gm150 commissioning manual

8/20/2019 GM150 Commissioning Manual

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Commissioning Manual Edition 01/2008

Medium-Voltage AC-Converter

SINAMICS GM150

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Introduction

1

Safety Instructions

2

Commissioning (software)

3

Commissioning (hardware)

4

Parameter assignment /

addressing

5

Functions

6

Alarm, error and system

messages

7

Appendix

A

Medium-Voltage AC Converters

SINAMICS GM150

Commissioning Manual for

SINAMICS GM150, Software

Version 2.5, STARTER Version 4.1

Commissioning Manual

1/2008

A5E00923869K

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Safety Guidelines

This manual contains notices you have to observe in order to ensure your personal safety, as well as to preventdamage to property. The notices referring to your personal safety are highlighted in the manual by a safety alertsymbol, notices referring only to property damage have no safety alert symbol. These notices shown below aregraded according to the degree of danger.

DANGER

indicates that death or severe personal injurywill

result if proper precautions are not taken.

WARNING

indicates that death or severe personal injurymay

result if proper precautions are not taken.

CAUTION

with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.

CAUTION

without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.

NOTICE

indicates that an unintended result or situation can occur if the corresponding information is not taken intoaccount.

If more than one degree of danger is present, the warning notice representing the highest degree of danger willbe used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating toproperty damage.

Qualified Personnel

The device/system may only be set up and used in conjunction with this documentation. Commissioning andoperation of a device/system may only be performed by qualified personnel. Within the context of the safety notesin this documentation qualified persons are defined as persons who are authorized to commission, ground andlabel devices, systems and circuits in accordance with established safety practices and standards.

Prescribed Usage

Note the following:

WARNING

This device may only be used for the applications described in the catalog or the technical description and onlyin connection with devices or components from other manufacturers which have been approved orrecommended by Siemens. Correct, reliable operation of the product requires proper transport, storage,positioning and assembly as well as careful operation and maintenance.

Trademarks

All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in thispublication may be trademarks whose use by third parties for their own purposes could violate the rights of theowner.

Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and softwaredescribed. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, theinformation in this publication is reviewed regularly and any necessary corrections are included in subsequenteditions.

Siemens AGIndustry SectorPostfach 48 4890327 NÜRNBERGGERMANY

Ordernumber: A5E00923869KⓅ 05/2008

Copyright © Siemens AG 2008.Technical data subject to change

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Commissioning Manual for SINAMICS GM150, Software Version 2.5, STARTER Version 4.1Commissioning Manual, 1/2008, A5E00923869K 3

Table of contents

1 Introduction................................................................................................................................................ 9

1.1 Purpose of this document ..............................................................................................................9

1.2 Performing a receiving inspection..................................................................................................9

2 Safety Instructions ................................................................................................................................... 11

2.1 Observing the five safety rules.....................................................................................................11

2.2 ESD-sensitive components..........................................................................................................112.3 Safety concept .............................................................................................................................132.3.1 Monitoring functions.....................................................................................................................132.3.2 Insulation monitoring....................................................................................................................132.3.3 Undervoltage tripping...................................................................................................................142.3.4 High-speed grounding switch.......................................................................................................152.3.5 Emergency shutdown (trip line) ...................................................................................................162.3.6 Controlled stop, EMERGENCY OFF category 1 (option L60) .....................................................16

3 Commissioning (software) ....................................................................................................................... 19

3.1 Commissioning tools....................................................................................................................19

3.2 Software installation.....................................................................................................................19

3.2.1 System requirements for installing STARTER.............................................................................193.2.2 Installing STARTER.....................................................................................................................20

3.3 Description and configuration of the PROFIBUS interface..........................................................203.3.1 Hardware components required for PROFIBUS communication ................................................203.3.2 PROFIBUS interface, diagnostics LEDs, address switches ........................................................203.3.3 Connecting the PROFIBUS cables..............................................................................................233.3.4 Setting the PROFIBUS address switches....................................................................................243.3.5 Requirements for communication via PROFIBUS.......................................................................25

3.4 Data backup on the CompactFlash card and firmware update ...................................................263.4.1 Data backup.................................................................................................................................263.4.2 Upgrading firmware version automatically...................................................................................27

3.5 Switching on the auxiliary power supply ......................................................................................27

3.6 The STARTER Commissioning Tool ...........................................................................................283.6.1 Working with the STARTER project wizard .................................................................................283.6.2 Options for creating a project.......................................................................................................313.6.3 First commissioning ONLINE with the project wizard..................................................................323.6.3.1 Assembling a new project online .................................................................................................323.6.3.2 Downloading the drive project to the PG .....................................................................................383.6.3.3 Configuring a drive.......................................................................................................................393.6.3.4 Downloading the drive project to the target system and saving ..................................................553.6.3.5 Entering additional important parameters....................................................................................573.6.4 First commissioning ONLINE without the project wizard.............................................................603.6.4.1 Assembling a new project online without using the project wizard..............................................603.6.4.2 Configuring your drive project ......................................................................................................68

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Commissioning Manual for SINAMICS GM150, Software Version 2.5, STARTER Version 4.14 Commissioning Manual, 1/2008, A5E00923869K

3.6.4.3 Downloading the drive project to the target system and saving ................................................. 833.6.4.4 Entering additional important parameters (V2.5) ........................................................................ 873.6.5 First commissioning OFFLINE with the project wizard ............................................................... 91

3.6.5.1 Creating a new project ................................................................................................................ 913.6.5.2 Configure the drive unit ............................................................................................................... 973.6.5.3 Start drive project and download to target device..................................................................... 1163.6.5.4 Entering additional important parameters ................................................................................. 1213.6.6 Concluding parameter comparison ........................................................................................... 1243.6.7 Saving a project ........................................................................................................................128

3.7 Commissioning via the operator panel...................................................................................... 1323.7.1 General information about the AOP30 operator panel ............................................................. 1323.7.1.1 The AOP30 operator panel ....................................................................................................... 1323.7.1.2 The keys of the AOP30............................................................................................................. 1343.7.1.3 Basic operation of the AOP 30.................................................................................................. 1353.7.2 First commissioning and basic parameter assignment with the AOP30 operator panel .......... 1383.7.2.1 Initial commissioning with the AOP 30...................................................................................... 1383.7.2.2 Basic parameterization with the AOP 30 .................................................................................. 1393.7.3 Parameterization errors............................................................................................................. 1433.7.4 Saving the parameters permanently ......................................................................................... 1433.7.5 Individual configuration of the AOP30 operator panel .............................................................. 1433.7.5.1 Define operation screen............................................................................................................ 1433.7.5.2 Control settings ......................................................................................................................... 1483.7.5.3 Inhibit functions .........................................................................................................................1513.7.6 Menu description and setting options ....................................................................................... 1543.7.6.1 Introduction (AOP menus)......................................................................................................... 1543.7.6.2 Operation screen.......................................................................................................................1543.7.6.3 Parameterization.......................................................................................................................1563.7.6.4 Fault/alarm memory .................................................................................................................. 1593.7.6.5 Commissioning / service drive commissioning .........................................................................1613.7.6.6 Commissioning / service device commissioning.......................................................................1633.7.6.7 Commissioning / Service - AOP settings .................................................................................. 1663.7.6.8 Commissioning/Service - AOP diagnostics............................................................................... 1713.7.6.9 Language ..................................................................................................................................174

4 Commissioning (hardware).................................................................................................................... 175

4.1 Overview of parameter macro interconnections in table format ............................................... 175

4.2 Conduct signal check ................................................................................................................ 175

4.3 Conducting hardware tests ....................................................................................................... 1764.3.1 Introduction ...............................................................................................................................1764.3.2 Required hardware tests ........................................................................................................... 1774.3.2.1 Circuit-breaker test.................................................................................................................... 1774.3.2.2 Test of the make-proof grounding switch and the pre-charging ............................................... 1784.3.2.3 Testing the door interlocking and the door limit switch ............................................................. 1804.3.2.4 Test of the pre-charging and of the line switch ......................................................................... 1804.3.2.5 Testing the EMERGENCY STOP button .................................................................................. 1814.3.3 Recommended hardware tests ................................................................................................. 1824.3.3.1 Test of the main fans................................................................................................................. 1824.3.3.2 Test of the redundant main fan ................................................................................................. 1834.3.3.3 Test of the auxiliary fans ........................................................................................................... 183

4.4 Checking the signal wiring ........................................................................................................ 1844.4.1 Potential concept....................................................................................................................... 184

5 Parameter assignment / addressing ...................................................................................................... 185

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5.1 Parameters.................................................................................................................................185

5.2 BICO technology: Interconnecting signals.................................................................................188

5.2.1 Binectors and Connectors..........................................................................................................1885.2.2 Interconnecting signals using BICO technology ........................................................................1895.2.3 Additional explanations of BICO technology..............................................................................191

5.3 Data sets....................................................................................................................................192

5.4 Changing over units...................................................................................................................197

5.5 Reference parameters/normalizations .......................................................................................199

6 Functions............................................................................................................................................... 201

6.1 Instructions for commissioning induction motors (ASM)............................................................2016.1.1 Basic settings.............................................................................................................................2016.1.2 Motor data identification.............................................................................................................2046.1.3 Advanced settings......................................................................................................................205

6.1.3.1 Field weakening starting point ...................................................................................................2056.1.3.2 Notes on Operation with no Tacho-Generator...........................................................................206

6.2 Instructions for commissioning permanent-magnet synchronous motors .................................2066.2.1 Safety information......................................................................................................................2066.2.2 Basic settings.............................................................................................................................2076.2.3 Motor data identification.............................................................................................................2106.2.4 Pole position identification .........................................................................................................2116.2.5 Advanced settings......................................................................................................................2136.2.5.1 Field weakening starting point ...................................................................................................2136.2.5.2 Notes on Operation with no Tacho-Generator...........................................................................214

6.3 Note regarding the commissioning of separately excited synchronous motors ........................214

6.4 Drive Functions ..........................................................................................................................2146.4.1 Setpoint channel ........................................................................................................................2146.4.1.1 Description .................................................................................................................................2146.4.1.2 Jog .............................................................................................................................................2166.4.1.3 Fixed speed setpoints ................................................................................................................2206.4.1.4 Motorized potentiometer ............................................................................................................2216.4.1.5 Main/supplementary setpoint and setpoint modification............................................................2226.4.1.6 Direction of rotation limiting and direction of rotation changeover.............................................2246.4.1.7 Suppression bandwidths and setpoint limits..............................................................................2256.4.1.8 Ramp function generator ...........................................................................................................2266.4.2 Speed controller .........................................................................................................................2316.4.2.1 Description .................................................................................................................................2316.4.2.2 Speed controller adaptation .......................................................................................................2336.4.2.3 Speed controller pre-control and reference model ....................................................................2356.4.2.4 Droop function............................................................................................................................2386.4.2.5 Torque control ............................................................................................................................2406.4.2.6 Torque limiting............................................................................................................................2426.4.2.7 Current setpoint filter..................................................................................................................2446.4.2.8 Current controller .......................................................................................................................2456.4.3 Vdc control .................................................................................................................................2466.4.4 Flying restart ..............................................................................................................................2496.4.5 Automatic restart ........................................................................................................................2506.4.6 Bypass function..........................................................................................................................2566.4.7 Staging function .........................................................................................................................2616.4.7.1 Description of the staging function.............................................................................................2616.4.7.2 Staging without a staging command..........................................................................................2626.4.7.3 Staging with a staging command...............................................................................................263

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6.4.7.4 Sequence of a motor change.................................................................................................... 2656.4.8 Output-end disconnector or circuit breaker............................................................................... 2676.4.8.1 Description ................................................................................................................................267

6.4.8.2 Switching conditions for the disconnector................................................................................. 2696.4.8.3 Switching conditions for the output circuit breaker ................................................................... 2726.4.8.4 Startup.......................................................................................................................................2736.4.9 Switching frequency reduction .................................................................................................. 2776.4.10 Technology function: friction characteristic curve ..................................................................... 279

6.5 Monitoring and protective functions .......................................................................................... 2816.5.1 Block protection.........................................................................................................................2816.5.2 Thermal motor protection.......................................................................................................... 2826.5.3 Circuit breaker switching cycle.................................................................................................. 283

6.6 Hardware-related optional functions ......................................................................................... 2856.6.1 Redundancy mode.................................................................................................................... 2856.6.1.1 Control Unit redundancy mode ................................................................................................. 285

6.6.1.2 Power unit redundancy mode ................................................................................................... 2906.6.2 Parallel circuit configuration ...................................................................................................... 2906.6.3 Brake controller .........................................................................................................................2916.6.4 Recooling unit ........................................................................................................................... 2926.6.5 Fan control ................................................................................................................................2956.6.6 Ancillary fan monitoring............................................................................................................. 297

6.7 Function modules...................................................................................................................... 2986.7.1 Function modules...................................................................................................................... 2986.7.2 Technology controller................................................................................................................ 2996.7.2.1 Description/Commissioning....................................................................................................... 2996.7.2.2 Examples...................................................................................................................................3006.7.2.3 Integration of the technology controller..................................................................................... 3026.7.3 Extended monitoring functions.................................................................................................. 3036.7.3.1 Characteristics/Commissioning................................................................................................. 3036.7.3.2 Integration .................................................................................................................................304

6.8 Extended diagnostic functions .................................................................................................. 3056.8.1 Description ................................................................................................................................3056.8.2 Integration .................................................................................................................................307

7 Alarm, error and system messages ....................................................................................................... 309

7.1 Further information on alarms, error and system messages .................................................... 309

7.2 External alarms and faults......................................................................................................... 309

7.3 Message from the grounding switch ......................................................................................... 309

7.4 Diagnostics................................................................................................................................3107.4.1 Introduction ...............................................................................................................................3107.4.2 Diagnostics via LEDs ................................................................................................................ 3107.4.3 Diagnostics via parameters....................................................................................................... 3127.4.4 Indicating and rectifying faults................................................................................................... 316

A Appendix................................................................................................................................................ 317

A.1 Troubleshooting/FAQs .............................................................................................................. 317

A.2 List of abbreviations .................................................................................................................. 317

A.3 Parameters for interconnecting signals..................................................................................... 318A.3.1 BICO technology: Interconnecting signals ................................................................................ 318A.3.2 Information about the parameter nomenclature:....................................................................... 319

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Table of contents


A.3.3 Overview of standard cabling for the parameter macro PM001540 on VECTORMV................320A.3.4 Overview of standard cabling for the parameter macro PM001540 on VECTORMV................328A.3.5 Overview of standard interconnections for the parameter macro PM001540 on B_INFMV......329

A.3.6 Parameter interconnection overview for optional macro PM001555 for option G66 .................331A.3.7 Parameter interconnection overview for optional macro PM001557 Analog O PSA for

options K21 and K20..................................................................................................................332A.3.8 Parameter interconnection overview for optional macro PM001558 Analog O PSA for

options K22 and K20..................................................................................................................334A.3.9 Parameter interconnection overview for optional macro PM001571 for Emergency Button

1 option ......................................................................................................................................336A.3.10 Parameter interconnection overview for optional macro PM001580 Lamps and StartStop

Button.........................................................................................................................................336A.3.11 Parameter interconnection overview for optional macro PM001582 for option L27-L29

Bypass1 .....................................................................................................................................338A.3.12 Parameter interconnection overview for optional macro PM001583 for option L53 UPS .........341A.3.13 Parameter interconnection overview for optional macro PM001584 for option L55

Standstill Heating.......................................................................................................................342A.3.14 Parameter interconnection overview for optional macro PM001585 for options N20, N21Capacitor Tripping device Circuit Breaker .................................................................................342

A.3.15 Parameter interconnection overview for optional macro PM001587 for option Motortemperature sensors..................................................................................................................343

Glossary ................................................................................................................................................ 345

Index...................................................................................................................................................... 353

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Introduction

1

1.1

Purpose of this document

This documentation facilitates the safe handling of the SINAMICS GM150 medium-voltageconverter and contains comprehensive information on the commissioning and operatingutilization phases and the tools available for it.

●

This Commissioning Manual is part of the electronic documentation.

● This Commissioning Manual is valid for:

– Software version SINAMICS V2.5

– STARTER version 4.1

Table 1-1 Overview

Usage phase Document/tool

Commissioning Parameterization and Startup Tool STARTER

List Manual GM150

Documentation scope

In the interests of clarity, this documentation does not contain all the detailed information forall product types and cannot take into account every possible aspect of installation,operation, or maintenance.

Target group

This documentation is geared toward machine manufacturers, commissioning personnel andservice personnel who put the SINAMICS GM150 medium-voltage converter into operationand operate it.

1.2

Performing a receiving inspection

The incoming goods inspection involves the following:

● Visual inspection and mechanical testing of the control cabinet system

● Check the version number

● Testing the voltages

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Introduction

1.2 Performing a receiving inspection


Note

Perform each step of the receiving inspection in order to identify major faults or defectsimmediately.

A: Visual inspection and mechanical testing of the control cabinet system

● Pay particular attention to the doors, checking for damage that frequently occurs whenhandled incorrectly during shipping. Also check that all screws on the side walls are inplace.

● Check that the cable ducts are still covered.

● Check the converter for protruding wires.

B: Testing the voltages

● Check that the power supply voltage matches the rating specified on the rating plate. (Forexample, are the requirements AC 3~ and 1~ auxiliary voltage met, if suppliedseparately?)

● Check the rating plates of the medium voltage transformer and the motor.

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Safety Instructions

2

2.1

Observing the five safety rules

For your personal safety and in order to prevent material damage it is essential that youfollow the safety instructions given below and all safety-related instructions in your productdocumentation. In particular pay attention to the safety-related instructions on the product

itself and always read the section headed "Safety Instructions" in each document.

DANGER

Danger due to high voltages

High voltages cause death or serious injury if the safety instructions are not observed or ifthe equipment is handled incorrectly.

Potentially fatal voltages occur when this equipment is in operation which can remainpresent even after the converter is switched off.

Ensure that only qualified and trained personnel carry out work on the equipment.Follow the five rules at all times and during each stage of the work.

The five safety rules: 1. Disconnect the system.

2. Protect against reconnection.

3. Make sure that the equipment is de-energized.

4. Ground and short-circuit.

5. Cover or enclose adjacent components that are still live

2.2

ESD-sensitive components

Guidelines for Handling Electrostatic Sensitive Devices (ESD)

CAUTION

Electrostatic discharge

Electronic modules contain components that can be destroyed by electrostatic discharge.

These modules can be easily destroyed by improper handling.

To protect your equipment against damage, follow the instructions given below.

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Safety Instructions

2.2 ESD-sensitive components


● Never touch electronic modules unless absolutely necessary in the course of

maintenance and repair procedures.● If the modules have to be touched, the body of the person concerned must be

electrostatically discharged immediately beforehand and be grounded.

● Electronic modules should not be brought into contact with electrically insulating materialssuch as plastic foil, plastic parts, insulating table supports or clothing made of syntheticfibers.

● Always place electrostatic endangered assemblies on conductive bases.

● Always store and transport electronic modules or components in conductive packaging(e.g. metallized plastic or metal containers).

CAUTION

Use conductive packaging material

Electronic modules must be stored, transported and dispatched in conductivepackaging.

Electronic modules which are not correctly stored, transported or dispatched can bedamaged.

Pack electronic modules in appropriate conductive packaging (e.g. foam rubber oraluminum foil).

The necessary ESD protective measures for electrostatically sensitive devices are illustratedonce again in the following drawings:

d

f f f f

b

e

a a ac c c

e

b

f

d d

(1) (2) (3)

e

a

Figure 2-1 ESD protective measures

(1) Sitting

(2) Standing

(3) Standing/sitting

ESD protective measures

a = conductive floor

b = ESD table

c = ESD footwear

d = ESD coat

e = ESD wrist strap

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Safety Instructions

2.3 Safety concept


f = cubicle ground connection

[ID 6006.02]

2.3 Safety concept

2.3.1

Monitoring functions

The medium-voltage converter features hardware and software functions that protect itagainst faults and damage caused by impermissible operating statuses or hardwaremalfunctions. The control elements are located in the converter cabinet and support internal

microprocess-controlled monitoring and remote device monitoring.

2.3.2

Insulation monitoring

Insulation monitoring

The SINAMICS GM150 converter is operated ground-free via an IT system. This means thatthe converter can continue to operate if a ground fault occurs.

NOTICE

A second ground fault causes the converter to fail.

For safety reasons, it is necessary to detect such ground faults, in order to eliminate the riskof electric shock on the converter. For this reason, the SINAMICS GM150 converter isequipped with an A-ISOMETER insulation monitor (type IRDH275BM), which continuouslymonitors the condition of the converter, including the motor.

Only one insulation monitoring device can be connected to each live connected IT system.

The insulation monitor automatically adjusts monitoring in line with the line dischargecapacitance.

Before carrying out any insulation or voltage testing on the power system, the voltagemonitor's instrument cables must be disconnected for the duration of testing.

The A-ISOMETER Type IRDH275BM is connected between the ungrounded supply and theequipotential bonding conductor (PE).

Self-test

The A-ISOMETER IRDH275B automatically runs a self-test routine whenever the insulationresistance of the mains supply > 20 MΏ or every 24 hours if an output relay has beenpreselected for system fault signaling.

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Safety Instructions

2.3 Safety concept


Terminal monitoring

The connections to mains and ground (PE) are monitored continuously. If the cables are

interrupted or not connected, or if their resistance is high, this is indicated on the LCD.In this case, please check the terminal conductors immediately, as the insulation resistanceis not being measured properly.

The insulation resistance can be > 20 MΏ in new or small IT systems. An alarm would alsobe output in this case. In this case, terminal monitoring must be deactivated in Setup2.

The insulation monitor monitors the insulation resistance of the converter with respect to twolimit values:

Limit value 1: Insulating resistor < 500 kOhms = Signal 1 (alarm)Limit value 2: Insulating resistor < 100 kOhms = Signal 2 (fault)

The messages are wired as follows on the terminal strip TM 15, and output as messages tothe AOP30 and the starter.

Signal Terminal

Message 1 .HC-A11-X522:3

Message 2 .HC-A11-X522:4

For more detailed information on how the A-ISOMETER IRDH275B functions andinstructions on how it is operated, see "Supplementary instructions (options, third-partysuppliers)".

2.3.3

Undervoltage tripping

Tripping of the circuit breaker in case of undervoltage

If a serious fault occurs (e.g., overload in the DC link), the converter is immediatelydisconnected from the power supply by means of the safety shutdown function.

WARNING

This function cannot ensure that the drive stops immediately, nor can it ensure that residualvoltages do not still exist at the output terminals and within the unit.

The shutdown of the circuit breaker is triggered by a safety contactor combination.It is essential for the circuit breaker on the system side to be equipped with an undervoltagetrip to ensure the wire-break protection for the circuit breaker OFF command.

If a circuit breaker OFF command is issued as a result of an overvoltage trip, the circuitbreaker is switch off so that it is fail-safe.

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Safety Instructions

2.3 Safety concept


2.3.4

High-speed grounding switch

Description

The short-circuiter is triggered if an over-voltage occurs due to a serious fault and it cannotbe brought under control by opening the circuit-breaker and unlocking the pulse block of themachine.

When the short-circuiter thyristors are triggered, the circuit-breaker is always deactivated.Once the thyristors have been triggered, an acknowledgement signal is output to the closed-loop control system. Fiber-optic conductors are used to control gating of the thyristors andthe acknowledgement signals.

The short-circuiter is triggered by the Power Stack Adapter.

WARNING

It takes up to six minutes for the voltages to reach a safe level once the high voltage andauxiliary voltage have been switched off.

If the short-circuiter is defective, this can significantly increase the discharge time.

Always observe the five safety rules in "Safety information/personnel protection" and in theconverter documentation.

The response voltage depends on the rated output voltage of the converter:

Rated output voltage [kV] 2.3 3.3 4.16 6.0 6.6 7.2

Response voltage [kVdc](for each half of DC link)

2.2 3.125 4,.4 5.7 6.25 6.8

The resistors absorb the energy stored in the DC link and limit the current. In the event offalse tripping, the torque surge for the machine, which is still rotating, is limited by theresistors.

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Safety Instructions

2.3 Safety concept


2.3.5

Emergency shutdown (trip line)

Description

Figure 2-2 Networked structures for safe shutdown in an emergency

The overview diagram shows how central components are networked. The DRIVE-CLiQconnection between the control unit and the power stack adapter is considered securebecause communication on the DRIVE-CLiQ cable is monitored cyclically.

With regard to contactor control for the circuit breaker, a two-channel bypass to the opencircuits is provided for safety reasons. Refer to the overview diagram for circuit breakercontrol in the appendix. This ensures that the circuit breaker opens whenever a fault occurswithin the system, that is, system faults in the control unit or power stack adapter cause the

circuit breaker to trip. A bypass to the circuit breaker is also provided via a fiber-optic ring iffaults occur in other inverter systems.

The following time-coded signals are transmitted via the fiber-optic ring:

● Pulse inhibit

● Circuit breaker OPEN

● Crowbar CLOSED

● Arc-through of all IGCTs (only with GM150 IGCT)

2.3.6

Controlled stop, EMERGENCY OFF category 1 (option L60)

Description of the EMERGENCY STOP function

The EMERGENCY STOP function for controlled shutdown stops the drive by means of aquick stop process along a deceleration ramp that must be parameterized.

NOTICE

The drive is stopped during controlled deceleration without braking modules with only avery low % braking torque. Depending on the load machine, the ramp-down procedure maytake a long time.

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Safety Instructions

2.3 Safety concept


Testing the EMERGENCY STOP button

Most of the contacts of the EMERGENCY STOP button are integrated in the controller circuitof the circuit breaker. The two remaining opener contacts of the EMERGENCY STOP buttonare situated on the terminal block.

EMERGENCY

STOP button

Where connected

=.LA-S31:11-12

=.LA-S31:21-22

=.LA-S31:31-32

Circuit breakercontrol circuit

=.LA-X11:9-10

=.LA-X11:5-6

=.LA-X11:7-8

If jumpered STOP; if not jumpered EMERGENCY STOP(produces an instantaneous stopcommand on the circuit breaker)

=.LA-S31:51-52 EMERGENCY STOPcustomer =.LA-X51:1, 2

=.LA-S31:61-62 Excitation equipment =.LA-X51:3, 4

Max. connectable cross-section: 4 mm² (AWG 10)

You will find further information in the section "Circuit book" in your operating instructions.

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3

3.1

Commissioning tools

You have two options for commissioning the converter:

1. STARTER commissioning tool

–

We recommend you use the STARTER commissioning tool and Project Wizard foreasy commissioning.

– In this case, you must install the STARTER software, which you can find on thesupplied CD. For information on how to do so, refer to the section entitled Softwareinstallation (Page 19).

– You must also set up a PROFIBUS interface in order to perform the commissioningwith STARTER. For information on how to do so, refer to the section entitled" Description and configuration of the PROFIBUS interface (Page 20) ".

2. The AOP operator panel

– If you have no PC or programming device (PG), you can perform the commissioningusing the AOP operator panel. In this case, continue with the section entitled

" Commissioning via the operator panel (Page 132) ".

3.2 Software installation

3.2.1

System requirements for installing STARTER

Prerequisites for installing the STARTER

For successful installation and operation of the STARTER software, the followingprerequisites are needed:

Hardware requirements:

● Programming device (PG) or PC with

● Windows 2000: Pentium II 400 MHz, 256 MB RAM, or

● Windows XP Professional: Pentium III 500 MHz, 512 MB RAM

● 1024 x 768 pixel screen resolution

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3.3 Description and configuration of the PROFIBUS interface


Software requirements:

● Windows 2000 SP3 or SP4, or

●

Windows XP Professional SP1 or SP2 or● Windows Server 2003 SP1

● Internet Explorer V6.0.

3.2.2

Installing STARTER

Installing the STARTER via the SETUP file

Install STARTER via the "setup" file on the CD supplied.

✔ Double-click the "Setup" file.

The installation wizard guides you through the individual installation steps.

[ID 5105.00]

3.3

Description and configuration of the PROFIBUS interface

3.3.1

Hardware components required for PROFIBUS communication

To perform the commissioning with STARTER, you must set up a PROFIBUS interface.

Required hardware components:

● Prefabricated PROFIBUS or MPI cable

● Field PG

● CP5512 adapter (if using a laptop) or

● CP5611 interface card (if using a PC)

3.3.2

PROFIBUS interface, diagnostics LEDs, address switches

Introduction

The PROFIBUS connection, diagnostics LEDs, and the PROFIBUS address switch arelocated on the Control Unit CU320.

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Figure 3-1 View of the Control Unit with PROFIBUS interface

① X126 PROFIBUS connection

② PROFIBUS diagnostics LEDs

③ PROFIBUS address switches

X126 PROFIBUS interface ①

Figure 3-2 X126 PROFIBUS connection

Table 3-1 PROFIBUS interface X126

Pin Signal name Description Range

1 - Not assigned

2 M24_SERV Power supply for teleservice, ground 0 V

3 RxD/TxD–P Receive/transmit data P (B) RS4854 CNTR–P Control signal TTL

5 DGND PROFIBUS data reference potential

6 VP Supply voltage plus 5 V +- 10%

7 P24_SERV Power supply for teleservice, + (24 V) 24 V (20.4 V -28.8 V)

8 RxD/TxD–N Receive/transmit data N (A) RS485

9 - Not assigned

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CAUTION

No CAN cables may be connected to the X126 interface. If CAN cables are connected, theCU320 and other CAN bus nodes could be seriously damaged.

Note

A teleservice adapter can be connected to the PROFIBUS interface (X126) for remotediagnostics purposes.The power supply for the teleservice terminals 2 and 7 may have a max. load of 150 mA.

Diagnostics LED ②

The meaning is explained in the table below.

Table 3-2 Description of the DP1 LEDs

Color Status Description

----- Off Cyclic communication has not (yet) taken place.

Note:PROFIdrive is ready for communication when the Control Unit is ready to operate (DP1LED is on).

Green Continuously lit PROFIBUS is ready for communication and cyclic communication is taking place.

Green 0.5 Hz flashing

light

Full cyclic communication is not yet taking place.

•

The controller is not transferring any setpoints.During synchronous operation, no global control (GC) or a faulty global control (GC) istransferred by the Controller.

Red Continuously lit Cyclic communication has been interrupted.

PROFIBUS selector ③

The PROFIBUS address switch is located under the cover.

Figure 3-3 PROFIBUS address switch cover

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3.3.3

Connecting the PROFIBUS cables

Description

The figure below shows suitable PROFIBUS connectors with/without a programmingdevice/PC connector.

Figure 3-4 PROFIBUS connectors

✔ Connect the cables to the PROFIBUS connectors, as these connectors contain thenecessary bus terminating resistors.

✔ Connect the cable shield over a wide area on both sides.

Switching the bus terminating resistor on and off

The terminating resistors must be switched on at both ends of the bus line.

The bus terminating resistors must be switched off at all other connectors.

Figure 3-5 Position of the bus terminating resistors

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✔ Switch the bus terminating resistor on or off depending on its position in the bus,otherwise the data will not be transmitted properly.

3.3.4 Setting the PROFIBUS address switches

Description

The PROFIBUS address of the Control Unit CU320 must be set for PROFIBUScommunication.

You have two options for setting the PROFIBUS address:

●

DIP switch on the Control Unit CU320

● Parameter p0918 (default setting)

Setting via DIP switch

A value is assigned to DIP switches S1 to S7.

Table 3-3 PROFIBUS address switches

Switch Significance

S1 20 = 1

S2 21 = 2S3 22 = 4

S4 23 = 8

S5 24 = 16

S6 25 = 32

S7 26 = 64

✔ Move switches S1 to S7 to the required position to set the PROFIBUS address.

If the PROFIBUS address is set with DIP switches S1 to S7, then parameter p0918

(PROFIBUS address) is read-only and displays the set address for the Control Unit. If theaddress is changed, the new setting does not become effective until the Control Unit CU320is switched on.

Example: Using DIP switches to set a PROFIBUS address

In this example, PROFIBUS address 37 is set.

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Significance

Example:

Note

The PROFIBUS address switches have a default setting of 0 or 127 (set via parameterp0918).

Setting via parameter p0918

You can only do this if the address has been set to 0 or 127 using the address switches, thatis, all switches from S1 to S7 are set to ON or OFF (default setting). If the address ischanged, the new setting does not become effective until the Control Unit CU320 is switchedon.

Note

The set PROFIBUS address is saved by means of the "Copy RAM to ROM" function.

3.3.5

Requirements for communication via PROFIBUS

Description

The PROFIBUS master must always send a 1 in the eleventh bit (bit 10) of the first controlword (control by PLC). The process data (PZD) will not otherwise be processed furtherinternally.

It is not sufficient to interconnect parameter p854 permanently with a 1.

This also applies to slave-to-slave communication between multiple slaves (converter withDC master as an excitation device...). The eleventh bit (bit 10) must be preset to 1 in the firstcontrol word from the master to the converter. This also applies when no other mastercontrol commands are in use and slaves are communicating by direct slave-to-slave dataexchange only.

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3.4 Data backup on the CompactFlash card and firmware update


3.4

Data backup on the CompactFlash card and firmware update

3.4.1 Data backup

Data backup

CAUTION

The CompactFlash card must only be inserted or removed when the power is off.Otherwise there is a risk of data loss or damage to the card,

which would prevent commissioning of the drive.

Only remove or insert the CompactFlash card when the power is switched off.

✔ Check that a CompactFlash card has been inserted into the CPU.

✔ Remove the CompactFlash card from the CPU and back up the data stored on thecard.

Figure 3-6 CPU with a CompactFlash card

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3.5 Switching on the auxiliary power supply


3.4.2

Upgrading firmware version automatically

Introduction

When new converter firmware is installed, e.g. by installing a new CompactFlash card, thefirmware for the components is upgraded automatically after switching on.

Description

Automatic firmware upgrade is indicated by the LED on the CU flashing

orange/green, and by an LED on the component concerned also flashing.If the LED on the CU flashes rapidly in orange, this indicates that the update iscomplete.

CAUTION

During the firmware upgrade, the firmware of the individual components is updated.

Interruptions of the firmware upgrade may cause damage to the components.

Therefore, never interrupt the firmware upgrade process.

✔ Switch the converter off and on again.

3.5

Switching on the auxiliary power supply

Description

✔ Switch on the 230 V and 24 V auxiliary power supply. When doing so, refer to thecircuit diagram in the "Circuit diagram" section in the Operating Instructions.

Note

System power-up

It can take several minutes for the system to power up.

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3.6 The STARTER Commissioning Tool


3.6

The STARTER Commissioning Tool

3.6.1 Working with the STARTER project wizard

STARTER - Work areas

The STARTER user interface is divided into four work areas:

Figure 3-7 STARTER - Work areas

Work area Explanation

①: Toolbar In this area, you can access frequently used functions by clicking icons.

②: Project navigator The elements and projects available in the project are displayed here.

③: Work area Project-specific settings for drive configuration are made here.

④: Detailed view Detailed information about faults and alarms, for example, is displayed this area.

Calling up the STARTER program

You have two options for calling up the STARTER program:

1. Click on the "STARTER" icon on the desktop

2. Select theStart > Simatic > STEP7 > STARTER

menu command in the Windows startmenu.

After the first program start, the dialog screen of the STARTER project wizard appears.

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Figure 3-8 STARTER start dialog

Disabling the project wizard

You can disable the project wizard.

Figure 3-9 Disabling the project wizard

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✔ Click the "Display wizard during start" check box to remove the check mark. Theproject wizard then no longer appears the next time the STARTER program is calledup.

Calling up the project wizard

If the project wizard is disabled, you can call it up manually to create a project with theproject wizard.

✔ Select the "New with wizard" command in the "Project" menu.

Online Help

STARTER features a detailed online Help function. The online Help is automaticallydisplayed when you start up STARTER.

Figure 3-10 STARTER - Help

You can disable the online Help at any time.

✔ In the "Options" menu, select command "Settings"

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✔ On the "Workbench" tab, click the "Display first steps at the start" check box to removethe check mark. Now, the STARTER Help wizard will no longer appear the next timethe program is called up.

You can reactivate the online help at any time by selecting menu command "First steps" inthe "Help" menu.

Checking and configuring STARTER dialog screens

STARTER has a series of dialog screens for entering the data required for configuring yourdevice.

Note

The STARTER dialog screens are preassigned with defined values.

Carefully check the preset values in the dialog screens and adapt them to your requirementsas needed.

By carefully and diligently entering the configuration data, you can avoid any deviationsbetween the project data and the device data that are displayed in online mode.

3.6.2

Options for creating a project

Options for creating a project

You can create projects both in ONLINE and OFFLINE mode.

ONLINE MODE

In ONLINE mode, there is a communications link to the drive that enables data exchange.

● All parameters are directly read from the drive.

● Parameter changes are written to the drive and become immediately effective there.

● Parameter sets can be generated by upread.

●

Parameter sets can be written by download.

● Process data can be read and written to (setpoints, actual values, control commands,etc.).

For further information, refer to the STARTER Help.

In ONLINE mode, you can perform the first commissioning with or without the project wizard.

● First commissioning ONLINE with the project wizard.

– The drive device, the options, and the infeed are automatically detected by STARTERand entered into the corresponding dialog screens.

● First commissioning ONLINE without the project wizard (Page 60).

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– You must enter the drive device, the options, and the infeed into the correspondingdialog screens.

OFFLINE Mode

In OFFLINE mode there is no communication link to the drive. Data cannot be exchanged.All parameters are read from the parameter sets of the project rather than from the drive.

● Each drive and each drive component (DO (Control Unit, Motor Module, TerminalModule) of the SINAMICS drive system have a parameter set.

● Parameter changes are written to the parameter set.

● Parameter sets cannot be uploaded directly from the device.

● Parameter sets cannot be downloaded directly to the device.

● Process data cannot be editing (by defining a setpoint and control commands or

acquiring an actual value).

You perform "First commissioning OFFLINE with the project wizard" in OFFLINE mode.

3.6.3 First commissioning ONLINE with the project wizard

3.6.3.1

Assembling a new project online

User interface of the STARTER project wizard

Figure 3-11 STARTER - Project wizard

✔ Click on button "Find drive units online..."

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Create new project

Figure 3-12 STARTER - Create new project

✔ Type a name into the "Project name" input field.

✔ Type the author's name in the "Author" input field.

✔ Type a comment about the project in the "Comments" input field.

✔ Click on button "Continue >" to set up a PROFIBUS interface in the PG/PC.

Setting up the PG/PC interface

Figure 3-13 STARTER - Selecting the programming device/PC interface

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Note

The online connection to the drive unit can only be established via PROFIBUS,

✔ Click on button "Change and test..." to set the interface according to your deviceconfiguration.

Figure 3-14 STARTER - Setting the programming device/PC interface

✔ Buttons "Properties...", "Diagnostics...", "Copy..." and "Select..." are now available.

Note

To parameterize the interface, you must install the appropriate interface card (e.g.: CP5512.

✔ Click on button "Properties..." to change the properties of the PROFIBUS interface.

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Figure 3-15 STARTER - Programming device/PC interface properties

✔ Select the "PG/PC is only master on bus" check box and make the desired settings inthe appropriate drop down list "Timeout","Transmission rate", "Highest station address"and "Profile".

NOTICE

You must select the "PG/PC is only master on bus" check box if no other master (PC, S7,etc.) is available on the bus.

✔ Click on button "OK" to confirm the settings and to return to the project wizard.

✔ Click on button "Change and test..." and, in the next window, on button "Diagnostics" tocheck the interface.

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Figure 3-16 STARTER - PROFIBUS diagnostics

The "Test" and "Read" buttons are now available.

✔ Click on button "OK" to confirm the settings and to return to the project wizard.

Insert drive project

● Click on button "Continue >". The new drive project is inserted.

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Figure 3-17 STARTER - Insert drive units

✔ Click on button "Continue >".

An overview of the selected project data is displayed.

Figure 3-18 STARTER - Summary

✔ Click on button "Finish" to finish creating a new project for the drive unit.

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Saving the project

✔ Save your project to hard disk by selecting command "Save" in the "Project" menu.

3.6.3.2 Downloading the drive project to the PG

You have created a project and saved it to your hard disk.

Next, transfer the configuration data of your project to the PG.

Connect the STARTER to the target system

There are two methods by which you can connect the STARTER to the target system:

1. Select the "Connect to target system" command in the "Project" menu.

2. Click on the "Connect to target system" menu icon in order to connect to the targetsystem. A comparison is carried out between the drive and the previously created project.The differences are displayed.

Figure 3-19 STARTER - Online/offline comparison

✔ Click on button "Load to PG ==>". The following message appears:

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Figure 3-20 STARTER - Data loaded

✔ Click on button "OK". There must be no more differences on the display.

✔ Save your project to hard disk by selecting command "Save" in the "Project" menu.

3.6.3.3 Configuring a drive

Selecting the device configuration

✔ Select your project.✔ Select the "Drive navigator" in the Project navigator ①.

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Figure 3-21 STARTER - Selecting a drive navigator

✔ Click on button "Device configuration".

The following window appears:

Figure 3-22 STARTER - Device configuration

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✔ Click on button "Carry out drive configuration".

Selecting the function module

Figure 3-23 STARTER - Selecting a control structure

✔ Select the right function module for your application.If you require bypass mode for your application, you must activate check box"Technology controller". Activate the function module "Technology controller" only ifyour converter features this function.

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✔ Specify the type of control:

• P1300 = 0: Simple V/f control with linear characteristic curve

•

P1300 = 2: Simple V/f control with quadratic characteristic curve• P1300 = 18: Simple I/f control with linear characteristic curve

• P1300 = 20: Closed-loop speed control without a rotary encoder

• P1300 = 21: Closed-loop speed control with a rotary encoder

• P1300 = 22: Torque control without a rotary encoder

• P1300 = 23: Torque control with a rotary encoder

Modes 0, 2 and 18 are primarily intended for commissioning purposes. They are notreally suitable for ordinary operation. This is due to the fact that large motors tend tovibrate if operated purely under controlled conditions. The dynamics are also very poorand there is a high risk of stalling. Therefore, only modes 20 to 23 should be used.


Determine the standard and connection voltage

Figure 3-24 STARTER - Drive settings

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✔ Select the standard that applies to your motor from the "Standard"

drop down list:

•

IEC motor [50 Hz/kW]: Line frequency 50 Hz, motor data input in kW• NEMA [60 Hz/hp]: line frequency 60 Hz, motor data entry in hp.

✔ In the connection voltage input field, enter the value of the DC-link voltage for yourdevice. Normally, the supply voltage of the Motor Module is calculated as 1.414 xsupply voltage of the infeed.


For example, to determine the required supply voltage (DC link voltage for the drive/vector object):

10,465 V = 1.414 x device supply voltage (7,400 V)

NOTICE

The value for the supply voltage should not be changed at a later point.

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Selecting a motor type

Figure 3-25 STARTER - Selecting a motor type

✔ Enter a name of your choice for the motor in the "Motor name" input field.

✔ Select the motor for your drive unit from the "Motor type" drop down list. If you do notselect a motor type, you will not be able to exit this screen.


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Entering motor data

Figure 3-26 STARTER - Entering motor data

✔ Enter the motor data as per the motor type specifications on the rating plate of themotor in the "Value" input field.

The number of pole pairs is calculated automatically from p0310/p0311. Any

discrepancies in the data are shown in error message 7950 when commissioning iscompleted. The suspected incorrect parameter is shown in the appendage.

The error could be due to:

• p0307 >= 1.7321 * p0304 * p0305 *p308

• No motor selected (p0300=0)

• Slip = 0 or too low

For the induction motor, it is very important to enter the correct rated motor speedP0311 to assess the motor data.

✔ If necessary, activate the check box "Use or change available optional data?".

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✔ If necessary, activate the check box "Do you want to enter the equivalent circuitdiagram data?". Enter the required data:

Rating plate data: • p304, p305, p307, p310, p311

Optional data:

• p0322 = maximum motor speed

– If p322 is entered, you cannot select a technological maximum speed in p1082that exceeds p0322. Likewise, the current limit in p0640 cannot exceed p0323, ifp0323 > 0. These parameters are primarily designed to protect the motor.

• p0323 = maximum motor current

• p0341 = motor moment of inertia

– Parameters p0341 and p0342 are required for acceleration precontrol and forencoderless operation. If these parameters are left blank, then estimated values

are derived from p0341 on the basis of the rating plate data.• p0342 = moment of inertia ratio

• p0352 = cable resistance

– It is particularly important to enter line parameters p0352 and p0353 if there arelong supply cables between the converter and the motor.

• p0353 = cable inductance

ECD data:

• p0350 = motor stator resistance, cold

• p0354 = motor rotor resistance, cold

• p0356 = motor stator leakage inductance

• p0358 = motor rotor leakage inductance

•

p0360 = motor magnetizing inductanceThe control expects you to enter the physical ECD data for a motor star connection. Ifthe values for a delta connection are the only data available, all 5 parameters must bedivided by a factor of 3. This is relevant only if the data is entered physically. Correctentry of the ECD data has a beneficial influence on the control characteristics. Inparticular, the speed and torque can be estimated far more accurately duringencoderless operation. If the main inductance p0360 is unknown, the rated motormagnetizing current p0320 can be entered instead. This also allows for betterestimation of the parameters. The resulting magnetizing current, calculated on thebasis of the data entered, is displayed in r0331.

NOTICE

You should only select the "Do you want to enter the equivalent circuit diagram data?"check box if the data sheet with equivalent circuit diagram data is available.

If you do not enter all the required data, you will not be able to exit the screen.

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Calculating the motor/controller data

Note

If you enter the equivalent circuit diagram data manually, you must activate radio button"Complete calculation without equivalent circuit diagram data" as the equivalent circuitdiagram data you enter will otherwise be overwritten.

Figure 3-27 STARTER - Calculating the motor/controller data

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✔ In "Calculation of the motor/controller data", select the appropriate default settings foryour device configuration. Activate the appropriate radio button as required

•

Radio button "No calculation" – No controller / limitation parameters or equivalent circuit diagram data will be

calculated. All data are available and have been entered.

• Radio button "Complete calculation without equivalent circuit diagram data"

– The equivalent circuit diagram data must be entered; the controller and limitationparameters or equivalent circuit diagram data will be calculated from the ECDand rating plate data entered

• Radio button "Complete calculation with equivalent circuit diagram data"

– The equivalent circuit diagram data and controller / limitation parameters will becalculated only from the rating plate data.


Selecting an encoder type

Note

The menu "Configuration - Encoder" is displayed only if you have selected option K50.

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Figure 3-28 STARTER - Selecting an encoder type

You can set three encoders.

✔ Under "Which encoder would you like to use", select the check box corresponding tothe encoder that you want to configure.

If you select more than one encoder at the same time, a separate tab will be set up foreach encoder.

✔ Enter a name for the encoder in the "Encoder name" input field.If an SMC30 is connected but no encoder is present, select "No encoder" from the dropdown list.

✔ Select the interface for evaluating the encoder from the drop down list "Encoderevaluation".

✔ Select the appropriate default setting for the encoder evaluation. Activate thecorresponding radio button:

• Radio button "Select standard encoder from list"

• Radio button "Enter data".

✔ Select the corresponding encoder type from the list or enter the data.


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Default settings for setpoints and command sources

Figure 3-29 STARTER - Default settings for setpoints and command sources

✔ Select the pre-assignment macros for the command sources.From the drop down lists "CDS 0" (command data set 0) and "CDS 1" (command dataset 1), select the corresponding default settings for your device configuration.The following pre-assignment macros for the command sources can be selected:

• PROFIBUS

• Terminal block

✔ Select the pre-assignment macros for the setpoint sources.From the selection fields "CDS 0" (command data set 0) and "CDS 1" (command dataset 1), select the corresponding default settings for your device configuration.The following pre-assignment macros for the setpoint sources can be selected:

• PROFIBUS

• Terminal block

• Motorized potentiometer

• Fixed setpoint

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Note

By default, only "CDS 0" is assigned as a default setting of the command sources.

NOTICE

Make sure that the selected default settings correspond to the actual system configuration.

Once you have selected a pre-assignment macro, you cannot change it later via the"< Back" button!

If you have made an incorrect entry, you have to delete the entire drive unit from the projectnavigator and insert a new one.

✔ Check your default selections carefully and then click on button "Continue >".

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PROFIBUS process data exchange

Figure 3-30 STARTER - Process data exchange

✔ If PROFIBUS is being used to control the drive then you can enter the appropriatetelegram type here. If the programming device or the PC with STARTER is the onlyPROFIBUS partner, then you need to select "Free telegram configuration with BICO"(factory setting) from the drop down list.

✔ Click "Continue >".

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Entering values for key parameters

Figure 3-31 STARTER - Key parameters

✔ In input fields

• "Current limit",

• "Minimum speed",

• "Maximum speed",

• "Ramp-up time",

• "Ramp-down time",

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gm150 commissioning manual

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