer
to the example.

Increase the speed setpoint to 50% and ensure that the voltage at the measuring points is approximately doubled.

Since the flux controller is deactivated in OLTM mode, the output voltage at 50% of the rated speed corresponds to only
approximately 50% of the rated voltage. (Temporarily) set the flux setpoint (ID3150) such that the output voltage also
corresponds to 50% of the rated voltage.

Increase the speed setpoint to 100% and check the voltage at the measuring points VMA, VMB and VMC.
Required voltage values: 1.91 [3.82] +/- 0.1 Vrms or 5.4 [10.8] +/- 0.14 Vpp ( NXG II [NXG] ).

Change the speed setpoint to zero and switch off the drive ("Stop Command").

19_Commissioning LAB page 6 © Siemens Industry 2013 - subject to modification

 DriveAutomation
Technologies
andDivision
Drives

Testing the "Cell Bypass" Option

3 Testing the option "Cell Bypass"

If the converter is equipped with option "Cell Bypass“, the activation of the mechanical bypass contactors has to be checked.

Deactivate the function “Spinning Load", ID2430. [Since “Spinning Load“ is automatically activated in the sequence of operation of “Cell Bypass“,
the automatic activation can only be tested if the “manual selection” is deactivated.]

Change to control mode "OLVC" (ID2050).

Activate option "Fast Bypass" (ID2600) [ via: Drive > Cells > Fast Bypass ] and define the "minimum number of cells per phase"
(ID2540) at one less than true for the converter in fault-free operation.

On the operator panel, select the display for ID2620, "Bypass Status". The display must show an "A" (available) for each cell
(from left to right: phase L1, L2, L3).

a) Remove one of the fiber-optic connections from the "Fiber Optic Interface Board" and ensure that the "Bypass Status", ID2620
signals the "defective" cell with "B" (bypassed).

b) Re-connect the removed fiber-optic cable and use ID2640 to acknowledge the messages of the "Bypass Status" (ID2620)
("A" must be displayed for all of the cells again).

In case of a commissioning at plant, this test has to be carried out for all cells; on the lab-converter, carry out this test for one
cell only.

Deactivate option "Fast Bypass" (ID2600) [ via: Drive > Cells > Fast Bypass ].

19_Commissioning LAB page 7 © Siemens Industry 2013 - subject to modification

 DriveAutomation
Technologies
andDivision
Drives

Commissioning with Induction Motor in OLTM 1(2)

4 First commissioning with an induction motor

In this commissioning step, both the motor and the coupled load (if applicable) are checked as regards their capability to rotate; the
current measurement via the hall-effect transformers is checked basically.

Take all possible measures in order to be able to run the motor with the least load possible (ideal = uncouple load).

Switch on the auxiliary power supply to the converter and switch it on on the converter itself.

Change back to control mode "OLTM" (ID2050).

Parameterize the motor voltage (ID1040) and motor frequency (ID1020) according to the rating plate data of the motor
(via: Motor > Motor Parameters; if applicable, consider the ratio of an output transformer).
At the training drive: Motor voltage, ID 1040 = motor rating plate value x 10.5 = . . . . . . . . . . . . . V.

Ensure that the functions "Spinning Load", ID 2430 and "Fast Bypass", ID2600 are deactivated.

To begin with, set the ramp-up time (ID2270) and the ramp-down time (ID2280) to a large value, i.e. to 60 seconds each.

Reduce the flux setpoint to ID3150 = 0.5

Switch on the medium voltage supply of the converter and acknowledge all of the error messages and alarms.

! If the operator panel display indicates "RLBK" (torque limit reached) in the left section, change control mode ID2050 to "OLVC"
and read to the operating display:
in place of RLBK, MODE appears. Now re-parameterize ID2050 = "OLTM".

Configure the operator panel to display the magnetizing current Ids (IMAG), the torque-generating motor current Iqs (ITRQ) and
the motor voltage (VLTS).

Set a speed setpoint of 1% and check the shaft for free and unobstructed movement.

19_Commissioning LAB page 8 © Siemens Industry 2013 - subject to modification

 DriveAutomation
Technologies
andDivision
Drives

Commissioning with Induction Motor in OLTM 2(2)

Increase the speed setpoint to 25% and analyze motor voltage (measuring point VMA) and motor current (IMA) for phase L1.

If the motor is only negligibly loaded (almost purely reactive current)

the current leads the voltage by approximately 900, since the hall-
effects invert the current signal (resulting in an additional offset of 1800).

The magnetizing current Ids shown on the operator panel display must read a clearly positive value in average, the torque-
generating current Iqs will oscillate around zero without load. [In control mode "OLTM", currents are evaluated but not fed back.]

Analyze motor voltage and motor current in the same way for phases L2 and L3 as well.

Reduce the speed setpoint to zero and switch off the drive ("Stop Command"), then switch off the medium-voltage breaker.

19_Commissioning LAB page 9 © Siemens Industry 2013 - subject to modification

 DriveAutomation
Technologies
andDivision
Drives

Commissioning with Induction Motor in OLVC 1(5)

5 Commissioning in control mode "Open Loop Vector Control" with an induction motor
In this commissioning step, motor data and limits are set according to the process conditions and the actual values of the motor-side
voltage and current detection are checked in detail.
As regards control parameters, their "list factory settings" will still be maintained.
Please note that, if a synchronous machine is used, some different and additional steps are required, particularly with regard to field
control. In this case, follow the procedures as explained specifically in the "NXG Control Manual", paragraph 6-5.

Change to control mode “OLVC" (ID2050) and ensure that the functions "Spinning Load", ID 2430 and "Fast Bypass", ID2600 are
deactivated.

Parameterize ramp times for the ramp generator that are appropriate for the application, i.e. 30 seconds for pumps / 60 seconds for
fans (accel time = ID2270, decel time = ID2280)

Now parameterize the remaining motor parameters according to the rating plate data; consider the ratio of an output transformer.
Voltage: ID 1040 = motor rating plate value x 10.5 / current: ID 1050 = motor rating plate value x 0.095.

rated frequency [Hz], ID1020 = . . . . . . . . . . . . . . . rated speed [RPM], ID1030 = . . . . . . . . . . . . . . .

rated voltage [V], ID1040 = ............... rated current [A], ID1050 = ...............

rated power [kW], ID1010 = ...............

For the parameters given below, set those values which are listed in the parameter list under "default" (these values correspond to
a kind of "list factory setting", but can only be set to these values via "Reset to Factory Defaults" if no other values have been
defined as default values via "set factory defaults").
- Leakage reactance, ID1070 = 16% - Stator resistance, ID1080 = 0.1%
- No load current, ID1060 = 25% - Moment of inertia, ID1090 = 30 kgm2

19_Commissioning LAB page 10 © Siemens Industry 2013 - subject to modification

 DriveAutomation
Technologies
andDivision
Drives

Commissioning with Induction Motor in OLVC 2(5)

Unless required otherwise by the application, parameterize the following limit values as recommended:
- Overload select, ID1130 = Constant - Overload pending, ID1139 = 100%
- Overload, ID1140 = 110% - Overload timeout, ID1150 = 60s
- Motor torque limit, ID1190 = 100% - Regen torque limit, ID1200 = -0.3%
- Motor trip volts, ID1160 = 110% of the rated motor voltage
- Overspeed, ID1170 = 110% of the max. operating speed
(Please note that ID1170 refers to the rated motor speed!)

Ensure that the control-relevant parameters listed below are parameterized to the values of the specified "list factory settings“
(refer to manual “Next Gen Controls II”):
- Proportional gain "flux controller", ID3110 = 1.72
- Filter time constant "flux controller", ID3130 = 0.0667s
- Ramp time for the setup of the flux, ID3160 = 0.5s
- Proportional gain "speed controller", ID3210 = 0.02
- Evaluation factor "PI – PID" behavior, ID3230 = 0.60
- Proportional gain "current controller", ID3260 = 0.5
- "Braking with dual frequency", ID3360 = Off
- Scaling of the output current detection, ID3440 = 1.0
- Delay time "IGBT-activation", ID3550 = 12.0µs
- Reset time "flux controller", ID3120 = 1.0
- Flux setpoint, ID3150 = 1.0
- Minimum flux in energy-saving mode, ID3170 = 100%
- Reset time "speed controller", ID3220 = 0.046
- Filter time constant "speed controller", ID3240 = 0.0488s
- Reset time "current controller", ID3270 = 25.0
- Pulsation frequency of the torque, ID3370 = 275.0
- Scaling of the output voltage detection, ID3450 = 1.0
- Proportional gain "voltage pre-control", ID3560 = 0.0

Parameterize the values listed in the “Parameterlist for Robicon Perfect Harmony” which is provided along with the converter
with exception of those parameters marked with (1) respectively with (2); refer to the example on next page.

19_Commissioning LAB page 11 © Siemens Industry 2013 - subject to modification

 DriveAutomation
Technologies
andDivision
Drives

Commissioning with Induction Motor in OLVC 3(5)

Parameterlist for Perfect Harmony

Type: PH 4.16kV/4.16kV/140A; 6SR4102-0FD41-1BG

(1) (1) These parameters always have to be set in

(1)
(1) accordance with the data of the motor used.
(1)
(1)

400V Training !
1040A Training !

(2) (2) At the end of commissioning these para-

(2) meters are set either to the values stated in the
(2) list or to values specified by the customer.
(2)

(2)

Switch on the medium voltage power supply of the converter and acknowledge all of the error messages and alarms.

Configure the operator panel to display magnetizing current Ids, torque-generating motor current Iqs and motor voltage.

Set a speed setpoint of 1% and check the shaft for free and unobstructed movement.

19_Commissioning LAB page 12 © Siemens Industry 2013 - subject to modification

 DriveAutomation
Technologies
andDivision
Drives

Commissioning with Induction Motor in OLVC 4(5)

Increase the speed setpoint to 10% and analyze motor voltage (measuring point VMA) and motor current (IMA) for phase L1.

If the motor is only negligibly loaded (almost purely

reactive current), the current leads the voltage by
approximately 900, since the hall-effects invert the
current signal (resulting in an additional offset of 1800).

- The magnetizing current Ids shown on the operator panel must correspond to the set no-load current (ID1060 = 25%) in average,
- without load, the torque-generating current Iqs will typically be in the range of 1% - 3% of the rated current (e.g. when operating
a pump or a fan),
- the motor voltage must read approximately 10% of the rated motor voltage.

Analyze motor voltage and motor current in the same way for phases L2 and L3 as well.

Increase the speed setpoint to 25%, 50%, 75% and to 100%; at each value, compare the measured values of the motor voltages
at measuring points VMA, VMB and VMC to the values specified in the following table:
speed setpoint [%] motor frequency [Hz] motor voltage at VMx [Vpp] motor voltage at VMx [Vrms]
10 5.0 0.54 0.19
25 12.5 1.35 0.48
50 25.0 2.70 0.96
75 37.5 4.05 1.43
100 50.0 5.40 1.91

19_Commissioning LAB page 13 © Siemens Industry 2013 - subject to modification

 DriveAutomation
Technologies
andDivision
Drives

Commissioning with Induction Motor in OLVC 5(5)

Ensure that with increasing load, the torque-generating current Iqs increases accordingly and the phase shift between voltage
(e.g. VMA) and current (e.g. IMA) changes towards 1800 (due to the additional 1800-shifting of the hall-effects; refer to sample
oscillograms). [In the current measuring signals, note following relation: rated motor current = 5.0 Vpp rsp. 1.77 Vrms.]

VMA, IMA OLVC n = 10% no-load VMA, IMA OLVC n = 10% rated load

VMA, IMA OLVC n = 100% no-load VMA, IMA OLVC n = 100% rated load

Reduce the speed setpoint to zero and switch off the drive ("Stop Command").

Set parameters marked as (2) on p.12 either to the values stated in the list or to values specified by the customer.

19_Commissioning LAB page 14 © Siemens Industry 2013 - subject to modification

 DriveAutomation
Technologies
andDivision
Drives

Optimizing the Drive

6 Optimizing the drive

The basic prerequisite for operating the motor is the correct entry of the rating plate data. Basic and undemanding applications require
no further measures beyond this.
The control properties of the current are improved by correct assignment of the motor substitute data. If these data are not given in the
test log for the motor, they should be determined either by using the identification routine "Autotune Stage 1" (ID1260) or by an
approximate calculation based on the rating plate data (as shown on page 3-28).
If the motor is connected via output transformer an identification of the motor substitute data via “Autotune” will not be possible; the
alternative calculation as mentioned above will equally fail to provide correct data.

A more precise optimization of the speed controller will be required in exceptions only. To do this, follow the details for optimizing at the
end of section 3, Motor Theory and Control. During the manual optimization of the speed controller, always ensure that you only apply
small steps of setpoint which are permissive for the load connected to the motor.
The steps of setpoint have to structurally prepared via the SOP; after the optimization is concluded, the original SOP should be used
again (without the modification introduced to provide the step of setpoint).

19_Commissioning LAB page 15 © Siemens Industry 2013 - subject to modification

 DriveAutomation
Technologies
andDivision
Drives

Setting up the Function “Spinning Load"

7 Setting up the function “Spinning Load” (Restart on the fly)

The function “Spinning load” allows the converter to be switched on without torque jerk while the motor is rotating.
It is recommended to be activated if one or more of the following criteria are met:
- Activated "Fast Bypass" - control modes "CLVC", "SMC" or "CSMC" - activated “Auto-restart” (via SOP and ID7120 - ID7150).

First, parameterize the following values as suggested:

- mode “Spinning load“, ID2430 = “process-specific” - flux limit for frequency search, ID2440 = 20%
- search current, ID2450 = "same as no-load current, ID1060" - ramp time for current rise, ID2460 = 0.01s
- maximum search current, ID2470 = 50% - search time for ∆n = 100%, ID2480 = 3.0s

a) Operate the drive at a speed of 30%.

Switch off the drive via "ESTOP" (inverter pulses are blocked, the drive coasts down)

Wait until the motor flux has dropped to less than 4% (takes several seconds; depending on the power rating of the motor).

Clear the "ESTOP", acknowledge the message and switch on the drive again.

* Using the “trace-function”, record the values of speed set point and of actual speed while carrying out the function “Spinning load":
- if, at the moment of “catching the motor speed” the speed set point is larger than the motor speed, the drive has caught the motor
too soon, the “scan end threshold“ (ID2440, percentage of rated flux where frequency search ends) has to be be increased
- if, at the moment of “catching the motor speed” the speed set point is less than the motor speed, the drive has missed the motor
and the “scan end threshold” (ID2440) has to be reduced.

* Repeat the steps from a) to here until speed set point and motor speed correspond to each other as much as possible at the moment
of “catching the motor speed”.

Activate option "Fast Bypass, ID2600", switch off the “medium voltage” and switch off the auxiliary power supply.
* with encoder (CLVC) only!

19_Commissioning LAB page 16 © Siemens Industry 2013 - subject to modification

 DriveAutomation
Technologies
andDivision
Drives

Fault Detection and Replacement of Components

8 Fault detection and replacement of components / Diagnosing of power cells

Components of the converter power section as listed below can be diagnosed quite easily. Said components are both built in
individually and are part of the power cells.

Suggestions to diagnose power cells are listed on the last page.

Component Fault appearance Probable causes Replacement

Resistor scorched, blown up, discolored, loose connection, over-voltage, of the defective resistor
resistance value not matching inscription duration of current flow too long

Capacitor loss of oil, burst over-pressure membrane, over-voltage, overheating, of the defective capacitor and
blown up, charging behavior unlike too old of all capacitors in series or
comparable capacitors parallel to the defective one

Reactor, scorched, discolored, fuse blown, loose connection, over-voltage, of the defective component
Transformer over-loaded wires or cables over-heating (cooling system failure)

Semiconductor shorted, fuse blown, over-current, over-voltage, Diodes, thyristors:

rarely "not controllable“
loose connection, overheating,
current rise di/dt too fast,
erroneous triggering,
faults in the snubber circuit
only of the defective component
IGBTs:
of the defective IGBT and of all
IGBTs in series or parallel to the
defective ones

19_Commissioning LAB page 17 © Siemens Industry 2013 - subject to modification

 DriveAutomation
Technologies
andDivision
Drives

Diagnosing a Power Cell with Diode Tester / Ohmmeter

Shorted semiconductors, burned resistors or faulty capacitors can be identified quite reliably using a diode tester respectively an
Ohmmeter; the switching property of an IGBT, however, cannot be tested this way.

For the function test of components as stated above, following criteria have to be applied:
- semiconductor in conductive direction low Ohm value (… tens to hundreds of Ohms)
- semiconductor in blocking direction high Ohm value (… tens of MOhms)
- capacitor (general) initially low Ohm value; increasing Ohm value while charging up (.. MOhm)
- capacitor parallel to resistor initially low Ohm value; after having charged up: “like resistor“
- capacitor (capacity) in comparison only; same charging time as some other capacitor of the same type

U_pos

L3

T1
L2

T2
L1

U_neg

19_Commissioning LAB page 18 © Siemens Industry 2013 - subject to modification