16 Motor Syn0 s

DR-SM150

Commissioning the Motor Module

Comm_Motor

page 0 01 1

SITRAIN / METAL ACADEMY

List of Contents

I T

4.1 4.2 4.3 4.4 4.5 4.6 6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21 4.22 4.23

Opening Cabin Opening Cabinet ett Door Doors s / Grou Groundin nding g Make Proo Prooff Swit Switch ch …... …....... ........ ........ ....... ....... ........ ........ ....... ....... ...... 4 Verifying Verif ying Esse Essentia ntial ti l Sett Settings ings on the Excit Excitatio ation n Unit (DC-M (DC-Maste aster) r) ….. …...... ........ ........ ........ ........ ........ ...... 4 Deleting Dele ting Faul Faults ts in the t ”mes ”message sage buff buffer” er” …... …...... ....... ........ ....... ....... ........ ....... ....... ........ ....... ....... ....... ....... ........ ........ ....... ...... ... 6 Energizin Ener gizing g g the h DC-Ma DC-Master ster …... …....... ....... ....... ........ ........ ........ ........ ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ....... ... 8 Measuring e the e Exciter Current …........ …................ ................ ................ ................. ................. ................ ................ ................. .............. ..... 22 Substitu Subs tituting ting i the “Aut “Automati omation” on” via “DCC-C “DCC-Chart hart,, LCOM LCOMRG” RG” ….. …...... ........ ........ ........ ........ ........ ....... ....... ...... 24 Automati Auto matic c Optim Optimizat ization ion and Iden Identifica tification tion of Curre Current nt Loop Data (in the DC-Ma DC-Master ster)) 30 Optimizat Opti mization ion of the “Exci “Exciter ter Curre Current nt Cont Controlle roller” r” (in the DC-Ma DC-Master) ster) …... …...... ....... ........ ........ ....... ... 32 Tracing Traci ng Sign Signals als at the Inpu Inputt- or Outp Output-C ut-Chan hannels nels of DCC-B DCC-Blocks locks …... …....... ........ ........ ........ ........ ...... 38 Verifying Essential Settings on the Motor Module …........ …................ ................ ................ ................. ................. ........ 44 Rotor Position Detection …....... …................ ................. ................ ................ ................ ................ ................. ................. ................ ............... ....... 48 Operation of the Motor in “I/f-Mode” …...... …............... ................. ................ ................ ................ ................. .................. .............. ..... 54 Operation Opera tion of of the Motor Motor in “Speed “Speed Control Control”” …... …....... ........ ........ ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ....... ...... ... 62 Transition “Current Model”  Volt Voltage age Mod Model” el” …... …....... ........ ........ ........ ........ ........ ........ ....... ....... ........ ....... ....... ...... 66 Setting Sett ing the “Scal “Scaling ing of the the Mag Magnetiz netizing ing Indu Inductan ctance, ce, d-ax d-axis” is” …... …....... ........ ........ ........ ........ ........ ....... ..... .. 68 Excitati Exci tation on Curren Currentt Adapta Adaptation tion (Bala (Balancing ncing-Fact -Factor or / G-Fa G-Factor ctor)) …..... …......... ........ ....... ....... ........ ....... ...... ... 70 Optimization of the Current Controllers Controllers (via I Sq ) …... …....... ........ ........ ........ ........ ....... ....... ....... ....... ........ ........ ....... ...... ... 74 Optimization of the Flux Controller …........ …................. ................. ................ ................ ................ ................. ................. ............. ..... 86 Optimizat Opti mization ion of the the Speed Speed Cont Controlle rollerr via “Step “Step of Setpoi Setpoint” nt” …... …....... ........ ........ ........ ........ ........ ........ ...... .. 92 Optimizat Opti mization ion of the the Speed Speed Contro Controller ller via “Step “Step of Load Load”” …... …...... ....... ....... ....... ....... ....... ........ ........ ....... ....... .... 98 Setting the Infeed Pre-Control …........ …................ ................ ................ ................. ................. ................ ................ ................. .............. ..... 102 Adjusting the Instrument Instrumentation ation Meters …....... …................ ................. ................ ................ ................. .................. ................. .......... .. 106 Final Steps ……………………… …………………………………….... ……………............ ................ ................. .................. .................. .................. ............... ...... 108

page 02

© Siemens AG 2011 2011 - all rights reserved

DR-SM150

Comparison of Essential Settings for the Excitation

- P100 serves serves as scaling scaling referen reference ce and as excitation current limit (along with with P171: I.exc.max I.exc.max = P100 * P171). - P78 acts acts as scali scaling ng reference reference for the line input voltage. r072 * P076



p390

P101



p388

Exciter setpoint from SIMOTION Exciter SIMOTION DCC via PROFIBUS PROFIB US and “Free Blocks” of DC-Master DC-Master - p390 defines the HW-rating HW-rating of the DC-Master and the scaling scaling reference on SIMOTION/SIN SIMOTION/SINAMICS AMICS.. - p388 represents the maximum armature voltage available for a line input voltage as set in P101; P101.max = 1.35 * “P78”). - p389 acts acts as exciter exciter current setpoint in no-load no-load condi condition tion (i.Sq (i.Sq = 0).

I

P820

Unless the exciter e winding is equipped with temperature sensors, the I2t-monitoring should not be deactivated.

Comm_Motor

4

page 03

SITRAIN / METAL ACADEMY © Siemens AG 2011 2011 - all rights reserved

Commissioning the Motor (Motor Module)

                                                                                   4.2 . Verifying Essential Essential Settings on the Excitation Unit (DC-Master) Basic commissioning commissioning of the DC-Master has already been carried out by downloading the assigned file (via Drive Monitor). Furthermore a number of faults which were due to some minor “mismatch” “mismatch” between the required parameterization of the DC-Master DC-Master and the settings assigned to it via download already have been cleared by adapting the respective parameters. Before the DC-Master is switched on for the first time, some essential parameters should be checked to verify that the download file which has been used matches with the given set-up: - P079 = 1, P601.3 = K9210 (particular settings, if the DC-Master is used for excitation) - P171 = 120%, P172 = -10% (current limits; unless required differently) 0 0 0 - P1 P150 50 = 10 (training rack: 60 ), P151 = 150 (alpha_G (alph a_G limit limit,, alpha alpha_W _W limi limit) t) The parameters for for “Rated excitation excitation voltage” and “Rated excitation excitation current” have to be functionally functionally identical identical both in the DC-Master and in the Motor Module; verify that this requirement is given in the current parameterization (refer to the information in the slide).

                                                   

page 04

DR-SM150

Comparison of Essential Settings for the Excitation

- P100 serves serves as scaling scaling referen reference ce and as excitation current limit (along with with P171: I.exc.max I.exc.max = P100 * P171). - P78 acts acts as scali scaling ng reference reference for the line input voltage. r072 * P076



p390

P101



p388

Exciter setpoint from SIMOTION Exciter SIMOTION DCC via PROFIBUS PROFIB US and “Free Blocks” of DC-Master DC-Master - p390 defines the HW-rating HW-rating of the DC-Master and the scaling scaling reference on SIMOTION/SIN SIMOTION/SINAMICS AMICS.. - p388 represents the maximum armature voltage available for a line input voltage as set in P101; P101.max = 1.35 * “P78”). - p389 acts acts as exciter exciter current setpoint in no-load no-load condi condition tion (i.Sq (i.Sq = 0).

I

P820

Unless the exciter e winding is equipped with temperature sensors, the I2t-monitoring should not be deactivated.

Comm_Motor

4

page 03


Commissioning the Motor (Motor Module)

                                                                                   4.2 . Verifying Essential Essential Settings on the Excitation Unit (DC-Master) Basic commissioning commissioning of the DC-Master has already been carried out by downloading the assigned file (via Drive Monitor). Furthermore a number of faults which were due to some minor “mismatch” “mismatch” between the required parameterization of the DC-Master DC-Master and the settings assigned to it via download already have been cleared by adapting the respective parameters. Before the DC-Master is switched on for the first time, some essential parameters should be checked to verify that the download file which has been used matches with the given set-up: - P079 = 1, P601.3 = K9210 (particular settings, if the DC-Master is used for excitation) - P171 = 120%, P172 = -10% (current limits; unless required differently) 0 0 0 - P1 P150 50 = 10 (training rack: 60 ), P151 = 150 (alpha_G (alph a_G limit limit,, alpha alpha_W _W limi limit) t) The parameters for for “Rated excitation excitation voltage” and “Rated excitation excitation current” have to be functionally functionally identical identical both in the DC-Master and in the Motor Module; verify that this requirement is given in the current parameterization (refer to the information in the slide).

                                                   

page 04

DR-SM150

Excitation-specific Excitation-sp ecific Settings of the DC-Master

Comm_Motor

page 05


4.3 Deleting Faults in the ”message buffer” During commissioning a large number of alarm and fault messages have been indicated and acknowledged; all alarm and fault messages are stored in the “message buffer” and can be viewed on the OP177 via key ”F4/MSG Buffer”. Have a look at the “message buffer” and delete its contents contents as follows: - HW key key “F6/ “F6/Dia Diagn. gn.”” - SW button button “Dele “Delete te Old Mess Messages” ages” - Us User er = ADM ADMIN IN or Use Userr = 010 0100 0 - Pa Pass sswo word rd = 100 100 - SW button button “Dele “Delete te Old Mess Messages” ages”

page 06

DR-SM150

Status Word 2 Excitation

Comm_Motor

page 07


4.4 Energizing the DC-Master To test the function of the DC-Master, r its line breaker has to be switched on (key “K5/Exc. Breaker ON”), followed by the on command to enable its pulses via key “K6/Excit. ON”. Response to the command “exciter “exciter i line breaker on” is enabled only if the Infeed signals “ready” “ready” (if it is switched switched on). Select “Local Mode, switch on the Auxiliaries, Auxiliaries, switch on the Infeed and switch on the “Exciter line breaker”: you will observe that the assigned contactor (K1 on the auxiliaries’ auxiliaries’ rack) closes but trips again nearly immediately. immediately. Which alarm message is (temporarily) displayed: ........ ......... ........ ........ ........ .. Refer to the “mill “ stand function diagrams” of the DC-Master and find out whether the feedback message “exciter “exciter breaker On” is indicated on the PMU while contactor contactor K1 is closed (use the PMU to read the message, because Drive Monitor is too slow to indicate a signal of such short duration).

page 08

DR-SM150

Source of Excitation Breaker Control

excitation breaker control via DC-Master

D445 / ET200

1

0

0

1

R E T A Comm_Motor

page 09


You will observe that no feedback signal is identified. i . The reason could be a true fault in the feedback circuit, but this signal will also be missing (not being wired to the DC-Master to terminal X171:36 at all) if the exciter breaker is controlled “from external”, typically via ET200 as true on the training rack. (To avoid additional trouble later on, close switch S16 which actually simulates an exciter contactor feedback fault.) The definition “control via via a DC-Master” respectively “control from from external” is set on blocks TPH949 TPH949 and TPH943 in chart AUXS, sheet B1; assign the correct control request to the related blocks.

R I T

page 10

Definition: Continuous Signal or Pulse Signal

DR-SM150

excitation breaker control via continuous signal 1

pulse signal 0

Comm_Motor

page a 11

SITRAIN / METAL ACADEMY © Siemens AG 2011 - all rights reserved

On repeating the test you will notice that the excitation i breaker is still tripping after a short delay. On chart AUXS, sheet E2, block EXB150 the switching characteristic r s of the exciter breaker control has to be defined (“continuous signal” or “pulse signal”). Check the wiring scheme of the training rack “Auxiliaries” to find out whether a continuous signal or a pulse signal is used; adapt the programming of the DCC-chart accordingly. Verify the success of this modification: the exciter breaker K1 closes and remains closed. (A lead to chart r AUXS, E2 is given by the temporarily displayed OP177 message “=.WA75/E2, Self tripping excitation breaker”.)

page 12

DR-SM150

Control Word 1 Excitation

r000 S1

S2

Comm_Motor

page a 13 1


Now switch on the exciter via “key K6/Excit. ON”. ”. You o will observe “no function whatsoever”. To find the very basic reason, check the drive’s status via “missing enables” and set the responsible parameter to its required value: p . . .. . . . .. . = . . . .. . .... . You will notice that a fault is i signaled. Identify the fault message indicated for drive device “VECTOR”: current fault: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Open the expert r list for object “Vector” and analyze the settings in p405 (this parameter was indicated to have a parameterization error) under the aspect of using an HTL-encoder in the given hardware. Crosscheck the respective settings in p404 and adapt them to the requirements of the HTL-encoder: s p......... ..... = ..........

p....... .... . .. = . . .. . .. . ..

Remove the 24VDC supply from component SMC30 and put it back on again: after a short delay the SMC30 reads “RDY = green”. Upload these changes to the PG/PC, save the changes in the project and s ave these changes on the CFC.

page 14

DR-SM150

Adapting the Encoder Settings

Comm_Motor

page a 15 1


Again switch on the exciter via “key K6/Excit. c ON”. Now you will observe the following: - the command is accepted but the pulses are nott enabled - after elapse of the monitoring time, the Motor Module and the Motor signal “Fault” (red symbols on the OP177) and - the excitation circuit breaker is tripped. Analyze the indication shown on the PMU of the DC-Master “before” and “after” the command “key K6/Excit. ON”. Refer to the supplied circuit diagrams of the training rack and to the function diagrams of the DC-Master to find the reason of the stilll observed malfunction. Take the appropriate r action to eliminate this cause: ........ ......... ........ ........ ........ ..

page 16

DR-SM150

Fault Messages of the DC-Master

L Comm_Motor

page a 17 1


Again switch on the exciter via “key K5/Ex.. Breaker ON”” and “key K6/Excit. ON”. You will notice that presently the Motor Module, the Motor and the Exciter indicate “Fault” immediately. Find out which fault message and which fault value is shown for the DC-Master: ........ ......... ........ ........ ........ ........ ........ ........ ........ ....... Assign the correct parameter value on the DC-Master ( EEPROM) and again switch on the exciter via “key K5/Ex. Breaker ON” and “key K6/Excit. ON”. Once again, the Motor Module, the Motor and the Exciter indicate “Fault” immediately. As before, find out which fault message and which fault value is shown for the DC-Master: ........ ........ ......... ........ ....... ......... ........ ....... ......... ....... Detailed information about the line voltages of the DC-Master is provided via connectors K301 to K303. Assign the correct parameter value on the DC-Master ( EEPROM) and again switch on the exciter via “key K5/Ex. Breaker ON” and “key K6/Excit. ON”. You will notice that: - the command is accepted but the pulses are not enabled (the LED assigned to K6 flashes) - after elapse of the monitoring time, the Motor Module and the Motor signal “Fault” (red symbols on the OP177). Again analyze the indication shown on the PMU of the DC-Master “before” and “after” the command “key K6/Excit. ON”; refer to the circuit diagrams of t he training rack and to the function diagrams of the DC-Master to find the reason. Take the appropriate action: ........ ......... ........ ........ ....... ...

page 18

Cross-Reference from OP177-Messages to Charts to Periphery

DR-SM150 actual messages

>display OP177<

X

Date

Time

Text

29/10/10

09:55:45

=.WA11 / I3 (=.DA/1.9) Switch on fault excitation converter fan 1

from OP177 chart reference (=.WA xx) to chart, section, page

=.WA 01 03 05 06 07 10 11 12

chart CPU SIMU AINF1 LCOMRG DOPAR COMCBE INPUT POSIT

=.WA 53 61 62 71 72 73 74 75

chart MOPRO INAUX INAUXD AUX1 AUX2 TMONI AUXCU AUXS

=.WA 77 78 79 81 82 97 98 99

chart AUX2D AUX1D TMONID PANEL MSG OUAUX OUAUXD OUTPUT

The assignment of the “message prompt” (e.g. =.WA11) can be found in “object properties” of the DCC-chart as “Author”

follow the message-relevant signal to the variable / relate variable to process data word / find assigned node and PZD-no.

follow the connected signal to the responsible origin

Comm_Motor


page a 19 1

© Siemens AG 2011 - all rights reserved

Once again switch on the exciter via “key K5/Ex.. Breaker ON” and “key K6/Excit. ON”: now the pulses are enabled and exciter current is flowing through the synchronous motor; message “exciter converter fan fault”, however, is signaled. Use the information on the OP177 to find chart, section and page which processes this message: information of OP177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . chart

............

section

............

page

............

Conclude “by logic i thinking” i which of the signals you have to follow upstream: ........ ......... ........ ........ ........ ........ ... Follow this signal by double-clicking on the signal connection to the left of the block assigned to the signal line until you reach the variable linking this message to the I/O-container: variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Follow this variable to its origin and substitute the binector of the missing input by a constant “H”: U . . .. . . . .. . = . . . . .. . . . ..

page 20

Measurement of the Exciter Current in the DC-Master

DR-SM150

G161

G162

G121

G121 Comm_Motor


page a 21


4.5 Measuring the Exciter Current Apart from the direct measurement of the exciter current via ammeter the exciter current can be measured via parameters on the DC-Master and via a indication on the OP177 (both as setpoint values and as actual values). Read the exciter current on all locations suggested below and crosscheck the readings to verify that they are all matching: OP177

main faceplate e IEact

I

= ...............

F10/Motor

FLUX

= . ..............

F10/Motor

IEACT

= ...............

K1/Actual values IEact

DC-Master diagram G162 r020

= ............... = ............... %

of . . . . . . . . . . A

= .......... A

diagram G162 K115

= ............... %

of . . . . . . . . . . A

= .......... A

diagram G161 K133

= ...............

The last step of commissioning the DC-Master consists of the optimization of the “exciter current circuit” on behalf of the DC-Master. As the exciter current for the synchronous motor is controlled via the armature current of the DC-Master, its “armature current controller” has to be optimized.

page 22

DR-SM150

Drive Control via DCC-Chart “LCOMRG”

Line CoOrdinator Master Ramp Generator

control commands

status messages

operating modes

actual values

Comm_Motor

L

setpoints / limits

page a 23 2


4.6 Substituting the “Automation” via “ “DCC-Chart, LCOMRG” Up to now the required sequence of switching on the Auxiliaries, the Infeed, the Exciter Breaker and the Excitation has been activated via OP177 in mode “Local”. Once the entire system is in operation, control of the SM150 will be in mode “Remote” via “Base Automation, MRG”. An alternative to “Automation” is provided on DCC-chart “LCOMRG, sheet C2”. From this chart the SM150 can be switched on in mode “Remote” “ ” the same way as from the OP177 (all “DCC-interlocking” for the required sequence is provided). Additionally a number of test-signals for the optimization of control loops are ready to be activated.

I

page 24

DR-SM150

Exciter Control via DCC-Chart “LCOMRG”

LCO_ACT_STATUS

LCO_CONTROL 2

Auxiliaries = On

BM_AUXON

4

Main C.B. = On

POW_ON

5

Excitation Breaker = On

ON

6

Excitation = On

BM_STC_ON

3

Excitation Startup Mode

EXC_STARTUP

Define the current setpoint before switching on the Test Signal

7

Test Signal = On

EXC_ENREF LCO_CTL_010 _

1

Startup Mode

STARTUP

A

sequence of operation

Comm_Motor

page a 25 2


Change over to mode “Remote” (key “K17/Remote”): / ” with exception of the Auxiliaries all systems switch off. Open DCC-chart “LCOMRG, sheet C2”, select “Test Mode” and set “Watch On” for blocks “LCO_ACT_STATUS”, LCO_ZSW_D1”, “LCO_CONTROL” and “LCO_CTL_010”. Verify that the feedback message e “BM_AUXONS” corresponds to the control command “BM_AUXON” by switching the Auxiliaries “off” and “on” via LCOMRG; verify that “Startup Mode” is selected. Using “LCOMRG”, switch c on the test signal for the optimization of the exciter current as suggested; if relevant, check the feedback on the t assigned a block: - EXC_STARTUP  Infeed switches on - ALM_ON  exciter breaker closes - ON  exciter pulses are enabled, current setpoint = 0 (“- -” on PMU) - BM_STC_ON  current setpoint > 0 (“ I “ on PMU) - EXC_ENREF

page 26

Definition of the Pulse-Width of the Test Signal

DR-SM150

EXC_SETP1 EXC_SETP2 Flashing duration

Flashing duration

E T

DANGER ! Please note that DCC-input values of 1.0 represent 100.0% . !

Comm_Motor

page a 27 2


Record the value of the exciter current e.g.. on the DC-Master’s PMU at r020: ........ ......... ........ ........ ........ ........ ... Calculate the values for “EXC_SETP1” and “EXC_SETP2” as follows (100% = “p390_Vector”): - EXC_SETP1 =

50% of the h rated exciter current (generally used); select 50% of the rated armature current of the DC-Master (P100) 

- EXC_SETP2 =

....... ........ .......

70% of EXC_SETP1 

....... ........ .......

Verify your settings by measurement: r020 = 35% / 50% / 35%, … (100% = “P100_DC-Master”). Follow the signal of the exciter current setpoint in the DCC-charts to find out where to set the pulse-width of the test signal: ........ ......... ........ ........ ........ ........ ... Change the pulse-width to 1s.

page 28

DR-SM150

Automatic Identification of Current Loop Data

2

Auxiliaries = On

BM_AUXON

4

Power = On

POW_ON

5

Excitation Breaker = On

ON

6

Excitation = Off / On

BM_STC_ON

3

Excitation Startup Mode

EXC_STARTUP

7

Test Signal = Off

EXC_ENREF

Comm_Motor

LCO_CONTROL

I

L


page a 29 2


4.7 Automatic Optimization and Identification of Current Loop Data (in the DC-Master) The exciter winding resistance and the exciter winding inductivity are typically preset by Siemens in parameters P110 (armature winding resistance) and P111 1 (armature winding inductivity). They can, however, also be crosschecked or identified by an automatic “Optimization and Identification” (manual tuning will not improve the settings beyond the result of the “automatic identification”). o First take a note of the t presently set values of following parameters (left column): - armature resistance

P110 = . . . . . . . . . . . . . . .

...............

- armature inductivity

P111 = . . . . . . . . . . . . . . .

...............

- proportional gain

P155 = . . . . . . . . . . . . . . .

...............

- integral e action time

P156 = . . . . . . . . . . . . . . .

...............

In LCOMRG, switch off the test signal (EXC_ENREF = L) and switch off the excitation (BM_STC_ON = L), set P51 = 25 (request to auto-tune the pre-control and the current controller) and start the routine by switching the excitation back on again (BM_STC_ON = H). You will notice that the DC-master issues F50. Analyze the prompted fault value, note down the curr ent value of the responsible parameter and TEMPORARILY adapt the setting to carry out the identification routine. P .. .. .. .. .. = . .. .. .. .. .. .. .. current setting

/

. .. .. .. .. .. .. .. temporary setting

On completion note down the automatically identified values in the column on the right. Armature resistance and armature inductivity have to match fairly well; values for the current controller may differ and will be manually optimized in the next step. Set the parameter you have temporarily adapted back to its original value.

page 30

DR-SM150

Trace-Tool of Drive Monitor

Start of trigger “by command”

Start of trigger “as specified”

Selection of “signals to be recorded”

Sampling rate and pre-trigger

recording of signal samples

processing of signals

Comm_Motor

L

transfer r of samples to PG/PC


page a 31


4.8 Optimization of the “Exciter Current Controller” ” (in the DC-Master) To optimize the exciter current controller the e “exciter current actual value” has to be recorded and its response to a step of setpoint has to be evaluated. To correctly analyze any optimization, none of the variables of the closed loop in question must be limited; in the given situation this applies for the firing angle. a The trace recording can be done both within the DC-Master (Drive Monitor) and within Simotion (Scout). To optimize the PI-controller, the “exciter current actual value”, the step of “exciter current setpoint” and the firing angle will be recorded using the tool Drive Monitor. Refer to function diagrams G162 and G163 and assign the a.m. signals to be recorded (as close to t he current controllerr as possible): - “exciter current setpoint”

K . .. . .. . .. . ..

- “exciter current actual value” K . . . . . . . . . . . . - “firing angle current controller” K . . . . . . . . . . . . - “firing angle pre-control” K . . . . . . . . . . . . To be able to identify a limiting of the firing angle, relate the percent r eading of K100 representing the currently set limit of the firing angle to its degree reading (refer to the given characteristic): r018 = . . . . . . . . . . . . . . . degrees K100 = . . . . . . . . . . . . . . . %

α [%] (K100) +100

60 -33.3 page 32

120

α [degr] (r018)

Pre-Control and PI-Controller

DR-SM150

P154 = 0 I-controller blocked 1 I-controller active

*

P164 = 0 P-controller blocked 1 P-controller active

set as P111

P153 = 0 no pre-control 3 pre-control for field windings of SYN-motors r

*

to minimize mutual influence of Pre-control and PI-controller

Comm_Motor

L

T A

page a 33 3


(Armature) Current Pre-Control and (armature) t current PI-Controller act in parallel. To manually optimize the PI-controller, first deactivate the Pre-Control (P113 = 0); the response must show no visible overshoot. The PI-controller will be optimized t in its classical way by starting with a P-controller with a small proportional gain (P155) and then increasing the gain such that the current steps up to its setpoint value without overshoot and without developing noticeable l noise (in doubt, select the smaller value rather than the larger). Optimized “proportional r n gain”, P155 = . . . . . . . . . . . . . . To optimize the integral property the integral component is activated, a large integral action time (P156) is selected initially and then reduced to get a response with an overshoot of close to 15 % with the pre-control contributing to the transient; r with the PI-controller by itself an overshoot of about 4 % would be expected. Optimized “integral action time”, P156 = . . . . . . . . . . . . . .

page 34

DR-SM150

Optimization of the Exciter Current Controller (in DC-Master) Optimization of the gain (k.P)

0.2 / 10.0s

k.P = 0.5 / 10.0s OPT

1.0 / 10.0s

L

Optimization of the integral action time (T.N)

0.5 / 50 ms

Comm_Motor

k.P = 0.5 / T.N = 0.01s OPT

page a 35 3

0.5 / 0.003s


Having added Pre-Control in parallel to the PI-controller a significant overshoot results. Improve the transient response to avoid the overshoot while keeping the dynamic setting of your optimization as follows: - check the impact of P191 by looking at the controller output (K110) - set this filter to get a minimum overshoot of the current actual, P191 = . . . . . . . . . . . . . . (Note: P191 is not adjusted by the autotune function; it has to be set manually). All settings on the DC-Master have now been completed. Make sure that you have made these settings on the EEPROM and save the parameterization by uploading the data (i.e. as a delta-file, type “changed parameters only”).

page 36

DR-SM150

Trace-Tool of Scout signal to be traced

chart “OUTPUT” block “SFLD20” signal “Y”

chart “OUTPUT” block “SFLD30” signal “X”

I Comm_Motor

page a 37 3

L


4.9 Tracing Signals at the Input- or Output-Channels of DCC-Blocks The “exciter current setpoint” originates from Simotion DCC, the “exciter current actual value” is fed back to Simotion DCC; therefore both signals can also be traced using the Scout tracer. These variables can be picked k up in their nature as process data words; equally though they can be recorded at the output “Y” or at the input “X” of any block within the DCC-charts. Open the I/O-container and find out which variables are assigned to the following: - “exciter current setpoint”:

. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .

- “exciter current actual value”: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Via “Chart reference data” localize the DCC-chart and sheet where the a.m. signals originate: - “exciter current setpoint”:

. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .

- “exciter current actual value”: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Follow both of these values until you come to a block which is referencing the signal; take a note of the name of the block and of its input / output at the “remote end” of the I/O-variable (select the unscaled value): - “exciter current setpoint”:

. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .

- “exciter current actual value”: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Select the “recording properties” of the Scout tracer as suggested in the slide.

page 38

DR-SM150

Assigning DCC-Signals as Pins to the Tracer

Comm_Motor

page a 39 3

Inputs and outputs of DCC-blocks can be picked up as “Pins” “ of the DCC-chart. Define the Scout trace tool to record the two exciter current values.

N I A R I T

page 40


DR-SM150

Analyzing the Step Response

OUTPUT. _dcc_instances. _output_sfld30.x . INPUT. _dcc_instances. _input_rfld210.y .

T

OUTPUT. _dcc_instances. _output_sfld30.x INPUT. _dcc_instances. _input_rfld210.y

trise = 33ms (typical y value v 20 … 30ms) tdead = 17ms (typical value 10 … 15ms)

Comm_Motor

page a 41

Analyze the step response of the exciter actual current as regards: - overshoot . . . . . . . . . . . . . . % of step

(must be no more than 15%)

- dead time . . . . . . . . . . . . . . ms

(typically 10 to 15ms)

- rise time

(typically 20 to 30ms)

. . . . . . . . . . . . . . ms

Discontinue the “Excitation Startup Mode” by reversing your steps on LCOMRG: - Test Signal = off EXC_ENREF = 0 - Excitation = off BM_STC_ON = 0 - Excitation Breaker = off ON = 0 - Infeed = o off ALM_ON = 0 - Excitation Startup Mode = off EXC_STARTUP = 0

page 42


DR-SM150

Essential “Siemens-Set” Values for the Motor

to be set as per motor rating plate

to be set in accordance with site measurements to be set as per motor data sheet or as per Siemens-data

to be set as per Siemens-data

Comm_Motor

page a 43 4


4.10 Verifying Essential Settings on the Motor Module SM150 drive projects as supplied by Siemens willl typically already contain all relevant “Motor Data”. The rating plate of the motor has to be checked against the data set in the project. If any differences are found, the reason has to be thoroughly investigated before taking an appropriate action. “Equivalent Circuit Diagram Data” and “Motor Characteristic” are preset as well and should not have to be modified. The slide above indicates the parameters involved; the values are relevant for the training unit and will only coincidentally correspond r to site settings.

I

page 44

DR-SM150

Encoder Data

track A track B zero mark

zero mark

.........

00

Comm_Motor

page a 45 4

A

position by adding pulses

L 3620 3600


“Encoder Data” have to be set in accordance with to the encoder used; these data are preset as well. As indicated in the slide above, parameters for the “voltage level” and for the “encoder pulse number” have to be parameterized to identical settings in two different pairs of parameters. 

If fault F31100 or F31101 is signaled, the “zero flag tolerance, p430[0].21” should be set to “Yes”.

                                                   

If the transition from current model to voltage model (this topic is dealt with later) becomes irregular with time, t he “rotor position adaptation, p430[0].22” should be set to “Yes”.

                                                                                      

If fault F31118 is signaled, the “dn/dt-monitoring” should be deactivated by setting p492 = 0.

                   

page 46

DR-SM150

Principle of Rotor Position Detection

ϕS

torque

ϕE

UL1

To achieve maximum torque at a given stator current ( stator flux) the stator flux vector has to be positioned perpendicular to the rotor flux vector; in consequence the rotor position has to be known at any time: - initially it is identified via “rotor position detection” (after switching on I.E) - from here on it is calculated by counting the encoder pulses while in current model operation (low speed)

Detection of the rotor position by trigonometric evaluation of the voltages induced in the stator (Ures in direction of UL1 is defined as zero degrees).

IE.set

UL2

UL1

UL3

IE

L

UL1 UL2

UL3 UL3

UL2

Comm_Motor

A

page a 47 4

Ures


4.11 Rotor Position Detection When switching on the exciter current, the di E/dt generates a voltage pulse in the stator windings; the individual values of the induced voltage depend on the respective angles. The trigonometric evaluation provides information about the currently valid rotor position.. The phase voltages UL1 to UL3 can be picked up on parameters r089[0] to r089[2], the actual flux is available on r084[0], parameters r1626[0] / r1641[0] indicate the excitation current setpoint / actual value and the pole position can be monitored by parameter a r93.

I

Set up the SINAMICS tracer to record these values for 250ms with a pre-trigger of 50ms.

page 48

DR-SM150

Rotor Position Identification

All signals are shown in their true physical relation i.exc.set

i.exc.act u.L1

u.L2

The “long time” view (1 s) reveals the different voltage values generated by the gradient di.E/dt

u.L3 rotor position

f = 300 0 Hz (t.P . = 3.3 ms)

The p persisting r in voltage originates from the ripple of the h exciter current (6 current pulses per 20 ms at lline frequency re = 50 Hz  3.3 ms per current pulse).

flux

Comm_Motor

page a 49 4


Monitor these values as a result to switching on the exciter current (either via LCOMRG or via OP177). The “rotor position detection” indicates the identified rotor position after evaluation of the motor voltages ( unsymmetrical initial values) induced by the di/dt of the exciter current. Even after the exciter current n has reached its steady state value, its ripple still generates motor voltages. With exception of the first tens of ms t he flux increases with PT1-property. Please note that the signals shown in the above slide are shifted on the time axis to represent t heir true physical relation. (For the values one can record, different delay times of the internal algorithms apply. In analyzing these signals relative to each other you would conclude that motor voltages are induced with the exciter current still zero and that the h rotor position is identified directly by switching on the exciter current setpoint; neither of these conclusions is physically possible!) Note down the identified “Pole position angle”, turn the shaft by a self estimated number of degrees and verify that the now identified position reads: “new value” = “previous value” +/- “degrees of movement”. After you have changed the rotor position you will notice that the three motor voltages show a difference of values and polarity (which of course is the input information for the calculation of the rotor position).

page 50

Actual Flux and “Ready for Operation”

DR-SM150

i.exc.act , i.exc.set = 20 % motor model

flux setpoint p1579 (100%)

iS´

iE iµ

85 %

Up

US

UE LHd

LHd

flux.act

- motor magnetizing inductance, p360 - scaling factor, p655

iE.set Φact

iµ

r e t s a M C D

flux characteristic

Φact

p655 = 135 L.Hd (motor model) = L.Hd ( real motor)

i.exc.act , i.exc.set = 15 %

iE.act flux actual r0084

iE.act

Φact

flux.act

current model (IMO)

100%

p655 = 170 L.Hd (motor model) >> L.Hd ( real motor)

Comm_Motor

Trace following signals: - exciter current setpoint - exciter current actual value - actual flux

page a 51


O

r1626 r1641 r84

You will observe that the actual flux increases up to 85% and then is substituted by 100%. This changeover to the substitute value will always occur at 85% and acts as an internal “enable” signal inevitably required to run the motor. You can monitor this essential response of the flux on the OP177 via key “F13 / Graph”. If the actual flux doesn’t reach the 85% value, one/several of the motor data or the voltage scaling (parameters p6753 to p6755) are r likely to be set incorrect. The setting of the “magnetizing inductance” (p360 * p655) for the motor circuit substitute diagram defines the exciter current setpoint to generate the requested flux. [A large magnetizing inductance (X.Hd) requires only a small exciter current (i.Exc) to generate flux.] The actual exciter current is converted to the actual flux via the i.Exc / Flux characteristic up to 85%. If this value has been reached the actual flux is defined “100%” until changeover from the current model (IMO) to the voltage model (UMO). [If the i.Exc / Flux characteristic is matched to the real motor, the small exciter current will be calculated into a sufficiently large actual flux, provided that the magnetizing inductance of the real motor is large. If, however, the magnetizing inductance of the real motor is smaller than programmed as substitute circuit value, the generated exciter current will be rather small and will in consequence be calculated into a small actual flux only.]

page 52

DR-SM150

Operation in “I/f-Mode” via OP177

I/f-mode is selected / deselected automatically if requested via the Start-up menu of the OP177

to force (even large) current (excess current  reactive)

Sequence of OP177 commands to go into operation K9 Local

K3 AUX ON

K4 Power ON

K5 Exc. Breaker ON

- acceleration t and deceleration a via ramps of the setpoint channel

Sequence of OP177 commands to quit operation F1 Start

K11 AUX OFF

Comm_Motor

- speed setpoint via “Start-up” menu of the OP177

K12 Power OFF

page a 53 5

K13 Exc.. E Breaker r OFF F

for details refer to next slide


4.12 Operation of the Motor in “I/f-Mode” Before changing to an operating mode which evaluates current and voltage feedback values, verify that the “Actual Value Offset Correction” is enabled and check the “identified offset value” (follow the procedure as suggested for the Infeed on pages 33/34; parameters p6902 and p6903 have to be set to “Enable Offset Calculation”; the values of the related “read parameters” have to float around zero). Trusting that currentt and voltage evaluation are correct further tests (speed feedback evaluation, transformation angle) can be carried out in “I/f-mode”, where the stator current is directly set. In case of doubt about correct current and voltage evaluation “V/f-mode” has to be used for analysis. In “V/f-mode” the current is defined via stator voltage, so great care has to be used not to have the current shoot up. In “I/f-mode o the stator current will be “forced” by the direct setting, possibly even to large values (taking all excess currentt as reactive current). To tolerate this condition, the “tolerance monitoring of the exciter current” has to be increased; verify that parameters p3201 and p3202 are both set to 100% (this value should actually be set already). As in “V/f-mode”, the rotor position calculation is not active in “I/f-mode” either. As logical consequence, the rotor has to be given ample time to follow the stator field. Due to control via OP177, the ramp settings of the “Vector setpoint channel” now determine the rate of change of speed unless you exclusively use the [ /\ ] or [ \/ ] buttons to control the speed. In this case ramps set to 60s within the “OP177 Motorpot” overrule the ramp settings in the setpoint channel. Set the ramp-up and the ramp-down time to 50s each (p1120, p1121). To operate the drive in “I/f-mode”, Auxiliaries, Infeed and Exciter have to be switched on beforehand; these control operations can be performed comfortably via OP177.

page 54

Operation in “I/f-Mode”

DR-SM150

F14

N_REF_LOCAL

Start up menu pops up

Start up

e c n e u q e s N O

F14

I/f-Control

Selection

“Status I/f-control” changes to “ON”, I/f-Control is set automatically Exciter current builds up (OP177: 20%); Stator current is enabled

Excit. ON

Changeover to “Local Speed Control”

Start up

I/f-Control is preselected

K6

Speed setpoint for “Local Speed Control”

e c n e u q e s F F O

K14 Excit. OFF

Selection one 0.5s pulse

Exciter current is switched off Stator current is disabled; I/f-control is deselected

I R E

Stator Current Setpoint (020%)

Stator Frequency Setpoint (0100)

Stator Current Setpoint (200%)

with ∆=2.5% up to 20%

f max = 10 Hz via DCC

with ∆=2.5% down to 0%

in steps of ∆=1Hz

Comm_Motor

page a 55 5

L


Now follow the sequence suggested above to activate the “I/f-mode”; with “Stator Current Setpoint = 0” the ““Actual Stator Current” already reads a small percentage Increase the “Stator Current Setpoint” in steps of 2.5% to initially 20% (the response to the setpoint is noticeably delayed) and verify the following:: - the “torque generating actual current” (r78) oscillates around 0% - the “actual statorr current” on the OP177 oscillates around 20% (Stator Current Setpoint) Now increase the “Stator t Frequency Setpoint” in steps of 1Hz to 5Hz. You will observe the following: - the drive i accelerates; “Stator Frequency Setpoint” and “Actual Stator Frequency” read 5Hz, - several alarms are indicated. In small steps decelerate the drive to 0Hz, in small steps reduce the current setpoint to 0 %, discontinue I/f-control, analyze the alarm messages, check related parameters and assign the correct settings: p . . . .. . . . .. = . . . . .. . . . .. p . . . .. . . . .. = . . . . .. . . . ..

page 56

DR-SM150

Current Measurement with “Clamp-on Probe” Measuring small currents (up to 10 A, e.g. gating current of SCRs) DC to MHz, typically monitored on scope

Measuring large currents (up to 1000 A). DC to kHz, monitored on display. Measuring moderate e currents (up to 100 A) DC to kHz, typically monitored on scope Comm_Motor

DR-SM150


page a 57 5


Current Measurement with Rogowski Coil If necessary, use open coil. With half a turn, just double the measured values.

Integrator

Coil

www.sirent.de

rearch term: “Rogowski”

Comm_Motor

page 58


DR-SM150

Verifying the Symmetry of Currents and Voltages

phase L1

1200

phase L2

1200

phase L3 current

5% / div

10ms / div

voltage

UL1

5% / div

10ms / div

L

Power Stack Adapter

r89[0]

UL2 r89[1]

UL2-L1

PSA raw values UL3-L1

Comm_Motor

page a 59 5


Resume operation in ”I/f-mode”, verify that no alarms are signaled and check the matching of the “speed setpoint value” to the “speed feedback value”.. Run the drive at 10Hz and record the phase currents, r69[0 to 2] with “Sinamics tracer 1” and the phase voltages, r89[0 to 2] with “Sinamics tracer 2” to get a recording similar to the one above. (Suggested settings: endless trace,, ring buffer, cycle clock = 2ms, recording time = 250ms.) A missing or unsymmetrical feedback value of phase voltages or phase currents would easily be identified. In case of some faulty f feedback value it may prove helpful to check the “raw actual values” as picked up by the PSA from the AVT-Cs via fiber optic on sockets X72 toX75 after having been assigned to r-parameters. Find out which assignment is true between socket, parameter number and physical quantity: socket physical quantity parameter no. X72

..............

...........

X73

..............

...........

X74

..............

...........

X75

..............

...........

Trace voltages UL1, UL2, UL2-L1, UL3-L1 and verify that the relation of the voltages to each other is correct.

page 60

Operation in Speed Control (with Encoder)

DR-SM150

K9 Local

K3

K4

AUX ON

Power ON

K5 Exc. Breaker ON

K6 Excit. ON

K10

ON-sequence

Increase of speed towards positive K18

Increase of speed towards negative F14 Start up K2 N*=0

OFF-sequence

F1 Start

K11 AUX OFF

K12 Power OFF

K13 Exc. Breaker OFF

Comm_Motor

K14 Excit. OFF

page a 61

N_REF_LOCAL

direct entry of speed setpoint

I R E T A

Request of speed = zero


4.13 Operation of the Motor in “Speed Control” ”

                       At the training drive, consider e the maximum speed to be 2400 rpm ( 80%). Using the control keys and buttons of the OP177, run the motor in responsible r steps up to the maximum speed presently possible (Training Center: 80%). If the drive should trip i before reaching 80% speed, evaluate the fault messages and set the responsible parameter to a sufficiently large l value: l p . . . .. . .. .. = . . . . .. . . . ..

page 62

Equivalent Circuit and Vector Diagram of the Synchronous Motor

DR-SM150 p0350

p0356

RS

LSσ

d-axis p0354 RDd

UP US

ECD d-axis

UE p0360

p0358

LHd

LDσd

q-axis

p0350

p0356

RS

LSσ

ECD q-axis

US

UP

p0355 RDq

p0361

p0359

LHq

LDσq

scaling parameters

i S * ( X

p652

S +

σ σ

) d

p659 p660 p653

i S *

p657 p658 p655 p656

uS

iS uS

LSσ emf

+ X H

X S ( σ σ

emf

uP

uS

emf

LHd uP

simplified ECD of synchronous motor

Comm_Motor

iSq

X

H d )

iS * (XσS + X Hd)

iS iS

uP

uS

E

iSq

iS

Φ

iSd

L

emf

uP

iSq

Φ iSd

page a 63 6


In the basic example above of the “salient pole machine” the magnetic field is set up by the permanent magnets. The magnetic field is positioned in the d-axis and changes its position once the rotor starts to rotate. The stator windings have to generate another magnetic field (in the q-axis) which is perpendicular to the field in the daxis to create a maximum of torque f or any given current. Depending on the data of the equivalent v circuit components and the counter-emf (which is proportional both to speed and to magnetic flux) a stator voltage has t o be generated such that the motor doesn’t develop a stator current component i.Sd. . By changing i the relation between the values of u.S and emf the stator current i.S can be shifted out of its vertical position. A positive component i.Sd will increase the flux of the motor, a negative component i.Sd will decrease the flux of the motor. o The data of the equivalent circuit components are defined in parameters (p350 – p361) and scaled (multiplied by a percent value) via p652 – p660. An adaptation of a set “motor value” is commonly carried out via the assigned scaling parameter.

page 64

DR-SM150

Transition “Current Model



Voltage Model” iE.act

rotor angle

Current Model (IMO)

iS´

flux angle via rotor angle; actual flux via characteristic, then substituted by 100%

LHD large LHD small

flux angle and actual flux via actual values of iS, uS and substitute circuit data

Φact

flux angle

US

iS.act

Up

UE LHd

iE.act

Voltage Model (UMO)

motor model

iµ

flux characteristic

Φact

iE

IMO

100%

uS.act Φact

UMO

flux value r84

Φ

flux p1752

p1752 * p1756

speed hysteresis

enable voltage model and flux controller voltage model (UMO) current model (IMO)

Comm_Motor

page a 65 6


4.14 Transition “Current Model”  Voltage Model” In “Vector Control Modes” the position of the vector of the rotor flux is permanently available on the basis of following relations: - when the excitation current is enabled, the rotor position is identified by trigonometric evaluation of the induced stator voltages - up to the next zero e pulse s the position is calculated by evaluation of the A/B-track pulses - at the next zero pulse the A/B-track pulse counter is reset and starts a new count (the number of A/B pulses to the next zero pulse is monitored). This flux angle is calculated by a “Current Model” (IMO) at lower frequencies and by a “Voltage Model” (UMO) at higher frequencies. While tthe current model calculates the flux angle initially on the basis of the rotor position and the flux value on the basis of exciter current and flux characteristic, the voltage model uses the actual values of stator current components, stator voltage and the substitute circuit diagram data of the motor to determine both the flux angle and the flux value. Using actual values for the calculation gives more accurate results once a certain minimum frequency is reached (typically: 10 – 20% of the rated frequency) if the substitute circuit diagram data of the motor are programmed correctly. The transition between the models is set by parameters “changeover speed, p1752” and “changeover hysteresis, p1756” (refer to above slide). If the substitute circuit diagram data of the motor are known, the transition parameters are preset by Siemens.

page 66

Setting the Magnetizing Inductance

DR-SM150 iS*RS

settings for these traces of exciter current (r1626) and actual flux (r84): p1752 = 40 % of n rated, p1756 = 50% / speed setpoint = 40 %

iS*XσS 100%

iS*XH uS

emf p655 = 175%

p655 = 145%

8%

up

100% iS

iSq p655 = 205%

iSd iµ

iE

8%

iS´

Comm_Motor

page a 67 6


4.15 Setting the “Scaling of the Magnetizing Inductance, d-axis” The design and evaluation of the vector diagram shows that a smaller magnetizing inductance (X.H) requires a larger magnetizing current (the smaller the inductivity i the more magnetizing current is required to generate the same flux). The larger magnetizing current r is provided by a near proportional increase of the exciter current. At the moment of enabling the voltage model (UMO), the flux as calculated by the evaluation of the actual stator current, stator voltage and magnetizing inductance X.H is output as actual flux (r84). If the magnetizing inductance is programmed to a value smaller than actually true in the motor, too much exciter current will result. The evaluation of exciter current and stator current in the vector diagram will conclude a large magnetizing current and a flux value larger than 100% in consequence. If this value of the actual flux as calculated is other than the setpoint (typically 100 %), the flux controller changes the exciter current to reach a calculated value of 100% of actual flux (once activated; even if X.H is programmed incorrectly). Ramp the drive up to e.g. 40% (1200 rpm) of speed and read the values for “actual flux” (r84) and “exciter current” (r1641) via expert list. Find a setting for the “Scaling of the Magnetizing Inductance, p655” such that the actual flux reads 100%. p655 = . . . . . . . . . . . . . % The “Scaling of the magnetizing Inductance d-axis” (p655) has to be optimized in the no load condition. The “Scaling of the magnetizing Inductance q-axis” (p656) is related to load and has to be optimized once load is available.

                                                                                                                        page 68

Excitation Current Adaptation / Magnetizing Inductance

DR-SM150

flux increases with - reduction of p655 - increase of p1625

Φ

p655  rated flux (100%) at iSd = 0

p1625 

-iSd

ideal response

+iSd

flux increases for negative i Sd when increasing p1625

Φ p1625 

site recording

ideal response

-iSd p0655 p1625

+iSd

scaling magnetizing inductance d-axis excitation current setpoint calibration

Comm_Motor


page a 69 6


4.16 Excitation Current Adaptation (Balancing-Factor / G-Factor) The flux of the synchronous motor is defined both by the “magnetizing stator current component, i sd” and by the “excitation current in the exciter winding, i i Excc”. Since the physical influence e on the flux is different for each of the two currents, their relative effects are taken into account by the implied algorithms of o Vector Control. As you can see in the diagrams above, the two parameters used in the definition of the flux setpoint (p1625, via DCMaster exciter current) and in the calculation of the actual flux (p655) both influence the value of the flux at i Sd = 0. The example of a site-recording in the above slide shows the variables recorded by the PDA recording system as response to a testing sequence commonly applied. The settings of a.m. parameters has to match statically (parameters set such as to get 100 % flux). Additionally, however, these parameters have to be set such as t o have the flux increase slightly if the stator operates with a negative field generating current component (negative i Sd). The mutual influence of these parameters has to be balanced (balancing-factor / G-factor). Note down the currently set values for the parameters listed below: p1625 [%] = . . . . . . . . . .

p655 [%] = . . . . . . . . . .

r84 [%] = . . . . . . . . . .

step 1

increase the field generating current component iSd (p1620) in steps of -5 % to -25 % observing the flux which should not exceed 140 %

step 2

reduce p1625 to get a flux of 105 %

step 3

in steps, set p1620 to zero

step 4

reduce p655 to again have a flux of 100 %

step 5

repeat the sequence (step 1 to step 4) until the flux reads 100 % with p1620 = 0 % and 105 % with p1620 = -25 %.

Note down the values finally set:



the flux will drop to less than 100 %

p1625 [%] = . . . . . . . . . . page 70

p655 [%] = . . . . . . . . . .

DR-SM150

Verification of the “Setting of the Balancing-Factor”

Interaction between “stator flux current” and “rotor exciter current”

field generating stator current component / r76 change of the “stator flux current” from 0% to -25% in steps of -5%

excitation current DC-Master / r1641 4

L

actual t flux / r84

Comm_Motor

page a 71


Verify the correct settings by studying the expected t interaction between ISd (r76), Iexc (r1641) and flux (r84) b y carrying out a test as follows (e.g. at 750 rpm):: - assign r76, r1641 and r84 to be recorded by the tracer (suggested recording: endless trace) - start the tracer and set ISd via p1620 successively to following values (in %): 0 / -5 / -10 / -15 / -20 / -25 / -20 / -15 / -10 / -5 / 0 (steps are in % of the rated motor current; p323) - stop the tracer and verify r that t the exciter current (r1641) increases whenever the field generating stator current (r76) decreases and thatt the flux increases slightly (up to 105 % at p1625 = -25 %). Please note: the exciter t current (r1641) must never become “zero” since this corresponds to an “open exciter circuit” and bears the risk s of resulting in “high voltage” on the exciter circuit. To allow the I Sd controller a fair margin of positive control, define a “ minimum stator current”: p1620 = -10 % (ISd = -10%). As observed in the previous test, this setting increases the exciter current of the DC-Master but keeps the flux constant.

page 72

DR-SM150

Principle of Generating a Step of I Sq-Setpoint / Torque Limit

speed controller

. .

nset

nact

torque limit

Φ s d e u t a b i f r g o e r t P n I

p1520

N_SET = steady state speed torque limit (from SIMOTION)

TQ_LIM = torque limit (pos + neg)

Comm_Motor

page a 73 7


4.17 Optimization of the Current Controllers (via ISq ) In this step the response of the “ISq-Controller” to a step of ISq-setpoint will serve to verify respectively to improve the optimization of the current controllers which has been carried out in the previous step. A common practical procedure to generate an “ISq-setpoint step” is to step up the speed setpoint by a fairly large value (i.e. 10%) but limit the torque setpoint to the value intended as “ISq-setpoint step” (this step acts temporarily only until the actual speed has reached the speed setpoint; for t he short rise time of the actual current, however, this time is more than required). Even though the torque limit could be set at the output of the speed controller directly (by “parameter”) a preferred approach is to manipulate the torque limit as it is requested from Simotion-DCC via Profibus. Alternatively v to the “technological limit” a “manual limit” can be set in LCOMRG, sheet C2, block SETPOINTS_010. The value at the input TQ_LIM is used to define the effective torque limit. (Please remember: a value of “1.0” in DCC represents “100%”.) Follow the torque limit TQ_LIM downstream through the charts to find out which PZD word transfers the torque limit to object “Vector”: - PZD word for “torque limit”: . . . . . . . . . . . . . . . . . . . In Starter, follow this PZD word to the menu where the torque is limited and find which parameter could be used alternatively: - parameter for “torque limit”: . . . . . . . . . . . . . . . . . . .

page 74

DR-SM150

Generating a Step of I Sq-Setpoint via LCOMRG

steady state speed general control of the drive

torque limit (pos + neg)

L

request for continuous steps

* p.77

A Comm_Motor

page a 75 7


To operate the drive via LCOMRG, set the operating mode to “Remote” (“K17/Remote”). For the current test the drive will be run at a base speed (set via block SETPOINTS_010, input N_SET) to which an additional step of speed will be added.. For this purpose LCOMRG offers a “continuous step” generator which is activated on block LCO_CTL_010 via input CONT_STEP_RE.

page 76

DR-SM150

*

p.75

Continuous Step Generator

request: continuous steps a (ms)

2*c a, b

0.5 * cycle time

c (ms)

cycle time adjustment

b

step value

Inevitable requirement: c > a / the settings of a and bb define the symmetry of the generated signal

Comm_Motor

page a 77 7


Activate the “continuous step” generator and follow the request to the next chart. Use input “Factor” of block OPTI_050 to define a (symmetrical) signal with a sweep time of 5s. Define a step of speed of 10% (setting: 0.1 !) and roughly estimate the result of your settings on output STEP_RESONSE of block OPTI_100. If satisfied, deactivate the “continuous step” generator. Now define the intended “I Sqq-setpoint step” by setting the torque limit TQ_LIM to 10% (setting: 0.1 !), assign a base speed of 30% (setting: 0.3 !) and start the drive via LCOMRG (after each command wait for the feedback information): STARTUP / BM_AUXON / ALM_ON / ON / BM_STC_ON / CNTR_EN The drive will run up to a steady speed of 30%. Activate tthe “continuous step generator” and verify that the speed is changing between 30% and 40%.

page 78

General View of the Step-Response of I Sq

DR-SM150

+10% +5% ISq-setpoint -10%

ISq-actual short sampling time recording for analysis and optimization 40% nsetpoint

30%

L

nactual

Comm_Motor

page a 79 7


Prepare the tracer to record following variables: - ISq-setpoint, r77 - ISq-actual value, r78 - speed setpoint, r60 - actual speed, r63 Suggested trigger settings - initially, to get a general view: - for the optimization: i

“endless trace, recording time = 8s” “sampling rate = 0.125ms / pre-trigger = 50ms / recording duration = 255ms / trigger condition = current setpoint > 10%”

You will observe v that the t torque generating current component steps from an average of +5% to the set value of +10% respectively -10% (the base torque of 5% is required to overcome friction). Increase the torque limit to get a change of “I Sq-setpoint” of about +20%.

page 80

DR-SM150

Optimization of the Current Controller (via I Sq-setpoint)

0.1 / 1000ms

0.25 / 1000ms

0.35 / 1000ms

0.25 / 8ms

0.25 / 6ms OPT

0.25 / 3ms

Comm_Motor

page a 81


The current controller settings as already set by optimizing the controllers via steps of i.Sd have to prove to be correct by applying steps of i.Sq. For training purposes, follow the standard procedure to optimize the “PI current controller” once more: - start with a large “integral action time”” ( P-controller) to optimize the “gain” - set the gain to get a fast response but no overshoot - reduce the “integral action t time” to again get a fast response but no overshoot Find the optimum values l for the current controller settings (they must be very similar to the values found by “optimization i.Sd”): ” “gain, p1715” = . . . . . . . . . . . . . . and “integral action time, p1717” = . . . . . . . . . . . . . . Analyze tthe resulting rise time; you should find a value in the range of 5ms – 10ms. If in doubt as to the correct setting, the “less dynamic” setting should be preferred.

page 82

DR-SM150

Step Response of the I Sq-Current Controller

site recording

rise time: 6ms rise time: 3ms

Comm_Motor

E T A page a 83 8


To give you a feeling of a site-recording, the above slide also shows the signals as they are f ound at site using the PDA recording system. Once you have finished the verification of your current controller properties, set the torque limit to a sufficiently large value, i.e. TQ_LIM = 0.75 (LCOMRG, C2, SETPOINTS).

I A R I T

page 84

DR-SM150

Flux Control Loop [6726, 6723, 6728]

p1590[D] (0.5)

p1592[D] (200) [%]

main control of the flux

[%]

via EMF; on basis of actual values of iS, uS and substitute circuit data

dynamic support

100%

Φset example for “rolling mill” application

p1643[D] (0.40)

base speed typ. 60%

max speed 100%

about zero in steady e state for correct X.H .

to verify the “G”-factor r1624

Comm_Motor

page a 85 8


4.18 Optimization of the Flux Controller Within the motor the flux is generated mainly by the excitation winding (via DC-Master, I Exc) but additionally by the flux generating current component (ISd) of the stator. Flux control is accordingly a assigned to two flux controllers, a PI-controller defining the setpoint for “I Exc“ and a P-controller for the setpoint of “ISd”.. For the optimization of the two flux controllers a step of flux setpoint acting simultaneously on both controllers will be used. By alternatively i assigning a value of 0% respectively 5% as “supplementary flux setpoint” (parameter p1572) a setpoint step is generated. The controller settings will be adapted to obtain an optimized step response. Since the “actual flux” is calculated on the basis of the EMF, the drive has to be run at a speed where the voltage model is active (for the given situation: n > 30%). Prepare the tracer to record following values: - actual flux, r84 - ISd-actual value, r76 - IExc-actual value, r1641 Suggested trigger settings: sampling rate = 0.625ms / pre-trigger = 400ms / recording duration = 1700ms / trigger condition = actual flux > 104%

page 86

DR-SM150

Optimization of the PI-Flux Controller

IExc, actual (r1641)

actual flux (r84)

0.4 / 10000ms

1.0 / 10000ms

1.4 / 10000ms

1.0 / 200ms

OPTIMUM 1.0 / 75ms

1.0 / 50ms

Comm_Motor

page a 87 8


The optimization of the the two controllers has to be done one by one (one controller is deactivated while the other controller is optimized). Note down the controller settings valid at the moment: p1600 = . . . . . . . . . . . . .

p1590 = . . . . . . . . . . . . .

p1592 = . . . . . . . . . . . . .

To carry out the optimization i of the PI-controller, the P-controller has to be deactivated by setting p1600 = 0. Run the drive at a speed of 40% (either via LCOMRG or via OP177). As for other PI-controllers, l follow the standard procedure to optimize the “PI flux controller”: - start with an “integral action time” of 10 000ms ( P-controller) to optimize the “gain” - set the gain to get a fast response but no overshoot - reduce the “integral action time” to get “next to none” overshoot Find optimized values for the flux controller settings: “gain, p1590” = . . . . . . . . . . . . . . and “integral action time, p1592” = . . . . . . . . . . . . . .

page 88

DR-SM150

Optimization of the P-Flux Controller / Final Result

ISd, actual (r76)

actual flux (r84) OPTIMUM 2.5

1.0

3.0

actual flux (r84) 50 ms/div

L

OPTIMUM rise time: 60ms

Comm_Motor

PI-controller: P-controller

1.0 / 75ms 1.2

page a 89 8


To optimize the P-controller, set its gain to its initially valid value (p1600 = . . . . . . . . . . . .), deactivate the PI-controller by assigning the gain to p1590 = 0 and optimize i the gain of the P-controller to again get a “next to none” overshoot: “gain, p1600” = . . . . . . . . . . . . . . Set p1590 back to its optimized value (previous page) and analyze the resulting transient of the actual flux. You will notice that the added influence of both flux controllers results in a too large overshoot. Reduce the gain of the P-controller to half of its current setting: gain P-controller, p1600 = . . . . . . . . . . The transient should s now show only a slight overshoot. Analyze the rise time; you should find a value in the range of 50ms to 100ms. Finally monitor the actual flux for a “down-step” of the flux setpoint from 105% to 100% (via changing p1572 from 5% to 0%).. The resulting overshoot will be larger than f or the “up-step”. If it is too large (or oscillating) the P-controller gain should be reduced still further to avoid the possible risk of DC-link overvoltage. When running the drive at constant speed also verify that the flux setpoint at the output of the PI-flux controller (r1593) reads “about zero”. Any noticeable deviation results from either an incorrect setting of t he magnetizing inductance; i.e. its scaling parameter p655 or an incorrect evaluation of the actual values of motor voltage or motor current.

page 90

DR-SM150

Speed Controller reference model off on

same rise time

t

Kp

Tn natural frequency damping dead time

Comm_Motor

page a 91


4.19 Optimization of the Speed Controller l via “Step of Setpoint” Any controller optimization is based on the consideration of the “system properties” of the respective control loops. Unlike all the other controllers where the t “system properties” are (at least to a very large extent) constant for any kind of load or speed, the “system properties” of the speed control loop may change considerably with a “change of speed” or with a “change of dynamic load” (moment of inertia). For this reason the optimization of the speed controller should not be based on one single operating point but it has to be valid for the entire range of operation. If the “system properties” change considerably (i.e. proportional to the speed or in relation i to the “number of revs of the shaft” like for a winding stand) the speed controller settings have to be (automatically) adapted as necessary (  menu “Adaptation”). DCC-chart LCOMRG, sheet C2 offers essentially following functionality to optimize the speed controller or to test speed control loop properties: 1) ramping the speed up to a constant value with subsequent setpoint steps (step up, step down at regular intervals) 2) performing reversing runs with defined ramp times within defined speed limits 3) “stepping” the speed up to maximum speed (preset step: 2%) 4) simulating a “step of load” (adding a step of torque) Adaptation: if the moment of inertia changes along with the speed or with time, the controller properties have to be adapted to the change of the controlled system. Reference model: the reference model converts a step of setpoint to a signal comparable to the actual speed feedback value. In consequence the set-actual deviation is nearly zero; the Integral-controller channel is not contributing to the PI-controller output which makes the PI-controller functionally a P-controller with “Value Optimum” Properties  no overshoot. Steps of load are controlled with the high dynamic property of the PI-controller.

page 92

DR-SM150

Functionalities to Optimize the Speed Controller CONT_STEP_RE

continuous step response generator activated additionally to N_SET

HIN und HER

the speed setpoint is ramped from plus N_SET to minus N_SET

ENABLE_OPT I

steps the speed up to maximum speed with a fixed step value

ENABLE TOPT

provides for steps of torque downstream of the speed controller

nactual

nset (r1438) nactual (r61)

speed is ramping up; controller properties cannot be analyzed!

must not be limited !

ISq,set q t

I R E

L

ISq, actual (r77)

Comm_Motor

page a 93 9


Functionality “Cont_Step_Re” will be used first to optimize the speed controller at a constant base speed which is preferably selected to correspond to the dominating i operating speed (or at a speed at which basic controller settings apply which will be adapted in operation ti i.e. with the change of speed). At the training rack the “system properties” of the speed loop are the same at any speed. Select a base speed of initially 60% (N_SET = 0.6 !) and define the step of speed to be 2% (LCOMRG, sheet D1, block OPTI_100, input X2 = 0.02). [The step value has to be small e nough not to have torque or current limited; so start with a really small value initially.] Switch on the drive via LCOMRG, have it run up to the set speed of 60% and activate “continuous setpoint steps” (CONT_STEP_RE). Prepare tthe tracer to record following values: - speed setpoint, r1438 - actual speed, r61 - ISq-setpoint, r77 Suggested trigger settings: sampling rate = 1.0ms / pre-trigger = 200ms / recording duration = 2000ms / trigger condition = speed setpoint > 61% Analyze the recorded signals. In particular have a look at the peak value of the torque generating stator current component (r77): peak value of r77: . . . . . . . . . . . . . . This peak value has to be noticeably smaller the set torque limit (p1520) to allow for the optimization (when the gain is optimized it may be increased well beyond its initial value; the larger the gain, the larger the I Sq peak value for the same value of step).

page 94

DR-SM150

Optimization of the Speed Controller via Step of Setpoint

8 / 10000ms

18 / 100ms

Comm_Motor

18 / 10000ms

OPTIMUM 18 / 40ms t.rise = 25ms

25 / 10000ms

18 / 25ms


page a 95 9


The “PI speed controller” is optimized following the same sequence as has been used for other PI-controllers. The typical aim of the optimization, however, is to find a step response featuring a considerable overshoot (details will follow). Start the optimization by following the standard procedure: - set an “integral action time” of 10 000ms ( P-controller) to optimize the “gain” - set the gain to get a fast s response but no overshoot - reduce the “integral action time” to get “only one” undershoot of the actual speed (the resulting overshoot will range within 20% to 50%; the value depends on the mechanical properties of the load). [The n noise of the actual speed may make it difficult to identify the undershoot; looking at the current setpoint in comparison i an identification of the correct setting will be successful.] Note down the optimized values for the speed controller settings and the resulting “rise time”: “proportional gain, p1460”

=..............

“integral action time, p1462”

= . .. . .. . .. . .. . .

“rise time”

=..............

                                                                                       

page 96

DR-SM150

Optimization via “Simulated Step of Load”

simulated load

-

i.Sq.set

current controller

i.Sq.act

Profibus Integrated

Comm_Motor

negative torque limiting symmetrical

page a 97 9


4.20 Optimization of the Speed Controller l via “Step of Load” In actual operation steps of setpoint as used in the previous approach of optimization will rarely occur because any request to change the speed will pass s a ramp function generator (either the one within the drive’s setpoint channel or some other implemented in the ““higher level control” like “Automation”. In practical operation the motor will have to handle steps of load. Since real steps of load can hardly be generated “on demand”, simulated steps of load are used to t est the response of the drive to a “step of disturbance variable”. Set the “commissioning i torque limit” in LCOMRG, block SETPOINTS_010, input TQ_LIM to 75% and verify via Starter that this value is active. This setting limits l the maximum torque the drive will accept on request from the speed controller to 75%. In consequence a simulated load of more than 75% cannot be counteracted by the speed controller; the drive would accelerate up to the voltage limit!

page 98

DR-SM150

Optimization of the Speed Controller via Step of Load c

cycle time “c” a, b a

step value

- inevitable requirement: c > a - the settings of a and b define the symmetry of the generated signal

b dynamic speed controller setting: Impact Speed Drop (ISD) < 0.25 %s

∆t ISD = 1.25 %s

ISD = 0.55 %s

ISD = 0.15 %s

18 / 200ms

18 / 40ms

∆n n: 1div=0.5% i: 1div=20% t: 1div=0.1s ∆ load = 50%

∆ load =20%

40%

8 / 200ms

60%

Comm_Motor

page a 99 9


Go to chart LCOMRG, sheet D5, block OPTI_101, input X2 and set the “disturbance variable” to simulate a “10% load” for 1s with a “1s zero load” interval (remember that a setting of 1 acts as 100% ! ). Switch on the drive via LCOMRG, have it run up to a speed of 60% and activate the simulated “disturbance variable” (ENABLE_TOPT). Trace the same signals as before for a “step of load” of 20%, 40% and 50%: you will notice that the maximum loss of speed is proportional to the step of load. If your drive should l trip i with “overcurrent, fault 30001” while simulating steps of load, check your current controller settings; at the ““TC-stand” they should read p1715 = 0.15, p1717 = 6ms (in particular your gain might be set too large). If necessary, adapt your settings. If you compare the step response for a constant step of load but for different controller settings you will notice that the “area” made up by the loss of actual speed versus the constant speed setpoint decreases the more dynamically the speed controller is set. This area defines the quality of the speed controller setup. It is known by the name “Impact Speed Drop” and should be less than “0.25%s” for a step of load of 50% according to following equation (you might want to substitute your signal by an approximated triangle): ISD = 0.5 * ∆t * ∆n

[∆t in s, ∆n in % (nmax = 100%), ISD in %s]

Take one of your traces for the optimized speed controller and calculate the ISD: ISD = . . . . . . . . . . . . %s Once you terminate this test, set the value of the “disturbance variable to 0% and disable the “additional step of torque”. To continue, be sure that the speed controller data are set to your optimized values.

page 100

DR-SM150

DC-Link Voltage Pre-Control

U.DC

with pre-control ideally zero

Pre-Control 0  off 100  on

active power setpoint

distribution of the overall i.Sq request to the overall number of ALMs

r82[3]

MoMo 1

. . .

k n i L U C

i.Sq pre-control of up to four Motor Modules

MoMo 4 r82[3]

Comm_Motor

page a 101 1


4.21 Setting the Infeed Pre-Control As you can see in the function diagram, the control of the DC-link voltage combines the outputs of the DC-link voltage controller and of the pre-control channel. As common in such an arrangement, the pre-control has to be set to fully provide the “voltage request”; the PI-controller will act as a correction controller only (it will become active to handle any step of disturbance variable which might occur in the DC-link itself). The active power requested by the Motor Module is transferred to the Infeed via CU-link and has to be scaled with the aim of minimizing the contribution r of the PI-voltage controller (r77 should ideally read “zero” with a setting of p3521 close to 100 %).

                                        

page 102

DR-SM150

Influence of the “DC-Link Voltage Pre-Control”

isq (UDCcontrol)

isq (precontrol)

UDC, actual

p3521 = 0%

Comm_Motor

p3521 = 100%

p3521 = 50%

page a 103 1

p3521 = 150%


At present the pre-control is already active (generally enabled by p3400.11 = ON / scaled with 100 % via p3521[0]). Prepare the tracer to record following “Infeed” values l (endless trace with 5s recording time / sampling rate = 4ms): - Iactive-setpoint, r77 - Ppre-control , r3522[0] - UDC-actual, r70[0] c To tune the “Infeed Pre-Control”, n a reversing run with about “50 % torque generating current component” will be required. Operate the drive using the commissioning mode “HIN und HER” and adjust the acceleration and deceleration ramps to get “I “ Sq-actual” = 50 %). Use the parameter for the scaling (p3521) to analyze its influence on the recorded signals: - without pre-control the PI-controller provides all active current for the change of load - with t 100% pre-control the PI-controller operates in “idle state” - if the pre-control is too large, the PI-controller counteracts - the quality of the DC-link voltage is roughly the same for any setting (UNLESS the limits of the PI-controller should be reached) Finally find the optimized setting (such that the PI-controller output, r77 shows the least deflection): p3521 = . . . . . . . . . . . %

page 104

Adjusting Instrumentation Meters

DR-SM150

m a r g a i d t i u c r i c

<1>

m a r g a i d n o i t c n u f

<2>

<3>

“+10V“

<4>

“+10V“

“+10V“

“out“

PSA-meters can be tested by assigning n 0%, 100% directly or by parameters r6888[0 … 3].

“+5V“ “-1.0“

“+1.0“

“-1.0“

“-1.0“

“in“

“+1.0“

These parameters additionally offer a -100% value and a sawtooth signal (-100% to 100%).

“+1.0“ “-5V“

“-10V“

Offset = 0 Scaling = 1

“-10V“

Offset = 0 Scaling = 2

“-10V“

Comm_Motor

Offset = -1 Scaling = 2


page a 105 1


4.22 Adjusting the Instrumentation Meters When you run the TC-drive you will notice that the instrumentation meters indicate unexpected values. The meters of the training rack are wired r “as per standard” (refer to the excerpt of the circuit diagram above). Find out first which meter is connected te to which PSA terminal: Signal “standard”

PSA terminal

Signal “required”

in-par.

out-par.

scaling p6860 cd.

offset p6870 cd.

Voltage

...........

Voltage

.......

.......

.......

.......

Current

...........

Current

.......

.......

.......

.......

Speed

...........

Speed

.......

.......

.......

.......

Power

...........

DC-link

.......

.......

.......

.......

Next find out which input-parameters you have to use to feed a signal to the assigned meters as required and which output-parameters you have to wire to get the physical quantity indicated (select the “smoothed” values). Use the “Calibration signals for PSA analog outputs” to test the assignment and function of the meter for the speed: constant value 0  0% / constant value -1.0 (1.0)  -100% (100%). Program the parameters for “scaling” and “offset” to tune the meter as required. Now assign the “smoothed actual speed” to this meter and verify that the speed is indicated as requested: - Speed 0rpm  0% / value as scaled in p2000  100% (same at positive and negative speed) (run the drive via OP177 at various positive and negative speed values). Follow the same approach for the other signals and have the meters indicate as suggested: - Voltage 0V  0% / value as scaled in p2001  100% (same at positive and negative speed) - Current 0A  0% / value as scaled in p2002  100% (same at positive and negative speed) - DC-link 0V  0% / 600V  100%

page 106

16 Motor Syn0 s

Recommend Documents