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Siemens SINAMICS PERFECT HARMONY GH180, Function Manual

The Siemens SINAMICS PERFECT HARMONY GH180 is a state-of-the-art, high-performance harmonic filter that ensures optimal energy efficiency and reliable operation. Improve your understanding and maximize its potential with the comprehensive Function Manual, available for free download from manualshive.com. Experience seamless power control like never before.

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SMC

Is an acronym for Synchronous Motor Control, one of the control modes of the drive. This mode 
computes the rotational speed similarly to open-loop vector control, and controls the field 
reference or the synchronous motor as in closed-loop synchronous motor control.

SOP

(1) SOP is an acronym for Sum Of Products. The term "sum-of-products" comes from the 
application of Boolean algebraic rules to produce a set of terms or conditions that are grouped 
in a fashion that represents parallel paths (ORing) of required conditions that all must be met 
(ANDing). This would be equivalent to branches of connected contacts on a relay logic ladder 
that connect to a common relay coil. In fact, the notation can be used as a shortcut to describe 
the ladder logic. 

(2) SOP, when used as a filename extension, refers to System Operating Program.

SOP Utilities

The program within the Siemens Tool suite used for converting between text and machine 
loadable code. It can also be used for uploading and downloading files over the RS232 
connection.

See Tool Suite definition.

Speed Menu function

Speed menu is a feature of the menu system that allows the operator to directly access any of 
the menus or parameters, rather than scrolling through menus to the appropriate item. This 
feature uses the [Shift] button in conjunction with the right arrow. The user is prompted to enter 
the four digit ID number associated with the desired menu or parameter.

Stop mode

Stop mode is used to shut down the drive in a controlled manner, regardless of its current state. 

Submenus

A submenu is one of four components found in the menu system. Submenus are nested menus 
(i.e., menus within other menus). Submenus are used to logically group menu items based on 
similar functionality or use.

Synchronous speed

Synchronous speed refers to the speed of an AC induction motor’s rotating magnetic field. It is 
determined by the frequency applied to the stator and the number of magnetic poles present in 
each phase of the stator windings. Synchronous Speed equals 120 times the applied Frequency 
(in Hz) divided by the number of poles per phase.

Glossary

Control Manual
Operating Manual, A5E50491925A

525

Summary of Contents for SINAMICS PERFECT HARMONY GH180

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Page 3: ...ro Control Description 4 Hardware User Interface Description 5 Parameter Assignment Addressing 6 Operating the Control 7 Advanced Operating Functions 8 Software user interface 9 Operating the Software 10 Troubleshooting Faults and Alarms 11 NEMA Table A Historical Logger B List of abbreviations C Index D ...

Page 4: ...re those who based on their training and experience are capable of identifying risks and avoiding potential hazards when working with these products systems Proper use of Siemens products Note the following WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation If products and components from other manufacturers are used ...

Page 5: ...troduction 39 4 2 Digital Control Rack DCR 40 4 3 Field Bus Communication Board 42 4 4 System Interface Board SIB 43 4 5 User I O 44 4 6 Control System Power Supply 45 4 7 Control Modes 47 4 7 1 Vector Control introduction 47 4 7 2 Components of Vector Control 47 4 7 3 Summary of the Control Modes 49 4 7 4 Open Loop Vector Control OLVC 50 4 7 5 Open Loop Test Mode OLTM 51 4 7 6 Synchronous Motor C...

Page 6: ...icated I O for Type 4 Pre charge 77 5 3 11 Dedicated I O for Type 5 and Type 6 Pre charge 79 5 3 12 Dedicated I O for Input Protection IP 80 5 3 13 Network Connections 82 6 Parameter Assignment Addressing 85 6 1 Menu Descriptions 85 6 2 Safety Notes for Parameter Changes 88 6 3 Options for Motor Menu 1 first half 90 6 4 Options for Motor Menu 1 second half 97 6 5 Options for Drive Menu 2 first par...

Page 7: ...Transformer by Limiting Secondary Currents 205 7 9 4 Excessive Drive Losses Protection 208 7 9 5 System Arc Detection 211 7 10 Drive Output Torque Limiting 212 7 10 1 Input Under Voltage Rollback 212 7 10 2 Extended Undervoltage Ride through 213 7 10 3 Input Single Phase Rollback 214 7 10 4 Transformer Thermal Rollback 215 7 10 5 Torque Limit Setting 216 7 10 6 Field Weakening Limit 216 7 10 7 Cel...

Page 8: ...g Parameters 246 8 9 3 Dual Frequency Braking Limitations 247 8 10 Regenerative Braking six step 248 8 10 1 Regen Braking Six Step 248 8 10 2 Regen Braking Six Step Parameters 248 8 10 3 Regen Braking Six Step Limit Conditions 249 8 11 Dynamic Braking with External Resistors 250 8 12 Voltage Attenuator Resistors 252 8 12 1 Voltage Attenuator Resistors 252 8 12 2 Voltage Attenuator Resistors Softwa...

Page 9: ... 6 Closed Pre charge 281 8 18 Pre charge using SOP 288 8 18 1 Electric Shock Hazard 288 8 18 2 Limiting Function applicable to all precharge types 288 8 18 3 Preconditions for Pre charge Types 1 to 3 288 8 18 4 Type 1 Closed Pre charge 6SR325 290 8 18 5 Type 2 Open Pre charge 6SR325 292 8 18 6 Type 3 Pre charge Parallel Drives 6SR325 294 8 19 Pre charge using Dedicated I O 297 8 19 1 Electric Shoc...

Page 10: ...HMI Display Brightness 362 9 2 Multi Language Keypad 366 9 2 1 ML Keypad 366 9 2 1 1 Multi Language Keypad Support 366 9 2 1 2 Manual Stop Key 366 9 2 1 3 Manual Start Key 366 9 2 1 4 ML Display T76 366 9 2 1 5 ML Fault Reset Key and LED Indicator T76 373 9 2 1 6 ML Shift Function Keys T76 376 9 2 1 7 ML Arrow Keys T76 377 9 2 1 8 ML Diagnostic Indicators T76 380 9 2 1 9 ML Display T76 381 9 2 1 1...

Page 11: ...6 10 7 Downloading the SOP 437 10 8 Uploading the SOP 438 10 9 Multiple Configuration Files 439 10 10 Selecting the active SOP 440 11 Troubleshooting Faults and Alarms 441 11 1 Troubleshooting Introduction 441 11 2 Status LED 442 11 3 Faults and Alarms 443 11 4 Drive Faults and Alarms Input Line Disturbance 445 11 5 Drive Faults and Alarms Motor Output Related 449 11 6 Drive Faults and Alarms Syst...

Page 12: ...ndard MG 1 1993 Part 20 42 converted to SI units Maximum Load Inertia for Polyphase Squirrel Cage Induction Motors in kg m 499 Table 11 18 Low voltage power supply related faults 493 Table 11 17 Cooling Related 488 Table 11 16 MV Mechanical Bypass Board Status LEDs 485 Table 11 15 AP cell faults 474 Table 11 14 Diagnostic cell faults 472 Table 11 13 Specific individual cell faults 466 Table 11 12 ...

Page 13: ...ypad 342 Table 8 3 Down Transfer States 262 Table 8 2 Up Transfer States 261 Table 8 1 Motor related data 247 Table 7 4 Auto resettable faults 232 Table 7 3 Fault alarm type and drive responses 231 Table 7 2 Symbols used in Figure Input Side Monitoring 203 Table 7 1 Signal polarities 181 Table 6 103 Parameter Menu for Slave Configuration 173 Table 6 102 Slave Setup and Configuration Parameters 172...

Page 14: ...le Parameters 145 Table 6 71 Analog Output Menu 4660 Parameters for External Outputs 144 Table 6 70 Pick list for Analog Input Sources 143 Table 6 69 Auxiliary Input 2 Menu 4580 Parameters 143 Table 6 68 Auxiliary Input 1 Menu 4500 Parameters 142 Table 6 67 Analog Input 5 Menu 4341 Parameters 142 Table 6 66 Analog Input 4 Menu 4332 Parameters 141 Table 6 65 Analog Input 3 Menu 4232 Parameters 140 ...

Page 15: ...8 Table 6 33 Internal Analog Input 9 Menu 2715 Parameters 118 Table 6 32 Internal Analog Input 8 Menu 2711 Parameters 118 Table 6 31 Internal Analog Input 7 Menu 2705 Parameters 117 Table 6 30 Internal Analog Input 6 Menu 2701 Parameters 117 Table 6 29 Internal Analog Input 5 Menu 2693 Parameters 117 Table 6 28 Internal Analog Input 4 Menu 2689 Parameters 117 Table 6 27 Internal Analog Input 3 Men...

Page 16: ...P Input Control Flags 78 Table 5 2 WAGO I O Module Color Codes 76 Table 5 1 NXGPro Test Port Signals Connector Pins P5 65 Table 4 1 Symbols used in Figure Vector Control Algorithms 49 Table 2 1 ESD Protective Measures Diagrams Key 30 Figures Figure B 5 Fault Word 4 508 Figure B 4 Fault Word 3 507 Figure B 3 Fault Word 2 506 Figure B 2 Fault Word 1 505 Figure B 1 Example of historic log as viewed i...

Page 17: ...y after key sequence 408 Figure 9 63 Status display after SHIFT 2 key sequence 408 Figure 9 62 Status display in metering mode 408 Figure 9 61 Dynamic Programmable Meter Display in Regeneration Mode 407 Figure 9 60 Dynamic Programmable Meter Display in Rollback Mode 407 Figure 9 59 Dynamic Programmable Meter Display 406 Figure 9 58 Identification version screen and meter display 406 Figure 9 57 Mu...

Page 18: ... screen and meter display 367 Figure 9 25 Display Menu Screen 365 Figure 9 24 Start Center Screen 365 Figure 9 23 Security Code Change 364 Figure 9 22 Security Code Screen 363 Figure 9 21 Speed Parameter Screen 363 Figure 9 20 NXG Main Menu Screen touch keypad displayed 362 Figure 9 19 Status display upon entering a value beyond the range of the system 360 Figure 9 18 Status display after pressing...

Page 19: ...l with Synchronous Motor 316 Figure 8 22 Type 6 Pre charge Component Connections 311 Figure 8 21 Type 6 Pre charge Circuit Schematic 310 Figure 8 20 Type 5 Pre charge Component Connections 306 Figure 8 19 Type 5 Pre charge Circuit Schematic 305 Figure 8 18 Type 3 Pre charge Component Connections 295 Figure 8 17 Type 2 Pre charge Component Connections 293 Figure 8 16 Type 1 Pre charge Component Con...

Page 20: ...or motor temperature 197 Figure 7 11 Default speed derating curve showing maximum motor load as function of speed 196 Figure 7 10 Motor Thermal Model 195 Figure 7 9 Available Voltage after a failure 190 Figure 7 8 Drive Output after loss of 5 Cells 189 Figure 7 7 Drive Output after loss of 3 Cells 188 Figure 7 6 Drive Output rebalanced using neutral shift 188 Figure 7 5 Drive Output rebalanced by ...

Page 21: ...egulator 57 Figure 4 10 Manual Mode Manual Network Mode negative Ids 56 Figure 4 9 Manual Mode Manual Network Mode positive Ids 56 Figure 4 8 Auto Mode 55 Figure 4 7 Disabled Mode 55 Figure 4 6 Flux Regulator for PMM Control Mode 54 Figure 4 5 Drive Arrangement for Synchronous Motor with AC Brushless Exciter 52 Figure 4 4 Vector Control Algorithms 48 Figure 4 3 Functional Sections Interaction 46 F...

Page 22: ...Table of contents NXGPro Control Manual 20 Operating Manual A5E50491925A ...

Page 23: ...f and to the extent such a connection is necessary and only when appropriate security measures e g firewalls and or network segmentation are in place For additional information on industrial security measures that may be implemented please visit https www siemens com industrialsecurity Siemens products and solutions undergo continuous development to make them more secure Siemens strongly recommend...

Page 24: ...Security NXGPro Control Manual 22 Operating Manual A5E50491925A ...

Page 25: ...ng and an adequate auxiliary power supply must be strictly observed Fault free operation is also dependent on careful operation and maintenance The power sections are designed for variable speed drives use with synchronous and asynchronous motors Operating modes overload conditions load cycles and ambient conditions different to those described in this document are allowed only by special arrangem...

Page 26: ... operators The VFD is also equipped with monitoring functions to protect external components The VFD operates safely when the interlock and protection systems are functioning properly Nevertheless there are areas on the medium voltage drive that are hazardous for personnel and that can cause material damage if the safety instructions described in this section and throughout the product documentati...

Page 27: ...is de energized 4 Apply grounding means 5 Cover or enclose adjacent components that are still live DANGER Danger Due to High Voltages High voltages cause death or serious injury if the safety instructions are not observed or if the equipment is handled incorrectly Potentially fatal voltages occur when this equipment is in operation which can remain present even after the VFD is switched off Ensure...

Page 28: ...ntended for high voltage measurements that is isolation is provided inside the instrument not provided by isolating the chassis ground of the instrument Never assume that switching off the input disconnector will remove all voltage from internal components Voltage is still present on the terminals of the input disconnector Also there may be voltages present that are applied from other external sou...

Page 29: ... an Arc Resistant option M57 for a unit that has been tested and rated for arc fault protection In these instances the following safety warnings and information apply DANGER Fire from Pressure Relief Flaps Fire can escape through the pressure relief flaps if arcing occurs Never climb on the equipment Never place any objects on the roof of the equipment Persons and objects are not permitted on the ...

Page 30: ...sure the use of an even and flat truck bed to transport the VFD system Before unloading be sure that the concrete pad is level for storage and permanent positioning Always confirm proper tonnage ratings of cranes cables and hooks when lifting the VFD system Dropping the cabinet or lowering it too quickly could damage the unit Never disconnect control power while medium voltage is energized This co...

Page 31: ...nded piece of metal When handling a PC board always hold the card by its edges Do not slide printed circuit boards PCBs across any surface e g a table or work bench If possible perform PCB maintenance at a workstation that has a conductive covering that is grounded through a 1 Megohm resistor If a conductive tabletop cover is unavailable a clean steel or aluminum tabletop is an excellent substitut...

Page 32: ... transported or dispatched can be damaged Pack electronic modules in appropriate conductive packaging e g foam rubber or aluminum foil The necessary ESD protective measures for electrostatic sensitive devices are illustrated in the following drawings Figure 2 1 ESD Protective Measures Table 2 1 ESD Protective Measures Diagrams Key 1 Sitting 2 Standing 3 Standing Sitting a Conductive Floor b ESD Ta...

Page 33: ...ant operator is responsible for taking appropriate measures labels and hazard warnings to adequately protect operating personnel and others against any possible risk Observe the relevant nationally applicable health and safety regulations For example in Germany electromagnetic fields are subject to regulations BGV B11 and BGR B11 stipulated by the German statutory industrial accident insurance ins...

Page 34: ...Safety notes 2 6 Electromagnetic Fields in Electrical Power Engineering Installations NXGPro Control Manual 32 Operating Manual A5E50491925A ...

Page 35: ...d for use with SINAMICS Perfect Harmony GH180 medium voltage drives This manual is intended for use by persons with a working knowledge of the NXGPro control system Specific configurations of the drive family are described in more detail in the specific Operating Instructions Manual pertaining to that hardware configuration In addition for information relating to maintenance and trouble shooting o...

Page 36: ...ase input and a single phase output which are configured in three individual concatenated strings of cells making up three output phases Control and diagnostic data is transmitted between the control and the cells on independent fiber optic channels Control Description 3 2 Power Topology NXGPro Control Manual 34 Operating Manual A5E50491925A ...

Page 37: ...firms that the switch pair gated 4 The control confirms gating from Output voltage divider Output Hall effect current transducer No two cells switch at the same time The cell switching rate is low compared to the effective switching frequency of the VFD Typically 600 Hz carrier frequency per pole results in 1200 Hz switching frequency per cell The VFD effective switching frequency is calculated si...

Page 38: ...ic cell control boards CCBs capable of communication using AP to be installed into a power cell Not all power cells are capable of utilizing AP type CCBs The control detects the presence of AP capable CCBs on an individual cell basis and can dynamically fall back to original protocol for an older cell type Although this capability is available in the control it may not be feasible within the power...

Page 39: ...ot compatible with AP or older cell types Mixing of EO and other older cell types is not permitted Control Description 3 4 Protocol for Cell Communication NXGPro Control Manual Operating Manual A5E50491925A 37 ...

Page 40: ...curity including the following items Firewall protection TLS protocol for authenticating the user from ToolSuite Encrypted and Signed firmware Encrypted and Signed control software Control Description 3 5 NXGpro Advanced Security NXGPro Control Manual 38 Operating Manual A5E50491925A ...

Page 41: ...so allows the cells to cleanly regenerate power back into the input power feed Cell An M MOTOR AC Cell A3 AC Cell A2 AC Cell A1 AC Cell Bn AC Cell B3 AC Cell B2 AC Cell B1 AC Cell Cn AC Cell C3 AC Cell C2 AC Cell C1 AC 9 24 Modulator Computer Analog to Digital Converter Signal Condi oning 3 2 3 2 Human Machine Interface Applica on Communica ons Analog Digital I O Fiber Op c to Cells Input Voltage ...

Page 42: ...eld Bus Communications Board Main Control Board Fiber Optic Main Board Network 3 optional Network 2 optional Network 1 optional Fiber Optic Expansion Boards s USB Port Status Indicator Test Port System Interface Power Supply Redundant Power Bypass User I O Fiber 1 and 2 Fiber 3 4 and 5 Figure 4 2 NXGPro DCR exploded view NXGPro Control Description 4 2 Digital Control Rack DCR NXGPro Control Manual...

Page 43: ...tic Expansion Boards Each fiber optic main board has a three part function Connection point and signal driver for all of the fiber optic connections for the control system Provide optional Safe Torque Off STO functionality Mechanical function utilizing different physical board dimensions which allow for the appropriate fiber optic bend radius to be applied during the mechanical assembly of the con...

Page 44: ...unications Board provides a flexible interface to support several different ANYBUS communication protocols Please refer to the NXGPro Communications Manual A5E50226719 NXGPro Control Description 4 3 Field Bus Communication Board NXGPro Control Manual 42 Operating Manual A5E50491925A ...

Page 45: ...o part function 1 interface between the drive system feedback and the DCR 2 platform for a dedicated circuit for the drive input breaker control M1 permissive NXGPro Control Description 4 4 System Interface Board SIB NXGPro Control Manual Operating Manual A5E50491925A 43 ...

Page 46: ...connected together to increase the number of I O that are available for use A single fiber optic user I O board requires a power supply capable of 24 VDC 5 1 A at 50 C at a minimum for board function any I O power requirements are in addition to this The external WAGO I O system may be included in certain applications but is not included in all systems This uses a dedicated serial interface connec...

Page 47: ...DCR Keypad and 1 User I O board internal usage only NO I O usage 2 Hall Effect 24 VDC for new systems 15 VDC for retrofits A single fiber optic user I O board requires a power supply capable of 24 VDC 5 1 A at 50 C at a minimum for board function Note I O power must be separate from 24 VDC used for the DCR digital control power NXGPro Control Description 4 6 Control System Power Supply NXGPro Cont...

Page 48: ...Figure 4 3 Functional Sections Interaction NXGPro Control Description 4 6 Control System Power Supply NXGPro Control Manual 46 Operating Manual A5E50491925A ...

Page 49: ... motor equations is obtained by transforming the three phase AC quantities which are referred to being in a stationary reference frame to DC quantities that are in a synchronously rotating or DQ reference frame A phase locked loop PLL within the motor model tracks the stator frequency and angle of the flux vector Flux and Speed Regulators Motor flux amplitude is controlled by the flux regulator it...

Page 50: ...on as shown in Figure Vector Control Algorithms 9ROWDJH FRPPDQGV WR 0RGXODWRU HDG 7LPH RPSHQVDWLRQ DQG 3HDN 5HGXFWLRQ 0DJQHWL LQJ XUUHQW 5HJXODWRU 7RUTXH XUUHQW 5HJXODWRU OX 5HI 6SHHG 5HI OX 5HJXODWRU 6SHHG 5HJXODWRU 0RWRU 6SHHG XUUHQW HHGEDFN QWHJUDWHG 9ROWDJH HHGEDFN RZ UHT RPS DQG 7R 4 7R 4 4 7R 6OLS FDOFXODWLRQ VOLS 0RWRU 0RGHO XDO UHTXHQF UDNLQJ HQFRGHU ˆ6 U V V V OX 46 3 OX 6 OX 6 2 9 9 60 6...

Page 51: ... output frequency of the drive This is motorspeed r Slip θs Flux angle This is the instantaneous position of the rotating flux vector Ia Ib Ic Motor phase currents Motor torque in newton meters and shaft power can be calculated as Torque Nm 3 Pole_Pairs Flux V secs Iqs A 3 Pole_Pairs Motor_Voltage V Iqs A 2 π Frequency Hz Shaft Power W Torque Nm Speed rad s Torque Nm Speed rpm 9 55 Rated Speed 120...

Page 52: ...on of load torque and provides a performance that matches a vector controlled drive with speed sensor transducer above a certain minimum speed With the correct motor parameters the control can provide good performance even at 1 of rated speed With this mode speed feedback is synthesized from the stator frequency and the estimated motor slip and slip compensation is automatic In this control mode i...

Page 53: ...de to adjust scale factors for input and output voltage and currents In this mode the drive goes through the magnetizing state to the run state without considering the motor flux Only motor nameplate values and some drive related parameters are required for this mode Ensure the following parameter settings are configured for this control mode Disable spinning load and fast bypass Increase accelera...

Page 54: ...iary power and the field exciter The circuit wheel needs only a rectifier Motor Protection The control provides for minimal motor protection when the motor is connected to the drive For a system that employs drive not cell bypass external protection of the motor is required The control will trip the drive on a loss of field fault if the motor draws excessive reactive current which will occur when ...

Page 55: ...e output The field current command is provided to the field exciter with the use of an analog output signal Summary of differences between SMC and OLVC The motor no load current parameter represents the field no load current value in SMC With SMC the flux loop gains are slightly lower than with OLVC Spinning load is always enabled with SMC The drive magnetizing current regulator uses only the prop...

Page 56: ...ors PMM control features differ from the synchronous motor control types One such difference is that PMM control automatically enables high starting torque mode Note There is no encoder capability for use with PMM control mode Do not use the CSMC for PMM control to include an encoder as this will not function correctly With PMM control the flux regulator output is disabled Instead Ids ref is calcu...

Page 57: ...mode the PF is controlled to produce the maximum torque per amp of the PMM motor by ensuring the torque producing current is aligned to the motor Cemf This is accomplished by compensating for the voltage loss and phase delay caused by the total stator inductance parameter Stator Ls Total 1081 Total Stator inductance is defined as Total Stator Inductance Leakage inductance Magnetizing stator induct...

Page 58: ...e q axis The figures below show the vector diagrams for manual mode and manual network mode with positive Ids and negative Ids OX V M V HPI 4 D LV D LV XUUHQW V 9V GV TV Figure 4 9 Manual Mode Manual Network Mode positive Ids Ids ref 0 Drive output PF 1 based on the stator current vector Motor PF rotor reference 1 XL compensation is off motor inductance voltage drop not compensated OX V M V HPI 4 ...

Page 59: ...ting for the voltage loss and phase shift due to the stator inductance Above base speed a voltage regulator is enabled to maintain the voltage of the PMM at the base rating by producing negative Ids ref The flux produced in the stator counteracts the constant flux of the magnets thereby maintaining the motor terminal volts constant as the counter EMF goes up PMMs have a fixed flux and therefore a ...

Page 60: ...ve base speed Ids ref is from the output of the voltage regulator Drive output PF 1 motor inductance voltage drop is compensated Motor PF 1 XL compensation is on Ids 0 Parameter Settings for PMM Control The parameters associated with this control mode are Stator Ls Total 1081 to select auto PF or auto phase advance control Reactive current mode 2981 to select the mode of operation Output Ids 2982 ...

Page 61: ...od already implemented in the control code It adds a separate starting state machine that requires only the selection of SMDC control mode High starting torque mode is set internally and automatically Once operational the machine will continue in operation as a standard SM Spinning load and fast bypass cannot be used in this control mode these features are disabled internally NOTICE Potential Dama...

Page 62: ...t of the speed loop forms the torque current command Iqs ref The default speed loop gains work well when the motor and the load have similar inertia Speed loop gains require tuning when its output shows significant oscillations during small changes in speed command In general when this occurs reduce the integral gain first and then reduce the proportional gain Default values for the double speed K...

Page 63: ...e default flux loop gains work well for most induction motor applications For synchronous motor applications use lower gains Flux loop gains require tuning when the regulator output shows significant oscillations during steady state operation NXGPro Control Description 4 8 Advanced Functions Control Loops NXGPro Control Manual Operating Manual A5E50491925A 61 ...

Page 64: ... watchdog This watchdog triggers if any processes of the drive s operating system stop functioning The watchdog is held off for 180 seconds at boot up This feature which is enabled by the Enable Watchdog parameter 2971 monitors the state of all processes and trips the drive up to 60 seconds before any processes are non functioning Enable Watchdog parameter 2971 is located in the Watchdog Menu 2970...

Page 65: ...ive and customer interfaces including hardware descriptions of the various components This chapter is divided into two sections as follows the first section provides an overview of the non user accessible interfaces these components are internal to the design and construction of the drive and are provided for reference only the second section provides more detailed descriptions of the user accessi...

Page 66: ... allows for a unitless control algorithm that is consistent in response from application to application since the rated values are entered once for the inputs and the drive responds in a similar fashion to scaled per unit signals This is known as a normalized system System Interface Board SIB In the NXGPro Control a System Interface Board SIB that is external to the Digital Control Rack DCR provid...

Page 67: ...als beyond the test point board consult the design documentation for proper scaling Refer to the table below for details of the available signals Table 5 1 NXGPro Test Port Signals Connector Pins P5 Quantity Name Description Pin Number Scaling at Break out Board 3 VIA VIB VIC Phase A B and C input voltage 1 A3 B5 A2 5 3864 Vpeak 3 VIA2 VIB2 VIC2 Phase A B and C input voltage 2 B2 B3 B4 5 3864 Vpea...

Page 68: ...trol board provides coordinated control of the power cell units that comprise the power section of the drive to provide a clean three phase sinusoidal output source to the motor The control system inputs the desired control reference signals and through the chosen control mode regulates the desired output by providing the cells with the appropriate pulse width modulation PWM information from the m...

Page 69: ... if a critical component on a cell fails the cell can be bypassed at the output of the cell and the drive will continue to run at near full capability This is done through output contactors for each cell The modulator controls the activation of the bypass contactors via a fiber optic link to the medium voltage MV bypass board The MV bypass board contains driving and sensing circuitry to interface ...

Page 70: ...ended consequences such as inducing ESD and damaging internal components or bricking the DCR Connecting to internal ports could render the DCR unusable or unsafe for proper device operation Connecting internal ports is strictly for factory use by authorized personnel Hardware User Interface Description 5 2 Non user Accessible Interfaces NXGPro Control Manual 68 Operating Manual A5E50491925A ...

Page 71: ...the NXGPro control diagnostic information is available through connection to the Ethernet port on the DCR Refer to the NXGPro ToolSuite Software Manual A5E3086439 for further information 5 3 2 Inhibit Input Control Relay 3 CR3 The inhibit input previously known as the control relay 3 CR3 input is used to directly control the output of the drive by removing the drive enable bit in the modulator and...

Page 72: ...gs The shielding between the encoder and the drive must never be terminated at both ends due to the potential for damaging noise currents The resulting channel A and channel B signals from the differential pair signals are directly proportional to the motor shaft speed The signals are 90 out of phase with each other The signals switch phase relationship depending on the direction of rotation Figur...

Page 73: ...ater capabilities The first board in the series is always dedicated to I O points critical to the drive operation The other expansion I O connections as required are intended for user to system I O that is for typical drive operation or non critical for protection In defining the I O the I O points associated with the user I O board s are referred to as internal I O and the WAGO is referred to as ...

Page 74: ...0 mA or 4 to 20 mA 2 and 3 inputs Selectable between 0 to 20 mA or 4 to 20 mA or 0 to 10 VDC or 3 wire 100 Ω RTD Analog output 2 0 to 20 mA or 4 to 20 mA output Digital input 20 All 24 VDC or all 120 VDC depending on the board chosen Digital output 16 Form C Relay 1 Amp 250 VAC COSo 0 4 1 Amp 30 VDC Hardware User Interface Description 5 3 User Accessible Interfaces NXGPro Control Manual 72 Operati...

Page 75: ...g circuits are internally powered and do not require a separate supply In addition the 0 to 10 V inputs provide an isolated 11 VDC supply for the use of a 10 K Ohm potentiometer While the circuits have a higher isolation rating the actual isolation is limited by the ratings of the connectors used 300 VAC Actual usage of these connections will depend on the individual wiring of the drive to the TB2...

Page 76: ... Standard Analog input AI1 to AI3 N a Analog output AO1 to AO2 N a Digital input DI1 0a to DI20 3e InternalDigitalInput0a_I to InternalDigitalInput3e_I Digital output DO1 to DO16 InternalDigitalOutput0_O to InternalDigitalOutput15_O Board 2 Optional Analog input AI4 to AI6 N a Analog output AO3 to AO4 N a Digital input DI21 0a to DI40 3e InternalDigital2Input0a_I to InternalDigital2Input3e_I Digit...

Page 77: ...s manual for details of setup and usage 5 3 7 Interface for External I O The interface that connects external control signals to the drive is the WAGO I O system A dedicated serial port communicates with the WAGO I O system via Modbus protocol Configuring the WAGO I O System It is possible to customize the system per application requirements via the WAGO I O modules digital in out analog in out Th...

Page 78: ...Colorless Setting DIP switches on the Modbus coupler The Modbus coupler provides the communication between the control and the WAGO I O system The Modbus coupler is configured at the Siemens factory and there is normally no need to make changes NOTICE Changing standard settings Only personnel trained by Siemens are entitled to perform changes of standard settings Work carried out incorrectly can r...

Page 79: ...ors allow great configurability to the logic Note TheSOPiswrittenandcompiledexternally thereforeerrorcheckingisdoneatthecompilerlevel Follow correct implementation of the SOP as described in Chapter Operating the Software If not followed correctly this could result in drive instability 5 3 9 Dedicated I O NXGPro control systems must utilize at least one user I O board Some of the I O on the first ...

Page 80: ..._O PCVMRStatus Precharge voltage CB UV trip status 1 voltage okay CB2Status_O CB2Status Precharge CB status 1 CB is closed There are 16 digital outputs on the first user I O board DO 0 to DO 15 There is one digital output on the system interface board SIB M1 DOUT Table 5 4 Type 4 Dedicated and SOP Outputs Dedicated Output Terminal SOP Feedback Function Description DO 14 J4 7 8 9 CIMVType4 CIMV Com...

Page 81: ...lInput2d_I PrechargeReques t Request to start pre charge DI 3D J8 10 InternalDigitalInput3d_I M2CloseACK Feedback of M2 contact DI 0E J9 1 InternalDigitalInput0e_I M3CloseACK Feedback of M3 contact DI 1E J9 2 InternalDigitalInput1e_I M4CloseACK Feedback of M4 contact DI 2E J9 3 InternalDigitalInput2e_I M1CloseACK Feedback of M1 contact DI xx Refer to specific drive wiring diagram for DI xx designa...

Page 82: ...re code and still be active on Table 5 7 Dedicated Inputs DI xx Terminal SOP Feedback Function Description DI 3E J9 4 InternalDigitalInput3e_I LFRInputProtectACK Latch Fault Relay LFR status DI xx Refer to specific drive wiring diagram for DI xx designations Table 5 8 Dedicated Outputs DO xx Terminal SOP Feedback Function Description DO 15 J4 10 11 12 InternalDigitalOutput3e_I LFRInputProtect Comm...

Page 83: ...sed before the drive will be permitted to run The test must be run once initially and will rerun automatically any time the system opens the input breaker The result of the test is initially stored in nonvolatile memory and run every time the ICB is opened The test result is stored in the memory of the NXGPro control so that it does not need to be performed every time the system is repowered If th...

Page 84: ...mper Resistant Input Protection to measure the ICB response time The input breaker will open during the test and removal of medium voltage within the required time period will be verified Refer to Chapter Troubleshooting Faults and Alarms Section Handling Tamper Resistant Input Protection Related Faults for fault related information The following table provides information for terminal block TB1 c...

Page 85: ... 1 2 Network 2 3 Network 3 future Figure 5 6 Anybus Networks on NXGPro DCR Ethernet Port Hardware User Interface Description 5 3 User Accessible Interfaces NXGPro Control Manual Operating Manual A5E50491925A 83 ...

Page 86: ...ds Note Siemens strongly discourages connection of this port to any network Refer to the NXGpro Communication Manual A5E50226719 for further information and supported protocols Figure 5 7 Ethernet on NXGPro DCR Chassis bottom view Hardware User Interface Description 5 3 User Accessible Interfaces NXGPro Control Manual 84 Operating Manual A5E50491925A ...

Page 87: ...r Menu 1 Motor parameter 1000 Motor Parameter Menu Enter motor specific data These parame ters provide per unit ratings for most of the output variables Current Profile 1092 Current Profile Menu Limits 1120 Limits Menu Auto tune 1250 Auto tune Menu Encoder 1280 Encoder Menu CLVC only Drive Menu 2 Drive parameter 2000 Drive Parameter Menu Configure the VFD for various load condi tions and drive app...

Page 88: ...ommunications 9 Communications Menu Security edit functions 5000 Security Edit Functions Menu Configure security fea tures Logs Menu 6 Event log 6180 Event Log Menu Configure and inspect the event alarm or fault and historic logs of the VFD Alarm fault log 6210 Alarm Fault Log Menu Historic log 6250 Historic Log Menu Drive Protect Menu 7 Input protection 7000 Input Protect Menu Adjust set point li...

Page 89: ... Submenu does not show in drive tool Applies to keypad only In drive tool submenu displays in top row of status menu Parameter Assignment Addressing 6 1 Menu Descriptions NXGPro Control Manual Operating Manual A5E50491925A 87 ...

Page 90: ...er parameter values unless you are completely sure of the effect your changes will have You are responsible for providing correct parameter values Note Consulting Siemens applications engineering The parameters discussed in this chapter are based on hardware used within the drive and on the design limits of drive components Do not change these settings in the field to match the conditions on the s...

Page 91: ...e If Network 1 Type 9901 is set to none then all associated parameters and menus from ID 9902 to 9966 network configuration and register data are not displayed Table Menu and Submenu Summary lists menus with associated Off submenu names only Parameters and functions found in these menus are described in the following sections Use the associated submenu name from this table to locate the section of...

Page 92: ...om the nameplate Full load speed is base or rated speed minus slip Motor voltage 1040 V 4160 380 13800 Enter the rated voltage for the motor from the nameplate Full load current 1050 A 125 0 12 0 1500 0 Enter the rated nameplate full load current of the motor No load current 1060 25 0 0 0 100 0 Enter the no load current of the motor from the nameplate if it is provided or use the default value Use...

Page 93: ...xis mutual inductance L Enter as percent of base drive impedance This is used to com pensate for current ripple as the rotor poles interact with stator magnetic fields Max DC Exciter Curr 1105 0 25 0 00 1 00 Set the maximum exciter current when start ing a SM with a DC exciter SMDC mode Initial Mag Current 1106 0 04 0 00 1 00 Initial magnetizing current for starting SM with DC exciter Note Stator ...

Page 94: ...d on the thermal model mo tor heating This parameter is not used for legacy inverse TOL options Overload 1140 110 0 for constant and inverse time set tings 100 0 for Legacy TOL modes 20 0 210 0 Set the motor thermal overload trip level and an impending trip warning Once this level is reached the timeout counter is started for the overload fault Constant mode based on motor total current as a perce...

Page 95: ...nable or disable underload protection I underload 1182 10 0 1 0 90 0 Set the current underload level based on the rated motor current Underload timeout 1186 sec 10 0 0 01 900 0 Set the time for underload trip The time is cumulative increasing and decreasing to measure total time less than the underload limit Once the timeout is reached the drive will trip The drive alarms if the current falls belo...

Page 96: ...over voltage trip during deceleration of the drive Phase Imbalance Limit 1244 40 0 0 0 100 0 Set the current threshold level for the output phase current imbalance alarm Ground Fault Limit 1245 5 0 0 0 100 0 Set the threshold of voltage for the output ground fault alarm Ground Fault Time Const 1246 sec 0 017 0 001 2 000 Set the filter time constant for averaging the ground voltage and delaying the...

Page 97: ...50 speed 100 Percent Break Point 1157 100 0 0 0 200 0 Set the maximum motor load at 100 speed The parameters in this table are used to set the inverse time TOL algorithm for speed de rating in parameter Overload select 1130 Table 6 5 Auto tune Menu 1260 Parameters Parameter ID Type Default Description Auto tune stage 1 1260 Function This function determines the stator resistance and leakage induct...

Page 98: ...uto tune Menu 1250 Refer to Section Drive Tuning in Chapter Operating the Control for further information CAUTION Stage 2 Auto tuning Use of Stage 2 auto tuning increases the current loop gains Do not use this function without guidance from Siemens customer service Failure to do so can lead to highly unstable performance Parameter Assignment Addressing 6 3 Options for Motor Menu 1 first half NXGPr...

Page 99: ...ile curve Motor current limit 2 1195 100 10 300 Current limit 2 set point for speed current profile Speed at cur rent lim 2 1196 100 200 200 Motor speed point 2 on the speed current profile curve Motor current limit 3 1197 100 10 300 Current limit 3 set point for speed current profile Speed at cur rent lim 3 1198 100 200 200 Motor speed point 3 on the speed current profile curve Motor current limi...

Page 100: ...he drive follows the curve made up of the nine set points as shown in the figure below The purpose of this function is to allow the user to set a maximum current limit point associated with a specified maximum speed point This limit is not absolute other factors may occur causing the control to reduce the limit as described below 0 20 40 60 80 100 120 0 730 960 1250 1560 1745 1985 2275 2585 3000 s...

Page 101: ... run at the current limits set in the profile but can not override the limitations in the limit logic The control uses the lowest magnitude of all limit sources in the limit logic Rollback Considerations The current limit setting in this profile is a maximum current limit setting that can be overridden by external drive factors such as loss of an input voltage phase loss of cells etc If such an ev...

Page 102: ...Menu 2700 External I O Menu 2800 Internal I O Menu 2805 Output Connection Menu 2900 High Starting Torque Menu 2960 Watchdog Menu 2970 These menus are explained in the tables that follow NOTICE IP Address Duplication Duplicating IP addresses will cause unintended communication issues that will lead to incorrect drive operation To avoid duplication of IP addresses ensure that the IP addresses of the...

Page 103: ...d power 2 Check to see if there is the following text on the transformer Rating Plate kVA sum of seconda ries rated at _ _ _ _ kVA 3 Take the larger of the two values as the trans former secondary power For water cooled transformers 1 If the transformer secondary kVA value is listed use this value 2 If the transformer secondary kVA is not listed use the listed transformer kVA Note For NXGpro versi...

Page 104: ... Hall effect transducer only Not intended for con tinuous motor or load control SMC without speed sensor CSMC with speed sensor SMDC which automatically sets high starting tor que PMM Parallel system 2051 Disable Enable parallel drive control operation Drives motor wind ing 2052 1 1 99 Number of drives connected to a single motor Number of windings 2053 1 1 99 Number of sets of motor windings Driv...

Page 105: ...Angle 2984 deg 0 0 0 0 180 00 Machine offset angle in electrical degrees Current Scan Angle 2985 deg 45 0 0 0 100 00 Maximum scan angle in electrical degrees Current Scan Time 2986 deg 10 0 0 0 100 00 Duration of scan in seconds Current Stabili ty Time 2987 deg 3 0 0 0 100 00 Stabilization of time for current before and after scan Table 6 10 Speed Setup Menu 2060 Parameters Parameter ID Unit Defau...

Page 106: ...or menu Control the source of the torque demand use either SOP flag or menu To utilize an analog or network source SOP flag must be selected The default torque demand is always the menu regardless of this setting unless one of the SOP flags is set true during pre con figuration Torque setpoint 2220 0 0 125 0 125 0 Set the desired torque demand when menu is selected or if no SOP is selected Holding...

Page 107: ...rst critical frequency band to be avoided Skip center freq 2 2360 Hz 30 0 0 0 360 0 Enter the center of the second critical fre quency band to be avoided Skip center freq 3 2370 Hz 45 0 0 0 360 0 Enter the center of the third critical frequen cy band to be avoided Skip bandwidth 1 2380 Hz 0 0 0 0 6 0 Enter the bandwidth of the first critical fre quency band to be avoided Skip bandwidth 2 2390 Hz 0...

Page 108: ...his action does not affect the spinning load mode paramete Table 6 15 Conditional Timer Setup Menu 2490 Parameters Parameter ID Unit Default Min Max Description Cond stop timer 2500 sec 0 8 0 0 999 9 Dwell time after stop is invoked User function de fined Not implemented Cond run timer 2510 sec 0 8 0 0 999 9 Dwell time after start is invoked User function de fined Not implemented Table 6 16 Cell M...

Page 109: ...tempting a fast bypass Once cell fault s occurs the drive may not be able to support actual motor voltage If the motor voltage does not decay below the max drive voltage capability with the faulted cell s within the time set by this parameter the drive will issue a fault Bypass type 2590 Mech Designate the type of bypass in the drive Mechanical None Fast bypass 2600 Disable Enables or disable fast...

Page 110: ... 10 Time delay for closing M4 to stabilize current Maintains the M3 contactor until timeout then allows the state machine to continue by closing M4 This feature will be released in a later software version Precharge voltage 2634 90 80 95 Sets the voltage level to stop M2 resonance and advance the precharge state machine Note The default parameter value is 90 Previously the voltage level was fixed ...

Page 111: ... correctly Incorrect parameter settings may impair the drive function and cause severe material damage Verify changed parameters and ensure that all parameter settings are correct Table 6 17 AP Settings 2585 Parameters Parameter ID Unit Default Min Max Description AP Cells phase 2581 0 0 8 Enter number of AP cells installed per phase AP cell current rat ing 2582 A 787 0 300 0 1500 0 Set AP input c...

Page 112: ...ives Set Angles 2598 Set the AP cell angles as they relate to the primary voltage AP cell ang off 1 2571 deg 181 181 180 Set the AP cell angle offset from the trans former primary voltage for this rank AP cell ang off 2 2572 deg 181 181 180 Set the AP cell angle offset from the trans former primary voltage for this rank AP cell ang off 3 2573 deg 181 181 180 Set the AP cell angle offset from the t...

Page 113: ...Frequency offset used during down transfer to establish torque current by driving the speed regulator into limit Up transfer time out1 2760 sec 0 0 0 0 600 0 If the time taken for up transfer exceeds this value then an up transfer timeout fault is generated Ensure this setting is greater than the accel eration time setting 2270 2290 or 2310 Set to 0 to disable the timeout fault Up transfer thresho...

Page 114: ...of digital outputs in the at tached external I O WAGO timeout 2850 sec 10 0 0 0 600 0 Set the WAGO watchdog timeout period Set to 0 to disable this function Configuring the External I O The External I O is configured from External I O Menu 2800 You must define the total number of I O per the table for each type of I O analog I O and digital I O If the I O count is incorrect the drive will indicate...

Page 115: ...I O module 4 See Table Internal I O Module 4 Menu 2809 Table 6 21 Internal I O Module 1 2806 Parameters Parameter ID Unit Default Min Max Description Module Type 2801 0 0 2 Set the type for internal I O module 1 0 no module installed Voltage 2561 V 120 200 200 Set the required module voltage Possible op tions are 24 V 120 V Int Analog In1 2815 Submenu Access the setup menu for internal analog in p...

Page 116: ...e Internal Analog Output 3 Menu 2645 Int Analog Out4 2653 Submenu Access the setup menu for internal analog out put 4 See Table Internal Analog Output 4 Menu 2653 Table 6 23 Internal I O Module 3 2808 Parameters Parameter ID Unit Default Min Max Description Module Type 2803 0 0 2 Set the type for internal I O module 3 0 no module installed Voltage 2563 V 120 200 200 Set the required module voltage...

Page 117: ...120 V Int Analog In10 2721 Submenu Access the setup menu for internal analog in put 10 See Table Internal Analog Input 10 Menu 2721 Int Analog In11 2725 Submenu Access the setup menu for internal analog in put 11 See Table Internal Analog Input 11 Menu 2725 Int Analog In12 2731 Submenu Access the setup menu for internal analog in put 12 See Table Internal Analog Input 12 Menu 2731 Int Analog Out7 ...

Page 118: ...are Zero 2827 0 200 200 Internal analog input 2 zero Hardware Span 2828 1 0 75 1 25 Internal analog input 2 span RTD Alpha Value 2101 0 39 0 1 0 7 Set the internal I O RTD s analog input alpha value Table 6 27 Internal Analog Input 3 Menu 2835 Parameters Parameter ID Unit Default Min Max Description Type 2836 1 Set the operational mode for internal AI3 0 to 20 mA 4 to 20 mA 0 to 10 V RTD Hardware ...

Page 119: ...l I O RTD s analog input alpha value Table 6 30 Internal Analog Input 6 Menu 2701 Parameters Parameter ID Unit Default Min Max Description Type 2702 1 Set the operational mode for internal AI6 0 to 20 mA 4 to 20 mA 0 to 10 V RTD Hardware Zero 2703 0 200 200 Internal analog input 6 zero Hardware Span 2704 1 0 75 1 25 Internal analog input 6 span RTD Alpha Value 2104 0 39 0 1 0 7 Set the internal I ...

Page 120: ... Set the operational mode for internal AI9 0 to 20 mA 4 to 20 mA 0 to 10 V RTD Hardware Zero 2717 0 200 200 Internal analog input 9 zero Hardware Span 2718 1 0 75 1 25 Internal analog input 9 span RTD Alpha Value 2106 0 39 0 1 0 7 Set the internal I O RTD s analog input alpha value Table 6 34 Internal Analog Input 10 Menu 2721 Parameters Parameter ID Unit Default Min Max Description Type 2722 1 Se...

Page 121: ...0 75 1 25 Internal analog input 12 span RTD Alpha Value 2108 0 39 0 1 0 7 Set the internal I O RTD s analog input alpha value Internal Analog Output Menus Table 6 37 Internal Analog Output 1 Menu 2845 Parameters Parameter ID Unit Default Min Max Description Analog variable 2846 1 Internal analog output 1 source pick list See Pick list for Internal Analog Output Source Output Mode 2848 0 Internal a...

Page 122: ... mode 4 to 20 mA 0 to 20 mA Output Min 2641 0 300 300 Internal analog output 3 minimum Output Max 2642 100 300 300 Internal analog output 3 maximum Hardware Zero 2643 0 200 200 Internal analog input 3 zero Hardware Span 2644 1 0 75 1 25 Internal Analog Input 3 span Output Default 2647 0 0 100 Analog output 3 watchdog default value Table 6 40 Internal Analog Output 4 Menu 2653 Parameters Parameter ...

Page 123: ... mode 4 to 20 mA 0 to 20 mA Output Min 2665 0 300 300 Internal analog output 6 minimum Output Max 2666 100 300 300 Internal analog output 6 maximum Hardware Zero 2667 0 200 200 Internal analog input 6 zero Hardware Span 2668 1 0 75 1 25 Internal Analog Input 6 span Output Default 2671 0 0 100 Analog output 6 watchdog default value Table 6 43 Internal Analog Output 7 Menu 2677 Parameters Parameter ...

Page 124: ...eed Demand Ah Harmonic Analog Input 1 Speed Droop Percent Speed Reference Bh Harmonic Analog Input 2 Torq Current Iqs Ref Raw Flux Demand Total Harmonics Analog Input 3 Torq Current Iqs Fb Flux Reference Xfmr Therm Level Analog Input 4 Torq Current IqsFilt Filtered Current RMS 1 Cycle Protect Analog Input 5 Zero Sequence Av Single Phase Cur Analog Input 6 Neg Sequence D Under Volt Limit Analog Inp...

Page 125: ... resistance value as a ratio of the base output impe dance of the drive Cable induc tance 2941 0 0 0 0 50 0 Output cable inductance is used for long runs of cable Enter in percent of drive base impedance Filter damping gain 2950 0 5 5 00 5 00 Control the gain for damping oscil lations due to output filter Use a positive constant typically 0 5 with cable length less than 30000 feet Use a negative c...

Page 126: ...me allowed for the phase locked loop to acquire the motorflux and frequency in high starting torque mode Default value is accept able in most cases Less time may be needed if the minimum speed limit is lower than 1 of rated speed Watchdog Menu Table 6 48 Watchdog Menu 2970 Parameters Parameter ID Unit Default Min Max Description Enable watchdog 2971 Enable Enable or disable the CPU watchdog which ...

Page 127: ...explained in the tables that follow Table 6 49 Stability Menu 3 Parameters Parameter ID Unit Default Min Max Description Input processing 3000 Submenu Access submenus related to drive line side pro cessing See Table Input Processing Menu 3000 Output processing 3050 Submenu Access submenus related to drive motor side pro cessing See Table Output Processing Menu 3050 Control loop test 3460 Submenu A...

Page 128: ...ntegral gain 3020 3840 0 0 0 12000 0 Integral gain of input PLL Input current scaler 3030 1 0 0 0 2 0 Set the scaling for input current feedback Default value is normally adequate CT secondary turns 3035 200 50 3000 Secondary side turns for input current CT with primary turns equal to 5 Input voltage scaler 3040 1 0 0 0 2 0 Set the scaling for input line voltage feedback Default value is normally ...

Page 129: ...Table 6 52 Output Processing Menu 3050 Parameters Parameter ID Unit Default Min Max Description Low freq comp 3060 Submenu Access parameters that affect compensation for hardware and software filter poles See Table Low Frequency Compensation Menu 3060 Flux control 3100 Submenu Access the flux control parameters See Table Flux Control Menu 3100 Speed loop 3200 Submenu Access the speed loop paramete...

Page 130: ...ency Compensation Menu 3060 Parameters Parameter ID Unit Default Min Max Description Low freq com gain 3080 1 0 0 5 5 0 Low Frequency compensation gain for scaling es timated flux S W compensator pole 3090 2 0 0 5 20 0 Pole of software integrator used for flux estima tion Note Help with higher starting torque using Low Frequency Compensation parameters To start a motor with higher starting torque ...

Page 131: ...inal current Increasing the motor flux when starting will also help with torque production since Torque FluxDS Iqs Parameter 3080 Low Freq Comp Gain can be used to apply more flux to the motor in the 0 to 4 5 Hz speed range By setting the parameter to 9 75 instead of the default of 1 0 will allow 133 of flux to be applied inverse of 0 75 at 0 speed which is linearly reduced to 100 at 4 5 Hz and hi...

Page 132: ...ulator proportional gain term Flux reg integral gain 3120 1 0 0 0 1200 0 Flux PI regulator integral gain term Flux filter time const 3130 sec 0 0667 0 0 10 0 Time constant of the low pass filter used on the flux error Flux table menu Note To be re leased in a later software version 3131 Submenu Flux shaping table parameters Flux demand Note To be re leased in a later software version 3150 pu 1 0 0...

Page 133: ... menu as Flux xx spd in PU flux demand The range is from 0 0 0 0 to 40 0 4 with the default flux set to 1 0 at each setpoint The 13th speed setpoint is at 50 and is set by the original parameter Flux Demand 3150 Refer to table Flux Table Menu 3131 Parameters When enabled by the parameter Flux Table Enable 3132 the flux demand it set by the flux demand at each speed setpoint and linear interpolatio...

Page 134: ...ux at lower speeds than rated Once the motor voltage is achieved it is held at this point for higher speeds at reduced flux This feature is set by the parameter Speed at rated volts ID 3145 and can be used with or without the Adjustable Flux Demand table provided the table is set up properly Essentially this feature sets the point at which field weakening begins Parameter Assignment Addressing 6 8...

Page 135: ...percent of speed Flux 2 0 spd 3137 1 00 0 15 2 0 Flux demand at 2 0 percent of speed Flux 2 5 spd 3138 1 00 0 15 2 0 Flux demand at 2 5 percent of speed Flux 5 0 spd 3138 1 00 0 15 2 0 Flux demand at 5 0 percent of speed Flux 10 0 spd 3140 1 00 0 15 2 0 Flux demand at 10 0 percent of speed Flux 15 0 spd 3141 1 00 0 15 2 0 Flux demand at 15 0 percent of speed Flux 20 0 spd 3142 1 00 0 15 2 0 Flux d...

Page 136: ...g prop gain 3260 0 5 0 0 5 0 Current PI regulator proportional gain term Current reg integ gain 3270 25 0 0 0 6000 0 Current PI regulator integral gain term Current reg prop gain2 3271 0 5 0 0 5 0 Current PI regulator second proportional gain term Current reg integ gain2 3272 25 0 0 0 6000 0 Current PI regulator second integral gain term Prop gain during brake 3280 0 16 0 0 5 0 Current PI regulato...

Page 137: ...s enabled Adjust for a different torque pulsation frequency The control always recalculates the desired value due to limited resolution Adjust to avoid mechan ical resonance frequencies Brake power loss 3390 0 25 0 0 50 0 Amount of high frequency losses at the onset of braking Affects the limit of the Vq component of output braking voltage VD Loss Max 3400 pu 0 25 0 0 0 5 Max amplitude of the loss...

Page 138: ...trictions for dual frequency operation When AFE or six step regeneration are enabled DFB is disabled Table 6 60 Control Loop Test Menu 3460 Parameters Parameter ID Unit Default Min Max Description Test type 3470 Speed Select the type of loop test desired Speed Torque Test positive 3480 30 0 200 0 200 0 Positive going limit of the test waveform Test negative 3490 30 0 200 0 200 0 Negative going lim...

Page 139: ...h the drive be gins following the speed command Exit point 4020 150 0 0 0 275 0 Set the percent of speed command at which the drive stops following the speed command Entry speed 4030 0 0 0 0 200 0 Set the speed command to which the drive accelerates when given a start command when the speed profile func tion is enabled Exit speed 4040 150 0 0 0 275 0 Set the speed command that the drive reaches at...

Page 140: ...r analog input 1 setup See Table Analog Input 1 Menu 4100 Analog input 2 4170 Submenu Access menu for analog input 2 setup See Table Analog Input 2 Menu 4170 Analog input 3 4232 Submenu Access menu for analog input 3 setup See Table Analog Input 3 Menu 4232 Analog input 4 4332 Submenu Access menu for analog input 4 setup See Table Analog Input 4 Menu 4332 Analog input 5 4341 Submenu Access menu fo...

Page 141: ... for analog input 1 0 to 20 mA 4 to 20 mA 0 to 10 V 10 V to 10 V Note This option is not allowed to be selected if the analog source is one of the internal I O inputs Min input 4120 0 0 300 0 300 0 Minimum analog input Max input 4130 100 0 300 0 300 0 Maximum analog input Loss point threshold 4140 15 0 0 0 100 0 Threshold where loss of signal action is activated Enter as a percentage of upper rang...

Page 142: ...ect loss of signal action Preset Maintain Stop Loss of signal set point 4230 20 0 200 0 200 0 Loss of signal preset speed Table 6 65 Analog Input 3 Menu 4232 Parameters Parameter ID Unit Default Min Max Description Source 4233 Off Set the input source for analog input 3 Off Ext 1 to 24 Int 1 to 12 See Table Pick list for Analog Input Sources Type 4234 4 20 mA Set the operational mode for analog in...

Page 143: ...g input 4 0 to 20 mA 4 to 20 mA 0 to 10 V 10 V to 10 V Note This option is not allowed to be selected if the analog source is one of the internal I O inputs Min input 4335 0 0 300 0 300 0 Minimum analog input Max input 4336 100 0 300 0 300 0 Maximum analog input Loss point threshold 4337 15 0 0 0 100 0 Threshold where loss of signal action is activated Enter as a percentage of upper range for any ...

Page 144: ...gnal action is activated Enter as a percentage of upper range for any type Loss of signal action 4347 Preset Select loss of signal action Preset Maintain Stop Loss of signal set point 4348 20 0 200 0 200 0 Loss of signal preset speed Table 6 68 Auxiliary Input 1 Menu 4500 Parameters Parameter ID Unit Default Min Max Description Source 4510 Off Auxiliary input 1 source Off Ext 1 to 24 Int 1 to 12 S...

Page 145: ...ption is not allowed to be selected if the analog source is one of the internal I O inputs Min input 4610 0 0 300 0 300 0 Minimum auxiliary input Max input 4620 100 0 300 0 300 0 Maximum auxiliary input Loss point threshold 4630 15 0 0 0 100 0 Threshold where loss of signal action is activated Enter as percentage of upper range for any type Loss of signal action 4640 Preset Select loss of signal a...

Page 146: ...r Bip bipolar Full range 4660 4 n 1 4 0 0 0 0 300 0 Scale the output range of the selected variable Each analog output parameter 1 to 16 contains a submenu consisting of the following parameters Analog variable Output module type Full range The formulas presented in the ID column give you the direct ID number for the corre sponding analog output For example for analog output 4 The analog output ID...

Page 147: ...ange 4664 0 0 300 Scale the output range of the selected variable Table 6 74 Speed Setpoint Menu 4240 Parameters Parameter ID Unit De fault Min Max Description Speed setpoint 1 4250 rpm 0 18000 18000 Programmable speed setpoint1 Speed setpoint 2 4260 rpm 0 18000 18000 Programmable speed setpoint1 Speed setpoint 3 4270 rpm 0 18000 18000 Programmable speed setpoint1 Speed setpoint 4 4280 rpm 0 18000...

Page 148: ...0 98 996 Set the PID loop Derivative D gain Min clamp 4390 0 0 200 0 200 0 Set the minimum value for the PID loop integrator Max clamp 4400 100 0 200 0 200 0 Set the maximum value for the PID loop integrator Setpoint 4410 0 0 200 0 200 0 Set a value to be used as the reference setpoint for the external PID loop The value is set as a percent of full scale This parameter can be used instead of Analo...

Page 149: ...omparator Setup Submenus Comp n B in variable select list n 1 32 Manual value The comparator flag compar_n_f where n 1 16 in the System Program is set true if Comp n A in Comp n B in var iable select list Comp n manual value 0 0 Min 1 000 Max 1 000 Compare n type list n 1 32 Mag if n 1 Off if n 1 Compare n can be set to the following signed e g 10 50 magnitude e g 50 10 disabled no compare is done...

Page 150: ... Analog Input 11 Analog Input 12 Magnetizing Current Ref Ids Ref Internal Analog Input 12 Analog Input 13 Magnetizing Current Ids Analog Input 14 Torque Current Ref Iqs Ref Analog Input 15 Torque Current Iqs Analog Input 16 Input Frequency Parameter Assignment Addressing 6 11 Options for Auto Menu 4 NXGPro Control Manual 148 Operating Manual A5E50491925A ...

Page 151: ... Drive Protect Menu 7 Meter Menu 8 Communications Menu 9 Security Edit Functions Menu 5000 Parameter Default File Functions Language and Security Functions Note Description of menu options The contents of menus 1 to 9 are explained consecutively in this chapter Refer to the appropriate section for descriptions of options within each menu You can access all of the menus directly using the keypad or...

Page 152: ...ons 9 Submenu Access the Communications Menu Security edit functions 5000 Submenu Access functions for editing a menu item s security codes Set current as default 5045 Submenu Set all default parameters to the current parameter settings Reset to defaults 5050 Submenu Reset all parameters to their factory defaults Select language 5080 Pick list Set language for keypad English default Italian future...

Page 153: ...anged while the drive is running 0 indicates that a parameter may be changed while the drive is running 1 indicates that a parameter may not be changed while the drive is run ning Change security codes 5090 Function Change the default security codes for the various security levels used by the drive See Section Security Access Levels and Codes This is how the parameter displays in the keypad CAUTIO...

Page 154: ...rive is configured for security level 7 access the Security Edit Menu 5000 is visible from the Main Menu 5 Functions within this menu are used to set the security levels for menu items hide menu items prevent changes to specific parameters The Security Edit Functions Menu 5000 contains security functions described in the table below Table 6 82 Default Security Access Levels and Access Codes Access...

Page 155: ...oad Level 7112 100 0 100 0 150 0 Cell current overload as a percentage of drive output rating allowed for 1 minute out of every 10 minutes Power Rollback Enable 7114 Enable Enable Disable Enable Transformer Secondary Power Roll back for bypass loading Auto reset ena ble 7120 No Enable the reset of the drive after a fault Auto reset time 7130 sec 1 0 120 Adjust the time between the fault and its au...

Page 156: ...Function Display the cumulative time under Cell OT Xformer OT Alarm Timer Note To be re leased in a lat er software version 7177 Function Display the cumulative time under Xfor mer OT alarm Parameter Assignment Addressing 6 14 Options for Drive Protect Menu 7 part 1 NXGPro Control Manual 154 Operating Manual A5E50491925A ...

Page 157: ...ex file to a USB connected disk drive Event Log 6180 Submenu Access menu for event log See Table Event Log Menu 6180 Alarm Fault Log 6210 Submenu Access menu for alarm fault log See Table Alarm Fault Log Menu 6210 Historic Log 6250 Submenu Access menu for historic log See Table Historic Log Menu 6250 Table 6 85 Event Log Menu 6180 Parameters Parameter ID Unit Default Min Max Description Upload eve...

Page 158: ...ble for the historic log 1 Historic log variable 4 6290 Pwr Out Select the 4th variable for the historic log 1 Historic log variable 5 6300 I Total Out Select the 5th variable for the historic log 1 Historic log variable 6 6310 Mag I Fdbk Select the 6th variable for the historic log 1 Historic log variable 7 6320 Mtr Flux Select the 7th variable for the historic log 1 Historic log upload 6330 Uplo...

Page 159: ... reactive power pu Drv Loss Internal drive power losses in pu of input power Xcess I Rct Excessive input reactive current above limit pu Spd Droop Speed droop pu Freq Out Output frequency pu Parameter Assignment Addressing 6 15 Options for Log Control Menu 6 NXGPro Control Manual Operating Manual A5E50491925A 157 ...

Page 160: ...is regulator is used to fault the drive in case high reactive currents flow in the in put other than when MV is applied to the drive Adjust the gain to change the re sponse to high reactive currents 1 Cycle Protect Limit 7081 50 0 0 0 100 0 Set the integrator output level at which the drive issues a 1 Cycle Protect fault Excess Loss Idle 7084 5 0 1 0 5 0 Set the excessive drive power loss level wh...

Page 161: ...eter ID Unit Default Min Max Description SPD prop gain 7020 0 0 0 0 10 0 Single phase detector PI regulator propor tional gain term SPD integral gain 7030 0 001 0 0 1 0 Single phase detector PI regulator integral gain term SPD threshold 7040 50 0 0 0 100 0 Regulator output level below which an alarm is generated Table 6 91 Drive Security Reset and Secure System Keys for USB flash disk Parameter ID...

Page 162: ...tion Secure USB Connection for secure USB system key details parameters 7749 7750 7751 and 7752 Parameter Assignment Addressing 6 16 Options for Drive Protect Menu 7 part 2 NXGPro Control Manual 160 Operating Manual A5E50491925A ...

Page 163: ...0 Input harmonics 8140 Submenu Access the input harmonics parameters See Ta ble Input Harmonics Menu 8140 Refer to chapter High Speed Recorder in the ToolSuite Pro Manual A5E03086439 for full descrip tion of the High Speed Recorder functionality High Speed Recorder Parameters 8220 Submenu Access High Speed Recorder parameters See Table High Speed Recorder Parameters Menu 8220 Fault display overrid...

Page 164: ...name of the display variable The content of the variable name column is displayed as you scroll through the list of available display variables The abbreviation column contains an abbreviation that is displayed after a variable is selected from the list The abbreviation is between 3 and 4 characters in length and is displayed on the front panel of the drive Table 6 94 Pick list variables for the f...

Page 165: ...Quadrature compo nent of the negative sequence input voltage responsible for input losses and heating VDIN Input D voltage Vrms Input voltage magnitude VQIN Input Q voltage V Input quadrature voltage This drives the input PLL A value that is too high implies the PLL is not locked onto the input voltage VAVI Input voltage V Input voltage 3 phase L L rms voltage FRIN Input frequency Hz KWIN Input po...

Page 166: ...current A Input reactive current over max allowed UXFR Up Transfer State value Up transfer state machine state variable DXFR Down Transfer State value Down transfer state machine state variable DRP Speed Droop Motor speed droop Speed slow down proportional to tor que current 7RS URZ RI GLVSOD VKRZV ILHOG QDPHV RWWRP URZ RI GLVSOD VKRZV G QDPLF YDOXHV L HG GLVSOD ILHOG 8VHU GHILQHG GLVSOD 9DULDEOH ...

Page 167: ...utput kW hour counter to a previous val ue when the microboard is replaced Reset output kWH meter 8070 Function Reset the output kW hour counter to zero Display input kWH meter 8072 Function Display the total input kW hours that have been ac cumulated since the drive was commissioned Preset input kWH meter 8074 Function Preset the input kW hour counter to a previous value when the microboard is re...

Page 168: ...anual A5E03086439 Fast Loop Re cording 8210 Selection Refer to section Recorder Operation in the ToolSuite Pro Manual A5E03086439 Enable Trigger ing 8211 Selection Refer to section Recorder Operation in the ToolSuite Pro Manual A5E03086439 Recorder Buffer Select 8212 Selection Refer to section Recorder Operation in the ToolSuite Pro Manual A5E03086439 Trigger Value 8213 Selection Refer to section ...

Page 169: ... the default configuration The Communications Menu 9 consists of the following menu options Network Control 9943 Network 1 Configure 9900 Network 2 Configure 9914 SOP Functionms 9110 TCP IP 9300 These menus are explained in the tables that follow Table 6 98 Communications Menu 9 Parameters Parameter ID Unit Default Min Max Description Serial port setup 9010 Submenu Access serial port setup paramet...

Page 170: ...s are not supported on newer drives fitted with NXGPro Controls or on older drives updated with NXGPro controls Table 6 100 SOP and Serial Functions Menu 9110 Parameters Parameter ID Unit Default Min Max Description System pro gram down load Note Not available in NXGPro 9120 Function Transfer the SOP to a USB connected disk drive System pro gram upload 9130 Function Transfer the SOP to a USB conne...

Page 171: ...B disk devices may not be compatible with NXGPro When attempting to upload information using a USB disk drive check the keypad display for a failure message such as An error has occurred or Error opening output file If the upload fails change the brand or type of USB flash disk and retry Refer to USB flash disk requirements Known Issues with USB flash disks and Keypad error messages for more infor...

Page 172: ...nd reboot the DCR For versions 8 1 0 and above the changes should take effect within a few seconds There is no need to reboot the DCR For all versions of NXGPro DO NOT USE the 192 168 1 xxx network range 192 168 1 1 through 192 168 1 255 for network configuration It will not work and ToolSuite access will be lost Access to ToolSuite iS recoverable via the Keypad Parameter Assignment Addressing 6 1...

Page 173: ...ged from the default setting or a if it has been changed from the default setting for example s9586 or 9586 Creating configuration files You can create configuration files at runtime in the drive s memory and then store them to the CompactFlash card Create slave files via the keypad menus To do so set the slave parameters as desired and write them to the CompactFlash card see Table Slave Setup and...

Page 174: ...he file names from a pick list or create new files as described Table 6 102 Slave Setup and Configuration Parameters Parameter ID Units Default Min Max Description Multiple config files 9185 Off Enable multiple configuration file opera tion Show active config file 9195 Display the current active configuration file on the flash disk Set active config file 9196 defaults sfg Set the displayed file to...

Page 175: ...imit 3 1230 0 Percent Break Point 1152 Regen torque limit 3 1240 10 Percent Break Point 1153 Phase Imbalance Limit 1244 17 Percent Break Point 1154 Ground Fault Limit 1245 25 Percent Break Point 1155 Ground Fault Time Const 1246 Drive Menu Control loop type 2050 Skip center freq 3 2370 Ratio control 2070 Skip bandwidth 1 2380 Speed fwd max limit 1 2080 Skip bandwidth 2 2390 Speed fwd min limit 1 2...

Page 176: ...in 3260 Slip constant 3545 Current reg integ gain 3270 Feed forward constant 3560 Prop gain during brake 3280 Auto Menu Entry point 4010 Delay on 4080 Exit point 4020 Prop gain 4360 Entry speed 4030 Integral gain 4370 Exit speed 4040 Diff gain 4380 Auto off 4050 Min clamp 4390 Delay off 4060 Max clamp 4400 Auto on 4070 Setpoint 4410 Log Control Menu Historic log variable 1 6260 Historic log variab...

Page 177: ...monics order 8160 Customer drive 8110 Harmonics integral gain 8170 Selection for HA 8150 Fault display override 8200 Parameter Assignment Addressing 6 19 Options for Multiple Configuration Files NXGPro Control Manual Operating Manual A5E50491925A 175 ...

Page 178: ...Parameter Assignment Addressing 6 19 Options for Multiple Configuration Files NXGPro Control Manual 176 Operating Manual A5E50491925A ...

Page 179: ...f the drive General and application specific drive features are covered Where applicable the functions are described by listing first the feature and then the associated menu parameters For more advanced drive features refer to Chapter Advanced Operating Functions NXGPro Control Manual Operating Manual A5E50491925A 177 ...

Page 180: ...ivided left to right by the direction of rotation and from top to bottom by the polarity of the torque in the machine Energy flow from the drive into the machine is called motoring Energy flow out of the machine and into the drive is called regeneration or braking Quadrants I and II represent the forward motoring and braking quadrants respectively QuadrantsIIIandIVrepresentthereverse motoringandbr...

Page 181: ...tion Once the motor is rotating in the forward direction if the applied torque becomes negative the quadrant will switch over into quadrant II showing that a negative torque produces negative acceleration i e deceleration which will stop the motor If however the same torque is applied continuously the speed of the motor will decrease to zero and begin to accelerate in the opposite direction produc...

Page 182: ... injection frequency must always be opposing the direction of rotation and is only used in the case of braking or negative energy flow Therefore it is zero in the motoring quadrants I and III and is the inverse polarity of the electrical frequency in the braking quadrants II and IV See Table Signal Polarities Operating the Control 7 2 Frame of Reference NXGPro Control Manual 180 Operating Manual A...

Page 183: ...al frequency ωs The electrical polarity is uncertain for the electrical frequency ωs in the braking quadrants II and IV where the slip opposes the rotational speed when the speed magnitude approaches the slip magnitude The sign will match that of the slip rather than the sign of the rotor speed when the slip magnitude is greater than the rotor speed This is due to the relationship between slip and...

Page 184: ...ays a drive fault Fast bypass issues an automatic reset to the drive after the cell has successfully bypassed Drive trip When the drive trips and stops delivering torque to the motor the motor acts like a generator and produces a voltage on the drive output terminals This voltage decays over time but can be near the drive rated output voltage for a few seconds If a cell is bypassed the remaining c...

Page 185: ...arameter Forced Cell Fault ID 2639 Two levels of security must be used to activate this feature The Factory or Siemens authorized personnel must have access to allow it to work at both Idle and Run drive states Since this could cause a problem while running it is not available for general purpose The customer has access when the drive is at Idle only and only in Level 7 security If an attempt is m...

Page 186: ...pass function if it is used for testing purposes only and no permanent cell fault exists This function is labeled Reset bypassed cells ID 2640 and is set to Level 7 security It cannot be invoked while the drive is running If the number of cells required for operation Permitted Min cell count ID 2541 is changed then the drive must re initialize cell diagnostics This automatically resets cells force...

Page 187: ...can be detected activates the mechanical bypass function Even a failure in the fiber optic link that communicates to the cell can be detected and bypassed Note Cell bypass limitations Cell bypass is limited to allow no more than nine cells at a time to be in bypass Attempting to bypass more than 9 cells will result in a bypass fault 7 4 4 Neutral Point Shift during Bypass U11 Neutral point shift e...

Page 188: ...mands to the three phase groups of cells will have phase A displaced from phase B by 120 and from phase C by 120 r W S 1 9 9 9 Figure 7 3 15 Cell Drive Simplified Drive output with two cells bypassed When cells are bypassed in one of the drive phases the output voltage will become imbalanced This example shows a 15 cell drive after bypass of two cells in phase A 87 of the cells are in use but the ...

Page 189: ...advantage of the fact that the star point of the cells is floating and is not connected to the neutral of the motor Neutral shift shifts the star point of cells away from the motor neutral adjusts the phase angles of the cell voltages helps to obtain a balanced set of motor voltages even though the cell group voltages are not balanced This approach is equivalent to introducing a zero sequence comp...

Page 190: ... functional cells would be bypassed in phase A Only 60 of the original cells would remain in use and only 60 of the original voltage would be available With neutral shift only the failed cells are bypassed The phase angles of the cell voltages have been adjusted so that phase A is displaced from phase B by 96 9 and from phase C by 113 1 instead of the normal 120 The star point of the cells no long...

Page 191: ...y 40 of the original voltage would be available With neutral shift only the failed cells are bypassed The phase angles of the cell voltages have been adjusted so that phase A is displaced from phase B by 61 1 and from phase C by 61 6 The star point of the cells is far removed from the neutral of the motor voltages but the motor voltage is balanced 67 of the cells are in use and 50 of full voltage ...

Page 192: ... capability of a drive after cell bypass can be calculated using the following calculation If X is the largest number of cells in bypass in two of the phases then the maximum voltage at the drive output will be Vout_bypass Vout 2 N X 2 N where Vout is maximum output voltage that the drive can deliver Vout 1 78 N Vcell N is the number of ranks i e number of installed cells 3 N Vcell is the cell vol...

Page 193: ...this information to automatically calculate the phase angles of cell voltages in order to maintain balanced motor voltages During neutral shift each phase of the drive operates with a different power factor Under lightly loaded conditions one or more phases may absorb real power while the other phase s are delivering power to the motor An increase of the cell dc voltage in the cells that are absor...

Page 194: ...d the motor flux level is automatically increased to maintain 70 power factor until rated flux or maximum possible flux is achieved This function ensures that the cells are delivering real power under all operating conditions Note Impact of load changes on drive response The response of the drive to sudden load changes is reduced with lower flux demand Setting Energy Saver Control Parameter Refer ...

Page 195: ...splay parameters refer to Table Pick list variables for the front display in the same section Note Software Model Estimate This software model does not measure the motor temperature directly but only estimates it from available data The estimate is no better than the available data and no better than the accuracy of the parameters entered In particular the software model has no data about the ambi...

Page 196: ...50 Speed derate curve 1151 Maximum motor inertia 1159 You may select one of four options for the overload select parameter for motor protection Constant Mode The first option constant is based on the current flowing into the motor A Motor Thermal Overload Alarm 1 of an impending overload fault is issued as a warning when the motor current exceeds the overload pending parameter A Motor Thermal Over...

Page 197: ...evels are in PU temperature and as such do not increase rapidly Therefore these parameters should not be adjusted from default unless absolutely necessary and only with a full understanding of the impact Raising them could result in defeating motor protection 0RWRU YROWDJHV FXUUHQWV 0RWRU ORVV FDOFXODWLRQ 0RWRU SDUDPHWHUV 0RWRU FRROLQJ PRGHO 6SHHG GHUDWH FXUYH 0RWRU WHPSHUDWXUH ː 07 Figure 7 10 Mo...

Page 198: ...ecreases in efficiency with speed This could lead to overheating of the motor and lack of protection Enter the allowable motor load curve values for various speed breakpoints via the keypad The default derating curve provides breakpoints for a quadratic cooling curve 6SHHG 0D 0RWRU RDG Figure 7 11 Default speed derating curve showing maximum motor load as function of speed The motor manufacturer n...

Page 199: ...to motors that are beyond the range of the NEMA table Therefore use this algorithm on out of range motor sizes only This algorithm uses the integration of power over the nominal load capability to determine the energy flow balance At rated conditions the system will be at equilibrium and can run continuously at this point provided the motor is running at or below rated current and voltage and the ...

Page 200: ...sed to characterize the derating based on the loss of cooling via an internal rotor based cooling fan on the shaft Overload select 1130 this parameter includes two additional pick list items Legacy TOL and Legacy TOL with derate When changing to either mode the TOL integrator resets to zero The following figure shows the typical TOL relay response in the inverse time graph of Motor Current overloa...

Page 201: ...rip time Itimeout menu trip time TI overload time to trip from table or figure at the overload amount used A first alarm occurs when the Tovld 0 75 TTimeout A second alarm occurs when the Tovld 0 90 TTimeout Trip occurs when Tovld TTimeout resulting in a TOL fault There is hysteresis on both alarms but not on the fault Thermal Memory Retention The system incorporates a feature that retains the the...

Page 202: ... When this occurs the algorithm will capture and store the torque command from the limit logic and use this as the starting point snapping to the IdsRef magnitude immediately then ramping down the torque limit toward the minimum level The torque limit continues to ramp down as long as two or more OT alarms are active and until the lower programmable limit is reached Once the alarm conditions have ...

Page 203: ...1R WRUTXH OLPLW 0LQLPXP UROOEDFN OHYHO ODUPV FWLYH ODUPV 5HVHW ODUPV FWLYH ODUPV 5HVHW Figure 7 14 OT Rollback Action Operating the Control 7 8 Thermal Over Temperature Rollback NXGPro Control Manual Operating Manual A5E50491925A 201 ...

Page 204: ... THD which is 1 above 60 of rated power Table Symbols used in Figure Input Side Monitoring lists symbols used in the following figure and describes the parameters they represent The definitions of Id and Iq components of the input current are different from the output side quantities Input side monitoring allows the drive to protect the secondary side of the transformer from abnormal conditions Ex...

Page 205: ...oring Table 7 2 Symbols used in Figure Input Side Monitoring Name Description Erms Average rms voltage of all three phases Ed Amplitude of voltage taking the transformer tap setting into account This represents the actual voltage being provided to the cells If the tap setting is 5 Ed will be 5 smaller than Erms and vice versa Ea b c Zero sequence DC offset corrected input phase voltages ωu Input f...

Page 206: ...from causing nuisance trips Implementation The following figure shows the implementation of one cycle protection 7UDQVIRUPHU 0RGHO FOH 3URWHFW LPLW DXOW 2QH F FOH PD LPXP UHDFWLYH FXUUHQW DW LGOH GHIDXOW LV 7UDQVIRUPHU SURWHFWLRQ FRQVWDQW JDLQ 5HDO 5HDFWLYH 5HDFWLYH 0D JDLQ 2QH F FOH SURWHFWLRQ LQWHJUDO JDLQ 7ULS WKUHVKROG FOH 3URWHFW LPLW T0D ː WU WU T0D JDLQ Figure 7 16 Implementation of One Cyc...

Page 207: ... above the slow loop is 1 10 of Fsamp 7 9 3 Protecting Transformer by Limiting Secondary Currents Normally a GH180 drive is designed such that the transformer secondary windings cannot be overloaded However in some instances drives have been provided with bypass but not cell redundancy In this case bypass allows for continued drive operation but the output power must be reduced to limit the load o...

Page 208: ... load types The rollback function will revert to rated torque below this speed no reduced torque limit The torque current will be limited to 5 below the fault level as the smaller value during rollback for the same reason Rollback Removal Power Rollback Enable 7114 may be set to disable to prevent the transformer secondary protection algorithm from affecting the torque delivered to the motor If ro...

Page 209: ...022 in kVA Harmonic loading factor Harmonic Load Factor ID 2024 Excessive secondary power loading rollback enable Power Rollback Enable ID 7114 turns off the rollback and relies on alarm and fault instead default is Enable Cell Overload Level 7112 Sets the upper limit of the integrator to not interfere with this feature Full load current 1050 motor rated current to calculate cell PU rated power Ce...

Page 210: ...r windings and at the same time is large enough to avoid nuisance trips When the drive is not supplying power to the motor the losses in the system are primarily due to the transformer the fixed limit is then lowered to increase the sensitivity of the protection routine An inverse power loss function is implemented for excessive drive loss protection The excessive drive loss algorithm is always en...

Page 211: ...rrent scaler 3030 Input voltage scaler 3040 Input CT turns ratio CT secondary turns 3035 Output scalers Output current scaler 3440 Output voltage scaler 3450 Low Freq Wo 3070 Implementation The following figure shows the implementation of the drive loss fault circuit QSXW 3RZHU 2XWSXW 3RZHU QSXW 7KUHVKROG QWHUQDO 7KUHVKROG DXOW ULYH RVVHV QYHUVH 7LPH LQ GOH 6WDWH LQ 5XQ 6WDWH ū ū Figure 7 19 Imple...

Page 212: ...rnal Threshold The internal threshold is a function of the rated drive input power For example in the run state the internal threshold is given as Internal Threshold Watts 0 07 rated Drive Input Power 0 07 3 Rated Input Voltage Rated Input Current Where Rated input voltage ID 2010 and Rated input current ID 2020 Parameters for Excessive Drive Losses Protection The running and idle setpoints can be...

Page 213: ...ells Arc flash detection is handled external to the control but a digital input must set SOP flag SystemArcFaultDetected_O to produce an error fault message and trigger an input protection This allows the drive to detect that the input protection has been triggered to record the event in the event and fault logs and that input power has been removed This SOP flag will trigger both an IP protection...

Page 214: ...his limit forces the drive to absorb power from the motor and maintain the cell DC bus voltages in case the input voltage recovers during MV ride through The limit is implemented as an inverse function of speed to maintain constant power flow to the cell DC bus A regulator is implemented to match the maximum drive power Pmax to the actual power flowing into the drive The output of this regulator s...

Page 215: ... to utilize the energy stored in the cells through short durations of less than 100 msecs to continue to supply positive torque at a reduced level to slow the collapse of the column of liquid Since the drive is still supplying positive torque this allows the drive to recover when voltage is restored in this time without waiting for the complete column to drain allowing for faster recovery than was...

Page 216: ...s a linear reduction as the unbalance voltage increases from 10 to 30 at which point the input has a single phase condition When the input line voltage unbalance increases above 30 the drive limits the amount of output power that can be delivered to the load to 40 of rated A regulator is implemented to match the maximum drive power Pmax with the actual power flowing from the drive The output of th...

Page 217: ...oolSuite 7 10 4 Transformer Thermal Rollback The input currents to the drive are monitored continuously The largest among the three input phase currents is limited to be at or below 105 of the nominal rating of the transformer Drive output torque is reduced when this current level is exceeded A regulator is implemented to limit the maximum input current to 105 by reducing the output current The ou...

Page 218: ...torque limit 2 1210 Motor torque limit 3 1230 Regen torque limit 1 1200 Regen torque limit 2 1220 Regen torque limit 3 1240 7 10 6 Field Weakening Limit The field weakening limit is a torque limit that is based on the motor flux and motor leakage inductance Under this condition the motor has limited torque capability This limit prevents the motor slip from exceeding pullout torque slip Therefore i...

Page 219: ...red on a drive The timers record the accumulative duration of multiple cell OT and transformer OT alarms The timers accumulate with one second resolution the amount of time that at least two cell OT or the single transformer first level alarms are active while the drive is in operation The timers record cumulative time similar to the kWHr recorder The timers activate on over temperature alarm cond...

Page 220: ...ected AND Ramp Stop not selected AND Run Request false Coast Stop for removing power to the motor quickly the load and motor will coast to rest based on friction and inertia Quick Stop not selected AND Ramp Stop not selected AND Run Request false 7 11 1 Analog Input Sources The control provides a means to provide multiple analog input sources that can be selected as demand inputs to the system The...

Page 221: ...tting SOP flag RawDemandPid_0 to true 2 The PID command feedback source is fixed from analog input 2 You can use any of the available analog inputs within the system but you must designate it as analog input 2 in the setup menu Refer to Analog Input 2 Menu 4170 in Section Options for Auto Menu 4 of Chapter Parameter Assignment Addressing 3 The PID command has two possible sources analog input 1 or...

Page 222: ...tem Jog Set to maximum active speed limit intended for test purposes to bump motor Communication Network Digital value as set per external communication interface to a PLC DCS 7 11 4 Speed Profile The speed profile uses the velocity demand signal as input and generates a modified best fit straight line BFSL velocity demand output Parameter for the Speed Profile Refer to Speed Profile Menu 4000 in ...

Page 223: ...ock is the opposite polarity of the input The selection of this feature is based solely on the SOP logic 7 11 7 Speed Ramp The speed ramp is a functional block that takes an input demand and generates an output with a controlled rate of change based on the acceleration and deceleration limits established by the end user Provisions are included for multiple sets of acceleration and deceleration set...

Page 224: ...re included for multiple sets of forward rotation maximum minimum limits and reverse rotation maximum minimum limits The control provides a means to use any one of three separate menu defined speed limit sets or PLC network control as selected by the SOP Operating the Control 7 11 Command Generator NXGPro Control Manual 222 Operating Manual A5E50491925A ...

Page 225: ...stands the VFD condition that has caused the general alarm to exist ProToPS Function In the ProToPS SOP all of the automatic roll back flags are turned off and both cell bypass and auto restart are implemented as standard The need to roll back is still necessary but the process operator is now responsible to implement a roll back as part of a process correction as opposed to having the VFD roll ba...

Page 226: ...ept is to provide the operator or the process program with a clear message indicating a status change in the VFD The WAGO I O system provides these five digital outputs The location of the outputs is maintained as a standard set of TB2 terminations ProToPS indicates the specific information on the VFD parameter change along with the general category information as a serial address across a serial ...

Page 227: ...each control loop is fixed internally in software and hence provides good performance in demanding applications Such a feature provides drive tuning without the need for an extensive adjustment procedure Although the auto tuning feature can be used with all induction motors there are some limitations Both stages of auto tuning can be performed with induction motors OLVC or CLVC When to use Auto tu...

Page 228: ...s are present on the drive outputs during both Stage 1 and Stage 2 of auto tuning Stay clear of drive outputs during auto tuning to avoid death or serious injury CAUTION Incorrect use of Stage 2 auto tuning Incorrect use will lead to drive instability Never use Stage 2 auto tuning with synchronous motors or when output filters are connected Only use Stage 1 auto tuning with synchronous motors SMC ...

Page 229: ...by the control 7 13 2 Spinning Load The spinning load feature allows the drive to determine the speed of a motor that is already rotating This allows the drive to apply output voltages at the same frequency as the rotating motor and minimize any chance of a speed or torque transient When to use Spinning Load Enable spinning load if any of the following operating modes or features are selected Fast...

Page 230: ...re during which a fixed level of current of varying frequency is applied to the motor This is set via the current level setpoint parameter 2450 The control monitors the measured motorflux When the motorflux exceeds a flux threshold set by the scan end threshold parameter 2440 the control assumes that the applied frequency is equal to the rotating speed of the motor This stage requires parameters t...

Page 231: ...ault in a truncated form to prevent event log overflow Significant events CPU bootup including installed NXGpro software version Medium voltage status Drive operating state changes e g idle magnetize run stop Precharge state changes Fault reset requests Complete pre charge sequence including success all states and faults Refer to Event Log Menu 6180 in Section Options for Log Control Menu 6 of Cha...

Page 232: ...nt log includes the option to copy and record the historic log so that all fault events are recorded The historic log is stored in memory with a total of 512 records Non volatile memory is used to store the most recent 78 records Snapshots are recorded at the slow cycle update rate Most snapshots are recorded before a fault occurs 20 snapshots are recorded after a fault occurs If parameter Store i...

Page 233: ...sponse for the various fault and alarm conditions WARNING High Voltages Disabling the drive does not necessarily remove voltage form the motor terminals The motor especially if spinning may have residual voltage on the terminals and anything connected to them Always adhere to the five safety rules and safety measures in Chapter Safety Notes Table 7 3 Fault alarm type and drive responses Type Drive...

Page 234: ... the RunRequest_I is maintained at the value true The FAULT RESET key of the keypad is also used to acknowledge alarms Table 7 4 Auto resettable faults Over Speed Fault Keypad Communication Encoder Loss Under Load Fault Network 1 Communication Loss of Signal 1 to 24 Output Ground Fault Network 2 Communication Int AI1 to AI12 Loss of Signal IOC Motor Over Volt Fault Loss Of Drive Enable Menu Initia...

Page 235: ... This chapter covers the NXGPro control related advanced operating functions of the drive Where applicable the advanced functions are described by listing first the feature and then the associated menu parameters NXGPro Control Manual Operating Manual A5E50491925A 233 ...

Page 236: ...f is generated from the output of the slip compensator The stator frequency ωout comes from phase lock loop an estimate of the actual stator frequency The frequency regulator is evaluated at 1 5 of the inner current loop update rate Advanced Operating Functions 8 2 Frequency Speed Regulator NXGPro Control Manual 234 Operating Manual A5E50491925A ...

Page 237: ...pes set the OverModulationEnable_O SOP flag true for overmodulation of cells To disable overmodulation set the OverModulationDisable_O SOP flag true Overmodulation may be used in place of standard modulation with the advantage that less cells are required A disadvantage of overmodulation is that it can increase output harmonics Advanced Operating Functions 8 3 Overmodulation NXGPro Control Manual ...

Page 238: ... 6 pole Motor A 6 pole motor rated for 60 Hz has a synchronous speed of 1200 rpm Enter the full load speed from the nameplate e g 1192 rpm to Full load speed parameter 1030 Sending a speed demand of 100 will produce a mechanical speed i e shaft speed of 1200 rpm with slip compensation This will result in a higher output electrical frequency to the motor to provide the necessary torque to achieve t...

Page 239: ...he torque necessary to produce that speed Limiting Frequency by Disabling SlipCompensation Slip compensation can be disabled to limit the motor to a specific electrical frequency Using the same example set the Full load speed parameter 1030 to 1200 rpm This disables the slip compensation by reducing equation 2 to produce a slip of zero Equation 3 and 4 reduce to 1 Slip 1200 1200 1200 0 2 SMOT fOUT...

Page 240: ...ors or rock crushers that are mechanically coupled to the same load Speed droop shares the load or current by decreasing the speed demand slightly as load increases Equilibrium is reached when the load is evenly shared between drives and or motors 0RWRU 6SHHG 7RUTXH XUUHQW 5HIHUHQFH 6SHHG URRS DLQ 6SHHG 5DPS 6SHHG 5HJXODWRU 6SHHG 5DPS 2XWSXW 6SHHG 5HIHUHQFH 6SHHG 5DPS QSXW 0HDVXUHG 7RUTXH XUUHQW F...

Page 241: ...eference λds ref is generated from the control s flux ramp The flux feedback λds comes from motor voltage D Q converter The flux regulator is evaluated at 1 5 of the inner current loop update rate Advanced Operating Functions 8 6 Flux Regulator NXGPro Control Manual Operating Manual A5E50491925A 239 ...

Page 242: ...rent as a linear function of Iq torque current The functionality of flux feed forward is essentially the same for both induction motors IM and synchronous motors SM The difference between the motor types is as follows IM compensate for leakage inductance losses only using parameter Leakage inductance 1070 to affect the amount of compensation SM compensate for the leakage inductance and a part of t...

Page 243: ...ed Forward Note Default Value for Saliency Constant Parameter 1091 Use the default value of 0 2 Only special cases may require changing the default value Consult Siemens customer service before changing from the default value Advanced Operating Functions 8 7 Flux Feed Forward NXGPro Control Manual Operating Manual A5E50491925A 241 ...

Page 244: ...r to the motor via the network register 8 8 2 External Flux Reference Parameters Parameters for External Flux Reference Location Drive Drive Protect Input Protect Parameters associated with external flux reference are detailed in the following table Parameter ID Units Default Min Max Description Global Data to Drive 9200 Sub menu Menu for Global registers for data sent to drive from the network Da...

Page 245: ...l frequency braking is another method to dissipate braking energy in the motor DFB provides higher torque per ampere than DC injection braking DFB permits continuous estimation of motor speed Like DC injection braking DFB is implemented in software and requires no additional hardware that can reduce the reliability of the drive Limitations of DFB When DFB is enabled the motor flux is reduced above...

Page 246: ... second ramp down It applies when the load inertia and load torque are those for which the motor is designed You can use DFB more frequently with lower values of load inertia and or smaller speed reductions Pulsation Frequency The second set of voltage vectors creates a counter rotating flux vector that produces high slip in the machine and generates these additional losses in the motor You can ad...

Page 247: ...VA2 is riding on the lower frequency waveform VA1 Figure 8 4 Dual Frequency Braking waveform The first vector set controls the torque and flux in the motor and is nearly synchronous The second vector set induces losses in the motor to absorb the braking power returned by the first vector set The amplitudes of the two vector sets are coordinated to best utilize the current and voltage limitations o...

Page 248: ... Parameters Parameters for DFB Refer to Braking Menu 3350 in Section Options for Stability Menu 3 of Chapter Parameter Assignment Addressing for parameters associated with this function Enable braking 3360 Pulsation frequency 3370 Brake power loss 3390 VD loss 3400 Braking constant 3410 Use these parameter settings to run the drive with DFB Choose a pulsation frequency that avoids the mechanical r...

Page 249: ...ng torque that can be achieved with DFB is lower than the values shown in the figure above Contact Siemens customer service with the motor related data listed below to determine the braking torque capability with a higher efficiency motor Information on critical frequencies will allow a selection for the torque pulsation frequency Table 8 1 Motor related data Rated HP Rated Voltage Rated frequency...

Page 250: ... configuration OV Rollback Function The OV rollback function limits the rise in the drive input voltage produced by regenerative current to prevent a cell DC bus overvoltage fault The output torque power reduces to a point that will not cause an overvoltage After this point is reached the torque limitation caused by the rollback is defeated and full braking torque is available NOTICE Limited drive...

Page 251: ...or enabling this rollback are as follows by priority The first two run the algorithm and the third is calculated by the limiting overvoltage algorithm Drive input power negative drive in regeneration only Drive is running in six step Drive input voltage is at or above 1 08 pu input voltage Pre charge is complete When this limit routine is active and its output is being used to limit regenerative t...

Page 252: ...r is aimed at fast braking action or fast deceleration action of the motors During braking the motor starts regenerating and as a result a large voltage is induced across the stator terminals The deceleration time required by the motor depends on the time required by the heat generated during regeneration to be dissipated For this purpose resistor banks are switched across the motors The resistor ...

Page 253: ...DO DQG WKHUPDO HQHUJ GLVVLSDWHG LQ WKH UHVLVWRU EDQN 5HVLVWRU DQN Figure 8 7 Dynamic Braking with External Resistors Advanced Operating Functions 8 11 Dynamic Braking with External Resistors NXGPro Control Manual Operating Manual A5E50491925A 251 ...

Page 254: ...late rating WARNING Electric Shock Hazard Protection of the transorbs in the attenuator circuit is violated by placing a third resistor inside the control cabinet in series with the medium voltage resistors If the protection of the transorbs in the attenuator circuit is violated dangerous voltages are introduced into the control cabinet which could cause death or serious injury Never place a third...

Page 255: ...operating at the sampling rate of the system This is typically 3 to 6 kHz or approximately 9 kHz for high speed motors Note The drive will switch to a higher sampling rate for high speed motors when either of two things occur if the motor rated frequency is set to 240 Hz or above or if the SOP flag HighSpeedInterruptEnable_O is set true To run at the higher sampling rate the high speed hardware in...

Page 256: ... feedback Ids comes from motor current D Q converter The magnetizing current regulator is evaluated at the inner current loop update rate This regulator is the innermost i e fastest control loop in the control operating at the sampling rate of the system This is typically 3 to 6 KHz or approximately 9 KHz for high speed motors Advanced Operating Functions 8 14 Magnetizing Current Regulator NXGPro ...

Page 257: ... The phase lock loop module is evaluated at 1 5 of the inner current loop update rate Motor terminal voltage feedback is integrated to provide a true flux feedback in volt sec units The PLL uses this to provide a flux vector phase reference for all internal motor control Advanced Operating Functions 8 15 Phase Lock Loop NXGPro Control Manual Operating Manual A5E50491925A 255 ...

Page 258: ...utput filter adds losses proportional to the square of the RMS output current The filter inductance is in series with the VFD output and motor load and can reduce the output voltage capability depending on the load power factor The filter also introduces an amplifying resonance which could limit the closed loop gain for high performance applications The filter consists of series inductors in each ...

Page 259: ...down transfers the output voltage of the VFD must match or exceed the amplitude of the line If the line is unstable with frequency and or voltage variations the VFD may not be able to synchronize and therefore transfer is inhibited Note Applications that use a synchronous motor In transfer applications where a synchronous motor is used the VFD must have control of the field supply with smooth tran...

Page 260: ...s low or when the VFD input is not energized Failure to ensure that this condition does not occur could result in severe damage to the VFD power cells 8 17 3 Synchronous Transfer Operation Generator Options and Potential Fault Conditions Verifying Command Generator Options Before attempting synchronous transfer examine the command generator options selected during pre synchronous transfer It is im...

Page 261: ...e timeout alarms may indicate that other conditions are causing the transfer to fail For example there are not enough active cells left in the drive to support the line voltage during down transfer In this case the drive sets the SOP flag InsufficientOutputVolts_I high 8 17 4 Input Output Signals for Synchronous Transfer L29 Input Output Signals for Synchronous Transfer Excluding standard run stop...

Page 262: ...firmed the drive output is immediately disabled and the state machine is set to the completed state The waiting for the transition to the transfer completed state to remove the drive enable is eliminated This minimizes the amount of time that both sources are supplying the motor There are no other changes in the up transfer state machine The magnitudes of both the Id and Iq current feedback must b...

Page 263: ... motor This drop is detected as the line contactor open feedback Once detected the drive speed regulator and ramp is preset and then the output enabled quickly The drive then takes control in a manner similar to a spinning load catch Since the operation is so different from the normal Down Transfer sequence which is a make before break operation a new state machine is needed The choice of which do...

Page 264: ...ration For Induction Motors Up Transfer L29 Up Transfer of Induction Motor Up transfer takes the motor up to speed on the VFD to match the frequency of the line once the drive software receives the Up Transfer Request The drive software uses the drive input line frequency as a velocity reference Once the frequency is matched the phase also needs to be matched with a predetermined leading phase to ...

Page 265: ...issioning process 8 17 8 Synchronous Transfer Operation For Induction Motors Synchronous Transfer with Multiple Motors L29 Synchronous Transfer with Multiple Motors The drive can control multiple motors using synchronous transfer methodology In such applications the drive sequentially controls a series of motors one motor at a time 9 9 3 0 0 9 Figure 8 10 Multiple Motor Synchronous Transfer Figure...

Page 266: ...e Software As a rule the smallest motor rating should be greater than 50 of the ratings of the largest motor to ensure feedback signal integrity When mismatched motors are used the proper configuration file must be active for the subject motor 8 17 9 Synchronous Transfer Operation For Induction Motors The PLC Interface L29 PLC Interface VFD control is accomplished over a RS485 serial or Ethernet c...

Page 267: ... no PLC or by direct logic control 8 17 10 Synchronous Transfer Operation for Synchronous Motors L29 Synchronous transfer with a synchronous motor SM is essentially the same as with an induction motor IM with the addition of transfer of the control of the motor field winding excitor from or to the drive to or from an external source Also for synchronous transfer with SMs an analog signal from the ...

Page 268: ...ntactor is opened and the drive coast stopped to end the transition 8 17 12 Synchronous Transfer Operation For Synchronous Motors Down Transfer Preconditions L29 Down Transfer of Synchronous Motor Down transfer with synchronous motor control transfers a motor running directly connected to a power line to the control via the VFD The VFD output is synchronized with the line connected to the motor no...

Page 269: ...This signal goes to the PLC as the drive source for the field command 3 Set SOP flag EnableAnalog4_O to true and select the Loss of Signal LOS action 8 17 13 Synchronous Transfer for Permanent Magnet Motors PMM NOTICE Potential Damage to Motor Line operation for a PMM is not recommended as there is no protection for the motor for pole slippage Use of synchronous transfer with a PMM could result in...

Page 270: ...ter Parameter Assignment Addressing for parameters associated with this function 8 17 15 Pre charge using Dedicated I O 8 17 15 1 Electric Shock Hazard DANGER Electric Shock Hazard During pre chargeelectric shock hazardDuring pre charge medium voltage is present on the primary side of the input transformer and upstream device even though the MV contactor is not closed Stay clear of the primary sid...

Page 271: ...for controlling all contactors Type 5 and 6 pre charge read inputs and control outputs directly with no intervention from the SOP The only exception is the StartCellPrecharge_O flag to start pre charge once the drive is ready to pre charge DriveReadyToPrecharge_I is true Note Water cooled 750 V AP type cells must use type 5 open or type 6 closed pre charge Other drive types may use type 5 open or ...

Page 272: ...erwise the DriveReadyToPrecharge_I flag is set false Therefore this flag should be used as part of the conditions to start pre charge Precharge cannot be initialized or started if this flag is not true Once precharge commences the flag goes false and remains false until all conditions are again met When all conditions are met the pre charge state machine advances from the initial state of PRECHARG...

Page 273: ...eDisable_O is false No pre charge circuit breaker alarm active Internal I O for M1 is working if an input breaker exists No pre charge contactor alarm active No pre charge main contactor fault No input protection fault Drive has an input breaker M1 Drive Has Input Breaker 7127 Precharge has not been attempted more than 5 times per hour and not within the past minute if enabled Pre charge sequence ...

Page 274: ...state advances to M1_CLOSE 7 Secondary M1 close command CIMV DO 15 J4 7 8 9 CIMV for Gen4e precharge type 4 is iss ued and the state advances to WAIT_FOR_M1_ACK Event log Precharge Waiting for M1 to close 8 While waiting for M1 to close M1 ACK PrechargeM1CloseAck_O the excessive drive loss decay curve is reset Event Log M1 Closed waiting for transformer voltage to rise Also it allows 5 seconds for...

Page 275: ...t to enable the precharge limiting algorithm PrechargeComplete_I Indicates that precharge is completed M1 closed and MV above 80 CimvPulsedOutputEnable_O Set this true if CIMV requires a pulsed output Dedicated I O used in Precharge Output to M1 Permissive SIB 51 53 55 TIMV Output to close M1 DO 14 J4 7 8 9 CIMV Pulsed or maintained SOP selection for pulsed Output to trip LFR DO 15 J4 10 11 12 LFR...

Page 276: ...ugh the pre charge circuit breaker when M4 closes The time M3 is closed is extended by holding off the closing of the M4 contactor The parameter Prechrg M4 Holdoff time ID 2633 may be used to specify the amount of time M3 is closed during pre charge Parameter 2633 may be adjusted from 0 to 10 seconds where the default value is 0 seconds which is the value used for the standard pre charge arrangeme...

Page 277: ... are met the pre charge state machine advances from the initial state of PRECHARGE_FAULTED through INIT_PRECHARGE2 into the PRECHARGE_READY state The loss of the DriveReadyToPrecharge_I flag causes the state machine to cycle back to INIT_PRECHARGE2 until the drive is ready Type 5 or 6 pre charge selected Drive not running MV is low not OK Output to M1 Permissive is open DO 2d P14 TIMV Output to cl...

Page 278: ...or any of the above conditions are not met 8 17 15 6 Type 5 Open Pre charge Type 5 pre charge controls the main contactor M1 and uses three pre charge contactors M2 M3 and M4 It is designed so that M1 will not close until after M4 opens This designates type 5 pre charge as a break before make or open pre charge type Type 5 pre charge can be implemented only with the user I O board due to the dedic...

Page 279: ...d on the right side is the connection to the pre charge secondary windings of the input transformer Voltage during pre charge is monitored through the input attenuators on the primary side of the transformer The M1 contactor connects the MV source to the primary The pre charge contactors are controlled directly by the NXGpro code and require no SOP interaction with the exception of the start pre c...

Page 280: ...echargeNeedsReset_I becomes true when pre charge is in this state The flag is reset once the drive receives a fault reset You can use this as an indicator that a fault exists but do not use to directly issue a fault reset 1 Drive starts with pre charge state machine set at pre charge faulted and all contactors are commanded open When all conditions are met it passes through pre charge initializati...

Page 281: ...hen the M4 contactor will not be commanded closed until after the hold off time delay 11 M4 is closed M3 is commanded open This sequence must complete in 30 seconds or a timeout will occur resulting in a pre charge fault 12 The drive then waits for cell diagnostics to complete If a cell is faulted pre charge waits for a fault reset The fault reset only acknowledges the fault and cell diagnostics e...

Page 282: ...vent discharge of the cell capacitors and must be closed before a low cell bus voltage alarm is received 16 Once the M1 acknowledge is received pre charge is complete and the drive is connected to the MV source and ready to run The pre charge state machine is exited and the exit state is recorded in the event log along with all other recorded pre charge events in the sequence Note The drive run is...

Page 283: ...ed personnel are authorized to change drive parameter settings See also Pre charge using Dedicated I O Page 269 8 17 15 7 Type 6 Closed Pre charge Type 6 pre charge is used primarily for water cooled SINAMICS Perfect Harmony drives but can be used with any drive It uses four contactors M1 M2 M3 and M4 It is designed so that M4 will not open until M1 closes This designates type 6 pre charge as a ma...

Page 284: ...ection of capacitors resistors and contactors mounted in the Fuse Pre charge Control FPC cabinet on the input section of the drive 3 DELQHW 7UDQVIRUPHU DELQHW 0 0 0 Figure 8 14 Type 6 Pre charge Circuit Schematic Located on the left side is the low voltage pre charge source coming in through the pre charge circuit breaker Located on the right side is the connection to the pre charge secondary wind...

Page 285: ...are controlled directly by the NXG code and require no SOP interaction with the exception of the start pre charge command 7UDQVIRUPHU ZLWK 9 VRODWHG 6HFRQGDULHV QGXFWLRQ 0RWRU HOO HOO HOO QSXW 3RZHU SKDVH QSXW 3RZHU SKDVH HOO HOO HOO HOO HOO HOO HOO HOO HOO 3UHFKDUJH 9ROWDJH 2KP SHU SKDVH 0 SHU SKDVH WR 9 SKDVH 6RXUFH 3UHFKDUJH XUUHQW 3UHFKDUJH LQGLQJ 0 0 0 0 9 Figure 8 15 Type 6 Pre charge Compon...

Page 286: ...e machine 5 M1 is confirmed open M2 is commanded to close 6 With M2 closed the drive input voltage climbs The drive waits until 90 of rated voltage is achieved The pre charge capacitors provide a resonant circuit with the input inductance allowing a lower secondary input voltage to charge to 90 of rated drive input voltage through the secondary 7 When the input voltage reaches 60 of rated cell dia...

Page 287: ... of the following conditions occur overvoltage fault cell under voltage fault input protection fault pre charge is aborted MV falls below 60 as read through the input attenuators The drive waits until the cell fault is reset Note Fatal Fault SOP Flag Any cell fault is a fatal fault and will set the FatalFault_I SOP flag Do not use this flag to remove the pre charge enable flag StartCellPrecharge_O...

Page 288: ... breaker is matched in frequency voltage and phase Software sync checking may be enabled to replace the external In Sync signal Sync checking can be enabled disabled with parameter 2631 Sync Check Enable The software will measure the frequency phase and magnitude of pre charge input and output voltages If the frequencies are equal if there are valid voltages and if the phase difference magnitude i...

Page 289: ... 6 pre charge Refer to Cell Menu 2520 in Section Options for Drive Menu 2 of Chapter Parameter Assignment Addressing for parameters associated with this function For normal operation Pre charge Enable 2635 to Type 6 Closed Use type 6 pre charge for any cell type but cell voltages 2550 750V AP and 750V AP 4Q must use either type 5 or type 6 pre charge These are the two settings that are defined for...

Page 290: ...eReadyToPrecharge_I is false an alarm Not ready to precharge is set and displayed on the keypad The alarm will be cleared when the DriveReadyToPrecharge_I condition is valid again but must be acknowledged as with other alarms Therefore this flag should be used in the logic to create the precharge attempt These conditions define the alarm active Alarm active when precharge enable is true drive is n...

Page 291: ...e state machine advances from the initial state of INIT_PRECHARGE into the WAIT_FOR_VOLTS state and pre charge becomes active The loss of the DriveReadyToPrecharge_I flag causes the state machine to remain in the INIT_PRECHARGE state until the drive is ready and the PrechargeStartEnable_O flag is set true Type 1 2 or 3 pre charge selected Drive not running MV is low not OK Output to M1 Permissive ...

Page 292: ...le limiting the inrush to both the transformer and the cell capacitors The voltage must be carefully monitored to prevent the cells from overvoltage To prevent cells from overvoltage a resistor circuit is connected through contactor M3 when the highest of the three input phase voltages measured on the primary of the input transformer reaches 95 of rated voltage The resistor overdamps the pre charg...

Page 293: ...capacitor in series with the secondary PrechargeM2Close_I is set equal to true 3 When the input primary voltage reaches the max phase voltage set by the parameter Precharge voltage level 2634 a damping resistor is connected through M3 PrechargeM3Close_I is set equal to true 4 The M3 acknowledge comes back PrechargeM3CloseAck_O is set equal to true M2 contactor is commanded to open PrechargeM2Close...

Page 294: ...emoval of pre charge start enable before the cycle completes All handshaking must follow the sequence of operation 8 18 5 Type 2 Open Pre charge 6SR325 Type 2 pre charge uses a resonant circuit Type 2 pre charge avoids inrush into the cells it does not prevent input transformer inrush This pre charge type has a break before make open contactor sequence that does not require close synchronization b...

Page 295: ...s Sequence of Operation 1 To start pre charge DriveReadyToPrecharge_I must be true PrechargeStartEnable_O is set true to start the sequence 2 M2 is closed to begin resonance by connecting a capacitor in series with the secondary PrechargeM2Close_I is set equal to true 3 When the input primary voltage reaches the max phase voltage set by the parameter Precharge voltage level 2634 M2 contactor is co...

Page 296: ...e the cell voltage gradually Pre charge of this type requires that the input source i e output of exciter power supply or independent source be rated with high enough voltage to reach the level set by the parameter Precharge voltage level 2634 of rated input voltage under all conditions without exceeding the pre charge trip voltage Two input sources can be used each is addressed according to its c...

Page 297: ...e sequence 2 M2 is closed to connect a resistor in series with the secondary to limit in rush to the cells PrechargeM2Close_I is set equal to true 3 When the input primary voltage reaches the level set by the parameter Precharge voltage level 2634 M2 is commanded to open PrechargeM2Close_I is set equal to false 4 The M2 acknowledge comes back PrechargeM2CloseAck_O is set equal to true M1 contactor...

Page 298: ...dy to run PrechargeDriveEnable_I is set equal to true Note Pre charge faults The following conditions will result in a pre charge fault failure to follow the sequence failure to leave a minimum of 250 msec between receiving a response and issuing the next command removal of pre charge start enable before the cycle completes All handshaking must follow the sequence of operation Advanced Operating F...

Page 299: ... hour will produce the message Precharge too often more than 5 per hour Both messages will appear in the event log along with the not ready alarm message Should a precharge attempt be made when DriveReadyToPrecharge_I is false an alarm Not ready to precharge is set and displayed on the keypad The alarm will be cleared when the DriveReadyToPrecharge_I condition is valid again but must be acknowledg...

Page 300: ...dded to the new drive with an open transference of power from the precharge source to the line The main purpose was to limit inrush current by limiting the charging current for the capacitors while not eliminating the inrush to the transformer For this package a damping resistor was not used For consistency the M1 contactor operation is the same as used in type 5 6 precharge However the other inpu...

Page 301: ...ltage Trip PCVMRStatus_O Input Protection Fault LFR Trip E Stop PB 4 M2 Contactor Open Status Failure Trip_CB2 is asserted TripPrechargeCB2_O through the SOP The CB trip can only be controlled via the setting of an SOP flag ClosePrechargeCB_I to trip the CB To simplify this flag will be used so that the desired action can be set to a single output point In addition to being triggered by an interna...

Page 302: ...e true the state advances to the PRECHARGE_READY state to wait for the precharge start Losing the Ready status will reset the state machine to INIT_PRECHARGE2 4 When the StartCellPrecharge_O is set true from the PRECHARGE_READY state it commands M2 to close connects capacitor PrechargeM2Close_I is set true and advances to the M2_CLOSE state Event Logs Precharge Start type 4 open Precharge Close M2...

Page 303: ...ete Event Log Precharge complete No errors 10 Once in the Precharge complete state is achieved it will be maintained until reset in the fault loop The precharge state machine will no longer run or check for errors The error checking is turned over to the normal fault detection The StartCellPrecharge_O signal should be removed at this point 11 If the CimvIsPulsed_O flag is true the CIMV close comma...

Page 304: ...harge sequence through an externally connected monitor or through the Debug Tool set to the Drive Misc Status Flags 2 using Ctrl Y on the keyboard or menu selection in the tool Note Operating pre charge applications with inductor usage In some applications the pre charge capacitors have been replaced with inductors In these applications it may be necessary to operate pre charge Type 5 and Type 6 w...

Page 305: ...met the pre charge state machine advances from the initial state of PRECHARGE_FAULTED through INIT_PRECHARGE2 into the PRECHARGE_READY state The loss of the DriveReadyToPrecharge_I flag causes the state machine to cycle back to INIT_PRECHARGE2 until the drive is ready Type 5 or 6 pre charge selected Drive not running MV is low not OK Output to M1 Permissive is open DO 2d P14 TIMV Output to close M...

Page 306: ...any of the above conditions are not met 8 19 6 Type 5 Open Pre charge Type 5 pre charge controls the main contactor M1 and uses three pre charge contactors M2 M3 and M4 It is designed so that M1 will not close until after M4 opens This designates type 5 pre charge as a break before make or open pre charge type Type 5 pre charge can be implemented only with the user I O board due to the dedicated I...

Page 307: ...the right side is the connection to the pre charge secondary windings of the input transformer Voltage during pre charge is monitored through the input attenuators on the primary side of the transformer The M1 contactor connects the MV source to the primary The pre charge contactors are controlled directly by the NXGpro code and require no SOP interaction with the exception of the start pre charge...

Page 308: ...geNeedsReset_I becomes true when pre charge is in this state The flag is reset once the drive receives a fault reset You can use this as an indicator that a fault exists but do not use to directly issue a fault reset 1 Drive starts with pre charge state machine set at pre charge faulted and all contactors are commanded open When all conditions are met it passes through pre charge initialization 2 ...

Page 309: ...he M4 contactor will not be commanded closed until after the hold off time delay 11 M4 is closed M3 is commanded open This sequence must complete in 30 seconds or a timeout will occur resulting in a pre charge fault 12 The drive then waits for cell diagnostics to complete If a cell is faulted pre charge waits for a fault reset The fault reset only acknowledges the fault and cell diagnostics exits ...

Page 310: ...discharge of the cell capacitors and must be closed before a low cell bus voltage alarm is received 16 Once the M1 acknowledge is received pre charge is complete and the drive is connected to the MV source and ready to run The pre charge state machine is exited and the exit state is recorded in the event log along with all other recorded pre charge events in the sequence Note The drive run is inhi...

Page 311: ...personnel are authorized to change drive parameter settings See also Pre charge using Dedicated I O Page 269 8 19 7 Type 6 Closed Pre charge Type 6 pre charge is used primarily for water cooled SINAMICS Perfect Harmony drives but can be used with any drive It uses four contactors M1 M2 M3 and M4 It is designed so that M4 will not open until M1 closes This designates type 6 pre charge as a make bef...

Page 312: ...n of capacitors resistors and contactors mounted in the Fuse Pre charge Control FPC cabinet on the input section of the drive 3 DELQHW 7UDQVIRUPHU DELQHW 0 0 0 Figure 8 21 Type 6 Pre charge Circuit Schematic Located on the left side is the low voltage pre charge source coming in through the pre charge circuit breaker Located on the right side is the connection to the pre charge secondary windings ...

Page 313: ...ontrolled directly by the NXG code and require no SOP interaction with the exception of the start pre charge command 7UDQVIRUPHU ZLWK 9 VRODWHG 6HFRQGDULHV QGXFWLRQ 0RWRU HOO HOO HOO QSXW 3RZHU SKDVH QSXW 3RZHU SKDVH HOO HOO HOO HOO HOO HOO HOO HOO HOO 3UHFKDUJH 9ROWDJH 2KP SHU SKDVH 0 SHU SKDVH WR 9 SKDVH 6RXUFH 3UHFKDUJH XUUHQW 3UHFKDUJH LQGLQJ 0 0 0 0 9 Figure 8 22 Type 6 Pre charge Component C...

Page 314: ...hine 5 M1 is confirmed open M2 is commanded to close 6 With M2 closed the drive input voltage climbs The drive waits until 90 of rated voltage is achieved The pre charge capacitors provide a resonant circuit with the input inductance allowing a lower secondary input voltage to charge to 90 of rated drive input voltage through the secondary 7 When the input voltage reaches 60 of rated cell diagnost...

Page 315: ...he following conditions occur overvoltage fault cell under voltage fault input protection fault pre charge is aborted MV falls below 60 as read through the input attenuators The drive waits until the cell fault is reset Note Fatal Fault SOP Flag Any cell fault is a fatal fault and will set the FatalFault_I SOP flag Do not use this flag to remove the pre charge enable flag StartCellPrecharge_O set ...

Page 316: ...ker is matched in frequency voltage and phase Software sync checking may be enabled to replace the external In Sync signal Sync checking can be enabled disabled with parameter 2631 Sync Check Enable The software will measure the frequency phase and magnitude of pre charge input and output voltages If the frequencies are equal if there are valid voltages and if the phase difference magnitude is wit...

Page 317: ...e charge Refer to Cell Menu 2520 in Section Options for Drive Menu 2 of Chapter Parameter Assignment Addressing for parameters associated with this function For normal operation Pre charge Enable 2635 to Type 6 Closed Use type 6 pre charge for any cell type but cell voltages 2550 750V AP and 750V AP 4Q must use either type 5 or type 6 pre charge These are the two settings that are defined for the ...

Page 318: ...multi phase synchronous motor Single HMI that collects data from all of the parallel drives Drives synchronize to each other without external inputs and maintain independent operation of speed and flux regulators while sharing torque current and field current Fast bypass is possible and drives can operate with unequal number of cells User can introduce a drive into a system that is already in oper...

Page 319: ...izes the torque capability of each drive for the motor total torque so that each drive is contributing the same amount of torque and magnetizing current The result is equal sharing between each drive The success of balancing the flux producing reactive currents between drives is more an exercise of balancing the attenuator impedances than in any control algorithm or setting of droop parameters 0RW...

Page 320: ... single three phase synchronous motor or a multi phase synchronous motor The master VFD can be determined from a digital input signal This signal along with the drive fault and drive torque control can be used to reconfigure the system such that the slave can become the master in case the master drive has a fault The system can be implemented using conventional analogue speed and torque signals as...

Page 321: ...s enabled to control application of torque changes Speed droop is disabled in torque mode If the VFD is used in torque mode the speed regulation must be done externally to the VFD The input to the drive in this type of application is a torque demand Figure Torque Mode depicts a generalized view of torque mode 7RUTXH 5DPS 7RUTXH LPLW RJLF 5DPS 5DWH 7RUTXH LPLWV YDLODEOH 7RUTXH 7RUTXH HPDQG 0RWRU 6S...

Page 322: ...mode and the necessary torque command established through the selected source 8 21 2 Torque Mode Parameters Parameters for Torque Mode Refer to Torque Reference Menu 2210 in Section Options for Drive Menu 2 of Chapter Parameter Assignment Addressing for parameters associated with this function SOP menu control 2211 Torque setpoint 2220 Holding torque 2230 Torque ramp increase 2240 Torque ramp decr...

Page 323: ... synchronous motor CSMC Enable the drive s Spinning Load function when this control mode is enabled 8 22 3 High Starting Torque Mode Special applications and motors require a high starting torque mode Examples of motors that require a high starting torque HST mode Permanent Magnet Motors PMM have a fixed flux source from the magnets and must be moving in order to lock on to the flux phase Synchron...

Page 324: ...7RSVLGH FDEOH NP 09 XPSHU NP Figure 8 28 High Starting Torque Mode Example System HST Secondary Current Level The HST secondary current level is for implementation after the initial starting state and before the control loops are enabled to prevent saturation of transformers used between the output of the drive and the connected motor due to the high currents and associated voltages Saturation can...

Page 325: ...ng for parameters associated with this function For long cable applications set the Minimum Speed Limit to approximately the same as the percent value of the total resistance in series with the motor For example if a long cable application has the total series resistance at about 30 of motor base impedance set a minimum speed limit of 30 or higher Advanced Operating Functions 8 22 High Performance...

Page 326: ... mode enabled and not complete and after completion for active damping Enabling and Using Fast Access 1 To enable this feature Network 1 is required to be a valid network type If it is not a valid network type and the user attempts to enable this feature the user will receive the message Network 1 not enabled and the feature will not be enabled 2 To use Fast Access Enable Network Data to the Drive...

Page 327: ...Command Normal Network Access Figure 8 30 Fast Network Access Routine 8 23 2 PLC Directed High Starting Torque Mode for Conveyor Applications The PLC directed High Starting Torque Mode HST adds the ability to control HST mode for an induction motor in OLVC by means of a PLC for use in conveyor systems that have multiple drives and motors run on a common belt controlled by a common PLC The PLC cont...

Page 328: ...ctor is locked on by the PLL the current feedback is decomposed into the d q components Slip is then calculated as normal for IM OLVC control mode Because they are controlled externally ramps for current and frequency are bypassed entirely until completion of the state machine At the completion of the state machine the drive smoothly transitions into the speed loop integrator preset and the speed ...

Page 329: ...orque limit Must maintain speed reg in satura on Slip Speed based on calculated slip compensa on HighStar ngTorqueModeComplete_I a er ini alizing loops and 1 second delay Run State Droop enabled and Slip based on Ids Ref Flux Inductance and Iqs current with slip constant Transi on from HST to normal opera on same current input is used for both switched internally Two signals from PLC Current and S...

Page 330: ...d The HST state machine remains at initialization T1 of the HST state machine until the drive enters the Run state The Fast Access Enable parameter 9971 must also be selected to divert the network based speed and current inputs to the proper variables and to update them at the desired rate 2 The PlcHstEnable_O SOP flag must be set true throughout the complete start up for use of the external signa...

Page 331: ...rences in a ramped fashion That is no internal ramps are used and imposed current and speed limits are not exceeded The PLC does not allow a speed setting above the slip frequency until the flux is established 9 Once the motor speed has reached the rated slip of the motor the state machine advances to the next state T3 where it delays for the length of the flux ramp rate After the delay the Magnet...

Page 332: ...and current references and bypasses internal ramps CompleteHstMode_O originates from the PLC to end the HST mode once desired starting speed is ach ieved AtMinSpeed_I used as a handshake output to the PLC that the CompleteHstMode_O signal has been received and acknowledged HighStartingTorqueModeComplete_I output to PLC for PLC based HST mode indicates the state machine has completed transition to ...

Page 333: ... fast enough to effectively counter oscillations in the cables This breaks down into two components the network speed for which the drive has no control and the reading and response to the damping signals To achieve the 10 msec bandwidth of the desired damping response the original communication thread of the drive is enhanced This is the purpose of the Fast Network Access Speed Input Ramp Speed R...

Page 334: ...duction motors active damping should work with or without the HST starting mode This would be similar to completion of the HST mode startup in which the speed demand enters into the ramp input and the Torque command exits into the limit logic for the torque current limit The speed demand will have to be high enough with slip to keep the speed regulator in saturation output clamped against the curr...

Page 335: ...impedance Vrated Drive rated output voltage Irated Drive rated output current The cable impedance must be compensated to ensure that the motor is getting the proper terminal voltage ULYH DEOH 0RWRU 0RWRU 7HUPLQDO 9ROWDJH 0RWRU HPI 9ROWDJH Lf Lc R Cemf Ls Figure 8 35 Motor Terminal vs Cemf 8 24 2 Cable Inductance Compensation Parameters Parameters for Cable Inductance Compensation Refer to the Outp...

Page 336: ... ID 2941 This should represent the total inductance in the output circuit including cable inductance and any output transformer inductance Enter in percent of drive base inductance Filter Inductance ID 2920 Set the output filter inductor i e impedance value as a ratio of the base output impedance of the drive typically 5 Filter Capacitance ID 2930 Set the filter capacitance parameter to the output...

Page 337: ... Long Cables using Single Drive Parameters are the same as those required for standard cable impedance and if required output filtering parameters Refer to the Output Connection Menu 2900 for these parameters Advanced Operating Functions 8 24 Long Cable Applications NXGPro Control Manual Operating Manual A5E50491925A 335 ...

Page 338: ... inductance LL Stator resistance 1080 motor stator resistance RS Cable resistance 2940 resistance of the cable len R len scaled by the turns ratio of T1 Cable inductance 2941 the total inductance of the cable the inductance of the secondary transformer T2 both through the turns ratio of T1 the inductance of T1 Filter inductance 2920 this can be used for the transformer inductance of T1 as an alter...

Page 339: ...Drive 2XWSXW WUDQVIRUPHU M LT LL RS Figure 8 38 Output Transformer Advanced Operating Functions 8 25 Drive with Output Transformers NXGPro Control Manual Operating Manual A5E50491925A 337 ...

Page 340: ...eed demand changes This parameter has no significant effect on steady state performance of the control 3 Stator resistance 1080 This parameter represents the per phase resistance of the stator windings For medium voltage motors this parameter is typically in the 0 02 to 2 0 range The larger the horsepower and higher the motor efficiency the lower the stator resistance value will be If the stator r...

Page 341: ...e navigation of the multi language keypad and the standard keypad in detail and introduces the more advanced external interface of the PC based drive tool The fourth listed method involves changing parameters by means of networks It involves programming on an interconnected platform e g an external PLC For more information refer to the NXGPro Communication Manual A5E50226719 NXGPro Control Manual ...

Page 342: ...other Keypad Functions H SDG 21 5 ZKHQ GULYH LV UXQQLQJ 21 5 ZKHQ FRQWURO SRZHU LV VXSSOLHG 21 5 ZKHQ IDXOWHG 0RGH RI 2SHUDWLRQ DXOW 5HVHW XWRPDWLF 6WDUW 6WRS LGH XWWRQ 1 6 5 ZKHQ DODUP LV DFWLYH RU XQDFNQRZOHGJHG H SDG Figure 9 1 SIMATICS Touchpad Use the keypad to navigate through the menu system activate control functions reset the system after faults have occurred edit parameter values enter s...

Page 343: ...llowing sections give descriptions and uses of each of the keys on the keypad as well as the diagnostic LEDs and the built in display CAUTION Improper Keypad Operation Although the drive comes standard with a keypad interface and the menu system is secured with multiple programmable password levels for security or other reasons the drive is capable of running without the keypad Switching component...

Page 344: ... specific to an application Fault LED Conditions The fault LED can be flashing on continuously or off A flashing fault LED means that an alarm is either active or unacknowledged A fault LED that is on continuously means that a fault condition exists LED conditions are detailed in the following table Table 9 1 Fault LED Status Multi language Keypad Fault LED Condi tion1 Display Fault Condi tion Ala...

Page 345: ...ESET key to acknowledge the alarm Use the down and up arrow keys to cycle through the active fault list Assumes Fault display override ID 8200 is Off Figure 9 2 Multiple Alarms Active Clearing and resetting a fault Note Fault Indication If an alarm condition occurs before or during a fault condition the LED and display will not indicate the presence of an alarm until the fault condition is cleared...

Page 346: ...T key twice to first reset the fault and then acknowledge the alarms Note Acknowledging faults or alarms in alarm fault log When the alarm fault log has more than 256 unacknowledged faults or alarms the display shows the message Fault Alarm log overflow The cause may be an alarm or several that have not been manually reset to acknowledge the alarm An alarm sets and resets itself with no external i...

Page 347: ... In standard applications the START key is programmed via the SOP to start the drive when under local control The velocity command under local control is controlled by the up and down arrows of the SIMATIC keypad or touch screen Note Modifying the factory supplied program Do not modify without first consulting Siemens customer service 9 1 7 Numeric Keys The numeric keys are located on the right si...

Page 348: ...strokes required to enter hex values A to F and the decimal equivalents The hexadecimal entry feature is available only during security code entry Table 9 2 Hexadecimal digit assignments on the SIMATIC keypad Key Combination Hex Value Decimal Equivalent A 10 B 11 C 12 D 13 E 14 F 15 Accessing menus via the Speed Menu function Use the numeric keys for the shortcut Speed Menu function Use the Speed ...

Page 349: ...ved items rather than only the 10 basic menus Accessing items in this manner requires that you know the four digit ID number associated with the target item This number is listed on the display each time the item is displayed To use this feature refer to Activating Numerical Access Mode in Section Arrow Keys of this chapter Changing values of system parameters Use the numeric keys to change the va...

Page 350: ...er Cancel Key The ENTER key is located to the bottom left of the numeric keys Its function is similar to the ENTER key on a standard PC keyboard The ENTER key is used to choose or accept a selection or confirm an operation For example after locating and displaying a parameter within the menu structure use the ENTER key to edit the parameter s value Common functions of the ENTER key include selecti...

Page 351: ...lease the SHIFT key When the SHIFT key is active it remains depressed The standard function label dissappears from the numeric keys and the shifted function label appears with the center of the key in black lettering When depressed the SHIFT key is highlighted 3 Press the desired function key The SHIFT key becomes inactive and the display of the numeric keys returns to their standard state Note Re...

Page 352: ...ode Manually advancing to the next digit in edit mode Increasing and decreasing the desired velocity demand of the drive in local manual mode Clearing security level by pressing SHIFT three times from the default meter display Entering Numerical Menu Access mode with SHIFT Using the Left and Right Arrow Keys 1 Use the left and right arrow keys to navigate through the menu structure of the system 2...

Page 353: ... LQFUHDVH DQG GHFUHDVH WKH YHORFLW GHPDQG 3ODFH WKH GULYH LQ ORFDO 0DQXDO PRGH 67 57 1 727 9 76 530 0 02 Figure 9 4 Control Velocity Demand using Up and Down Arrow Keys Note Default assignment on the front panel display The velocity demand field DEMD on the front panel display is assigned by default This display assignment and the other three variables can be changed from the menu system Editing P...

Page 354: ...opriate security codes but cannot lower the security access level using the standard Change Security Code option of the main menu Returning to security level 0 If entering level 7 as an experienced user or any other security level and you wish to return to level 0 for security reasons when you are finished you have the following options Wait 15 minutes with no activity and security will return aut...

Page 355: ...e contained within these menus While navigating inside a parameter list or pick list select CANCEL to exit to the menu While inside any menu select CANCEL to exit to the default meter display Table 9 3 Summary of common SHIFT key and arrow key sequences Key Combination Description 02725 6 7 Speed Menu to the Motor Menu Access from the default meter display Enter hexadecimal A from value edit and s...

Page 356: ...navigate through the menu structure In edit mode use to change the cursor position in the edit field of a parameter value It automatically jumps over a decimal point or field delimiter RU Use individually to scroll through lists of menu options lists and parameters Use to change velocity demand from the default meter display In edit mode increments decrements digits under cursor and changes sign 6...

Page 357: ... in Meter Menu 8 to re display the version number The version number is displayed on the identification version screen 1 727 9 76 530 0 02 Ve r s i o n D a t e S I N A M I C S P e r f e c t H a r m o ny Figure 9 6 SINAMICS Identification Version Screen and Meter Display Note The meter display shown may appear differently depending upon the metering parameters selected Description of the Meter Disp...

Page 358: ...pending on the current operational mode or the current state of the drive Rollback RLBK Mode The following figure depicts the display in rollback mode L HG GLVSOD ILHOG LQH ILHOG QDPH 8VHU GHILQHG GLVSOD ILHOGV 5LJKW FROXPQ RI GLVSOD VKRZV G QDPLF YDOXHV LQH ILHOG QDPH 3 727 9 76 530 0 5 Figure 9 8 Dynamic Programmable Meter Display in Rollback Mode The KYPD field displays the current operational ...

Page 359: ...ntrol Motor Frequency Example for changing ratio control parameters The metering display shows the commanded speed reference in percent 1 727 9 76 530 0 02 Figure 9 10 Status display in metering mode 1 Press the following key combination SHIFT 2 A r r o w Key s S e l e c t 2 D r i ve Figure 9 11 Status display after SHIFT 2 key sequence 2 From this point you can select from the nine standard menus...

Page 360: ...6 0 S p e e d s e t u p Figure 9 13 Status display after key sequence 5 Press the down arrow key once to access the ratio control parameter 2070 6 S H H G I Z G P L Q O L P L W 6 S H H G I Z G P D O L P L W 5 D W L R F R Q W U R O Figure 9 14 Status display after key sequence 6 Press ENTER to confirm and enter edit mode for the ratio control parameter edit appears in the display when a parameter i...

Page 361: ... is changed from its current default value This allows you to quickly see which parameters have been changed To return a parameter to its factory value press SHIFT while in edit mode Example for changing motor frequency parameters 1 Press SHIFT to get to the parameter ID display Enter parameter ID for motor frequency 1020 E n t e r P a r a m I D S p e e d Pa r a m e t e r 10 2 0 Figure 9 17 Status...

Page 362: ...on of the motor by decreasing the motor torque until flux is re established in the motor 7 C OL Cell overload rollback A cell current overload model has calculated a thermal overload condition of the drive cells and the drive has limited the amount of torque allowable 8 NET1 Network 1 limit Torque limited by network 1 setting 9 NET2 Network 2 limit Torque limited by network 2 setting 10 ALIM Analo...

Page 363: ...H CR3 inhibit The CR3 or drive inhibit input is asserted 3 OFF Idle state The drive is ready to run but is in an idle state 4 MAGN Magnetizing motor state The drive is magnetizing the motor or passing through the magnetizing drive state 5 SPIN Spinning load state The drive is trying to detect the speed of the motor in order to synchronize the drive frequency 6 UXFR Up transfer state The drive is i...

Page 364: ...s the fault message is displayed instead This is shown if the Fault display override 8200 feature is enabled 9 1 13 Adjusting the SIMATIC KTP700 HMI Display Brightness To adjust the KTP700 display brighness perform the following steps as indicated below 1 Ensure that NXG control power is ON The drive MODE must be NOMV INH or OFF 2 Start at the NXG Main Screen with the touch keypad displayed Figure...

Page 365: ...gure 9 21 Speed Parameter Screen 4 Type the number 5500 in the Parameter ID field Press ENTER twice Press ENTER and then press ENTER once again Figure 9 22 Security Code Screen Software user interface 9 1 SIMATIC Keypad NXGPro Control Manual Operating Manual A5E50491925A 363 ...

Page 366: ...lay until the indicating symbol changes color from red to green This may require touching the POWER field more than once Figure 9 23 Security Code Change Software user interface 9 1 SIMATIC Keypad NXGPro Control Manual 364 Operating Manual A5E50491925A ...

Page 367: ...enter Screen 7 The display brightness setting is located under the Display menu Note that this setting is saved in non volatile memory Figure 9 25 Display Menu Screen To return to the NXG Control menu cycle power to the SIMATIC KTP700 HMI and reboot it Software user interface 9 1 SIMATIC Keypad NXGPro Control Manual Operating Manual A5E50491925A 365 ...

Page 368: ...ey The MANUAL START key is a programmable key located below the AUTOMATIC key on the left side of the keypad In standard applications the MANUAL START key is programmed via the SOP to start the drive when under local control The velocity command under local control is controlled by the up and down arrows of the keypad Note Modifying the factory supplied program Do not modify without first consulti...

Page 369: ...ld is shown dynamically in the second column of the display 5LJKW FROXPQ RI GLVSOD VKRZV G QDPLF YDOXHV L HG GLVSOD ILHOG 8VHU GHILQHG GLVSOD ILHOGV LQH ILHOG QDPH LQH ILHOG QDPH 3 727 9 76 530 0 02 Figure 9 27 Dynamic Programmable Meter Display MODE field The MODE field is fixed The last four fields on the display contain parameter values that can be defined by the user All four variable displays...

Page 370: ...e of the drive Regeneration RGEN Mode The following figure depicts the display in regeneration mode L HG GLVSOD ILHOG LQH ILHOG QDPH 8VHU GHILQHG GLVSOD ILHOGV 5LJKW FROXPQ RI GLVSOD VKRZV G QDPLF YDOXHV LQH ILHOG QDPH 3 727 9 76 530 0 5 1 Figure 9 29 Dynamic Programmable Meter Display in Regeneration Mode Modifying Parameter Values The following sections illustrate the steps to take if attempting...

Page 371: ...u s u b m e n u s u b m e n u 2 210 To r q u e r e f e r e n c e 2 0 0 0 D r i ve p a r a m e t e r s 2 0 6 0 S p e e d s e t u p Figure 9 32 Status display after key sequence 4 Press the ENTER or right arrow key to enter the Speed Setup Menu 2060 A r r o w Key s S e l e c t 2 0 6 0 S p e e d s e t u p Figure 9 33 Status display after key sequence 5 Press the down arrow key once to access the rati...

Page 372: ...The parameter is written into memory once you press ENTER or the right arrow key 8 The following figure depicts the display when a number is entered and it is within the range of the system 6 S H H G I Z G P L Q O L P L W 6 S H H G I Z G P D O L P L W 5 D W L R F R Q W U R O Figure 9 36 Status display upon entering a value in the range of the system Note Use of asterisks An asterisk is used to den...

Page 373: ...t is displayed again O U T O F R A N G E M o t o r f r e q u e n c y Figure 9 39 Status display upon entering a value beyond the range of the system Summary of Operation Mode Displays The following tables list the possible operational mode displays of line 1 and 2 of the display in order of precedence Table 9 6 Line 1 of mode display Order Code Meaning Description 1 FRST Fault reset Displayed afte...

Page 374: ...is operating in regen torque limit 17 BRKG Dual frequency braking Appears while drive is decelerating with dual frequency braking enabled 18 OVLT Regen Limit for 6 step Indicates that the six step regeneration torque limit is in effect It is set when the cell voltage gets too high and serves to reduce the regen torque limit to limit the energy flow from the output motor to the cells to pre vent ov...

Page 375: ...D Hand mode Appears if the drive is running under normal conditions 15 BRAK Dynamic Braking Indicates that dynamic braking is enabled 16 DECL Decelerating no braking The drive is decelerating normally 17 COAS Coasting to stop The drive is not controlling the motor and it is coasting to a stop due only to friction 18 TUNE Auto Tuning The drive is in a Auto Tuning mode used to determine motor charac...

Page 376: ...knowledged No Flashing none N A Active acknowl edged Yes Flashing see figure below Status display will be reduced in height and alarm names will be shown in rotation in yel low box at bottom of display N A Multiple unac knowledged alarms No On continuously Fault name Note Background is red for fault display Active N A No On continuously Fault name within display Note Background is red for fault di...

Page 377: ... to determine the cause of the fault 2 Correct conditions that may have caused the fault 3 Press the FAULT RESET key on the keypad to reset the system Clearing and resetting an alarm When there are no fault conditions but an alarm condition occurs the fault indicator will flash red Perform the following steps to acknowledge the alarm condition 1 Check the display or the alarm fault log to determin...

Page 378: ...he center of the key The standard un shifted function of the key is listed in the center of the key in black lettering The shifted function of the key is shown at the top of the key in white lettering that matches the white lettering of the SHIFT key to identify that they are used together When the drive prompts you for a numerical value e g during entry of the security access code or parameter mo...

Page 379: ... the current security level to 0 by pressing SHIFT SHIFT SHIFT from the default meter display Setting a parameter value back to its factory default by pressing SHIFT while in the parameter edit function A summary of SHIFT key sequences is listed in Section Summary of Common SHIFT key sequences 9 2 1 7 ML Arrow Keys T76 There are four arrow keys on the keypad The up and down arrow keys and are loca...

Page 380: ...w key to reach the main menu press the down arrow key to scroll through the list of options within the main menu These options may be parameters pick lists or submenus Refer to the next section for information about the structure of the menu system Example incrementing or decrementing the velocity demand in manual mode Use the up and down arrow keys to increment or decrement the desired velocity d...

Page 381: ... of a parameter position press the right and left arrow keys to move to the next or previous position in the number to be edited This is required as opposed to using the number keys which automatically shift the underscore to the next digit in the number 4 Press the ENTER key to accept the new value or press SHIFT ENTER to abort the change Canceling the Current Security Mode Press the left arrow k...

Page 382: ...ecurity level permits access to that item then the desired item will be displayed Note Accessing higher security level menus If you request access to a menu number that is assigned a higher security level than the current security level the drive will prompt for the appropriate security level code Within the menu structure when not in edit mode the right arrow acts like the ENTER key upon the menu...

Page 383: ...ult The default meter display is the starting point of the menu system This display remains active until keys are pressed Re displaying the Version Number Use the display version number 8090 function in Meter Menu 8 to re display the version number The version number is displayed on the identification version screen 1 727 9 76 530 0 02 Ve r s i o n D a t e S i e m e n s H a r m o ny Figure 9 44 Id...

Page 384: ...owing figure depicts the display in rollback mode L HG GLVSOD ILHOG LQH 8VHU GHILQHG GLVSOD ILHOGV 5LJKW FROXPQ RI GLVSOD VKRZV G QDPLF YDOXHV LQH 3 727 9 76 530 0 5 02 ILHOG Figure 9 45 Dynamic_Program_Meter_Display_Rollback The KYPD field displays the current operational mode of the system This field can have any one of the displays summarized in Table Line 2 of mode display depending on the cur...

Page 385: ...point you can select from the nine standard menus Use the up and down arrow keys to select the desired menu 3 Press the down arrow key twice The following figure shows the display prior to the selection of the Speed Setup Menu 2060 s u b m e n u s u b m e n u s u b m e n u 2 210 To r q u e r e f e r e n c e 2 0 0 0 D r i ve p a r a m e t e r s 2 0 6 0 S p e e d s e t u p Figure 9 49 Status display...

Page 386: ...decrement the digit using the up and down arrow keys Use the up and down arrow keys to change the sign The parameter is written into memory once you press ENTER or the right arrow key 8 The following figure depicts the display when a number is entered and it is within the range of the system 6 S H H G I Z G P L Q O L P L W 6 S H H G I Z G P D O L P L W 5 D W L R F R Q W U R O Figure 9 53 Status di...

Page 387: ...it is displayed again O U T O F R A N G E M o t o r f r e q u e n c y Figure 9 56 Status display upon entering a value beyond the range of the system Summary of Operation Mode Displays The following tables list the possible operational mode displays of line 1 and 2 of the display in order of precedence Table 9 9 Line 1 of mode field Order Code Meaning Description 1 FRST Fault reset Displayed after...

Page 388: ...is operating in regen torque limit 17 BRKG Dual frequency braking Appears while drive is decelerating with dual frequency braking enabled 18 OVLT Regen Limit for 6 step Indicates that the six step regeneration torque limit is in effect It is set when the cell voltage gets too high and serves to reduce the regen torque limit to limit the energy flow from the output motor to the cells to pre vent ov...

Page 389: ...s in a Auto Tuning mode used to determine motor character istics 19 FALT Drive fault active This mode is selected if any drive fault exists but is not usually displayed as the fault message is displayed instead This is shown if the Fault display override 8200 feature is enabled 9 2 1 10 ML Summary of Common Shift Key and Arrow Key Sequences T76 Menu System Structure The menu system consists of the...

Page 390: ...display 3 6 7 Speed Menu to a context sensitive help menu Access from anywhere except the default meter display 1 6 7 17 5 Cancel the current action abort the current keystroke or exit the menu system RU Use individually to navigate through the menu structure In edit mode use to change the cursor position in the edit field of a parameter value It automatically jumps over a decimal point or field d...

Page 391: ...e value to its factory default 9 2 1 11 ML User Interface Multi Language Keypad T76 The drive is equipped with a keypad and display interface located on the front of the drive control cabinet 2Q UHG ZKHQ FRQWURO SRZHU LV VXSSOLHG LVSOD 0RGHV RI RSHUDWLRQ XWRPDWLF 0DQXDO VWDUW 0DQXDO VWRS 2Q UHG ZKHQ IDXOWHG EOLQNV UHG ZKHQ DODUP LV DFWLYH RU XQDFNQRZOHGJHG 2Q UHG ZKHQ GULYH LV UXQQLQJ 6WDWXV LQGLF...

Page 392: ...t cuts A summary of these key sequences is given later in this chapter 3 Use the SHIFT key in conjunction with the 10 numeric keys and the ENTER key to access nine common system menus a help display function and a CANCEL key Assignment of functions to the keypad keys The keypad contains 20 keys Each of these keys has at least one function associated with it some keys have more functions The follow...

Page 393: ...t Note Multi Language keypad is only available on NXGPro by the use of a passive adapter board available from Siemens A5E51460683 Software user interface 9 2 Multi Language Keypad NXGPro Control Manual Operating Manual A5E50491925A 391 ...

Page 394: ...itor and control the drive s functions The drive tool is a high level GUI that runs on a PC equipped with a Microsoft Windows operating system The control and the PC running the drive tool interface with each other using ethernet and TCP IP protocols The structure of the menu hierarchy is slightly different with this tool than with the keypad For full coverage of the drive tool refer to the NXGPro...

Page 395: ... action e g cell protection concept and integrate each component into a holistic state of the art industrial security concept Third party products that may be in use should also be considered For more information about industrial security visit http www siemens com industrialsecurity WARNING Danger as a result of unsafe operating states resulting from software manipulation Software manipulation ex...

Page 396: ...eters while the drive is in operation 9 4 5 Write Protection The GH180 drive contains a piece of software called a System Operating Program SOP This system operating program can be modified such that parameter writing cannot occur This SOP can be programmed such that a specific digital input network flag and or operating conditions must be present to allow keypad parameter modification Once set th...

Page 397: ...of USB flash drives for log retrieval SOP file retrieval parameter retrieval and secure USB system key creation and usage Great care should be taken with any exchangeable storage media to ensure no malicious software is allowed to reside on this media WARNING Risk of death due to software manipulation when using exchangeable storage media Storing files on exchangeable storage media poses an increa...

Page 398: ...be used Keypad error messages The following message definitions will be displayed on the keypad as Error See eventlog 9xx where xx is one of the following errors Error 900 USB partition error e g not 1st partition or not FAT32 Error 901 USB unmount error can generally be ignored but might indicate flash disk errors Error 902 USB unmount retry error can generally be ignored but might indicate flash...

Page 399: ...es The filename is of the form NxGproPlus_vXXYYZZ_RNNN init Example v8 0 0 Release 001 filename is NxGproPlus_v080000_R001 init CAUTION DO NOT RENAME FILENAME The filename cannot be renamed It will be ignored deleted by the DCR The recommended key for system recovery to customer specific DCR parameters is to use the nxgemergency key To update the base system software the nxgupdate key is used to a...

Page 400: ...oplus login password will be nxgproplus after running this key recovery Parameter 7751 Create Emergency Key This keypad function creates a file named nxgemergency the active base system file as shown on Debug Tool Software Firmware Versions active SOP hex files and current configuration file on USB flash drive It is a first resort function as it captures the current state of the DCR This key is us...

Page 401: ...ver then re insert into DCR 5 STOP HERE IF YOU ARE ONLY CREATING THE KEYS CAUTION STOP HERE IF YOU ARE ONLY CREATING THE KEYS STOP HERE IF YOU ARE ONLY CREATING THE KEY REMOVE USB FLASH DISK PROCEEDING WILL RESET YOUR DCR AND ERASE ALL SAVED PARAMETERS ON DCR 6 Reboot DCR leave USB flash disk inserted Wait approximately 5 7 minutes for Green LED blink 7x repeatedly If it does not e g Red LED blink...

Page 402: ...CR boot cycle If it didn t work remove USB from DCR reboot DCR and try again 1 On a PC remove all secure USB key files from USB flash disk OR rename them 2 Insert FAT32 based USB flash disk into DCR 3 See 3A and 3B 3A Versions below 8 1 0 The files should be created within 3 4 mintues It is a manual process where you must keep checking the status about every 30 seconds to 1 minute until the proces...

Page 403: ...via Drive Tool or Debug Tool then the USB flash drive was not recognized Try another brand and or model Remove USB flash disk from DCR and place into your PC Reboot DCR After 60 90 seconds you should be able to connect using Drive Tool and Debug Tool using default IP configuration Now you will be able to reload customer specific parameter configuration file and SOP file from the USB flash disk The...

Page 404: ...t for Successfully loaded initialization file success dialog and select OK Renaming init files IS NOT SUPPORTED if renamed the file will be ignored 8 Reboot DCR leave USB flash disk inserted 9 Wait approximately 5 7 minutes for Green LED blink 7x repeatedly If it does not e g Red LED blink 15x repeatedly recover FAILED If the DCR boots up normally and you can connect via Drive Tool or Debug Tool t...

Page 405: ...orage media Storing files on exchangeable storage media poses an increased risk infection from malicious software viruses and malware Incorrect parameter assignment can cause machines to malfunction which can lead to death or injury to personnel Be sure to protect files stored on exchangeable storage media Use appropriate software protection measures such as virus scanners Software user interface ...

Page 406: ...ofibus Ethernet IP DeviceNet ControlNet 9 5 2 Multiple Networks The control allows you to operate two independent network interfaces at one time where both can monitor the drive but only one can control the drive The networks do not need to be identical Each can map data separately The ability to provide two networks is not implemented as a redundant or dual interface The VFD provides a means to u...

Page 407: ...UAL START key is a programmable key located below the AUTOMATIC key on the left side of the keypad In standard applications the MANUAL START key is programmed via the SOP to start the drive when under local control The velocity command under local control is controlled by the up and down arrows of the keypad Note Modifying the factory supplied program Do not modify without first consulting Siemens...

Page 408: ...ch field is shown dynamically in the second column of the display 5LJKW FROXPQ RI GLVSOD VKRZV G QDPLF YDOXHV L HG GLVSOD ILHOG 8VHU GHILQHG GLVSOD ILHOGV LQH ILHOG QDPH LQH ILHOG QDPH 3 727 9 76 530 0 02 Figure 9 59 Dynamic Programmable Meter Display MODE field The MODE field is fixed The last four fields on the display contain parameter values that can be defined by the user All four variable di...

Page 409: ...t state of the drive Regeneration RGEN Mode The following figure depicts the display in regeneration mode L HG GLVSOD ILHOG LQH ILHOG QDPH 8VHU GHILQHG GLVSOD ILHOGV 5LJKW FROXPQ RI GLVSOD VKRZV G QDPLF YDOXHV LQH ILHOG QDPH 3 727 9 76 530 0 5 1 Figure 9 61 Dynamic Programmable Meter Display in Regeneration Mode Modifying Parameter Values The following sections illustrate the steps to take if atte...

Page 410: ...m e n u s u b m e n u s u b m e n u 2 210 To r q u e r e f e r e n c e 2 0 0 0 D r i ve p a r a m e t e r s 2 0 6 0 S p e e d s e t u p Figure 9 64 Status display after key sequence 4 Press the ENTER or right arrow key to enter the Speed Setup Menu 2060 A r r o w Key s S e l e c t 2 0 6 0 S p e e d s e t u p Figure 9 65 Status display after key sequence 5 Press the down arrow key once to access th...

Page 411: ... sign The parameter is written into memory once you press ENTER or the right arrow key 8 The following figure depicts the display when a number is entered and it is within the range of the system 6 S H H G I Z G P L Q O L P L W 6 S H H G I Z G P D O L P L W 5 D W L R F R Q W U R O Figure 9 68 Status display upon entering a value in the range of the system Note Use of asterisks An asterisk is used ...

Page 412: ...d edit is displayed again O U T O F R A N G E M o t o r f r e q u e n c y Figure 9 71 Status display upon entering a value beyond the range of the system Summary of Operation Mode Displays The following tables list the possible operational mode displays of line 1 and 2 of the display in order of precedence Table 9 12 Line 1 of mode display Order Code Meaning Description 1 FRST Fault reset Displaye...

Page 413: ...rive is operating in regen torque limit 17 BRKG Dual frequency braking Appears while drive is decelerating with dual frequency braking enabled 18 OVLT Regen Limit for 6 step Indicates that the six step regeneration torque limit is in effect It is set when the cell voltage gets too high and serves to reduce the regen torque limit to limit the energy flow from the output motor to the cells to pre ve...

Page 414: ... 14 HAND Hand mode Appears if the drive is running under normal conditions 15 BRAK Dynamic Braking Indicates that dynamic braking is enabled 16 DECL Decelerating no braking The drive is decelerating normally 17 COAS Coasting to stop The drive is not controlling the motor and it is coasting to a stop due only to friction 18 TUNE Auto Tuning The drive is in a Auto Tuning mode used to determine motor...

Page 415: ...not ac knowledged No Flashing none N A Active acknowl edged Yes Flashing see figure below Status display will be reduced in height and alarm names will be shown in rotation in yel low box at bottom of display N A Multiple unac knowledged alarms No On continuously Fault name Note Background is red for fault display Active N A No On continuously Fault name within display Note Background is red for f...

Page 416: ...lt log to determine the cause of the fault 2 Correct conditions that may have caused the fault 3 Press the FAULT RESET key on the keypad to reset the system Clearing and resetting an alarm When there are no fault conditions but an alarm condition occurs the fault indicator will flash red Perform the following steps to acknowledge the alarm condition 1 Check the display or the alarm fault log to de...

Page 417: ... in the center of the key The standard un shifted function of the key is listed in the center of the key in black lettering The shifted function of the key is shown at the top of the key in white lettering that matches the white lettering of the SHIFT key to identify that they are used together When the drive prompts you for a numerical value e g during entry of the security access code or paramet...

Page 418: ...setting the current security level to 0 by pressing SHIFT SHIFT SHIFT from the default meter display Setting a parameter value back to its factory default by pressing SHIFT while in the parameter edit function A summary of SHIFT key sequences is listed in Section Summary of Common SHIFT key sequences 9 6 7 ML Arrow Keys T76 There are four arrow keys on the keypad The up and down arrow keys and are...

Page 419: ...t arrow key to reach the main menu press the down arrow key to scroll through the list of options within the main menu These options may be parameters pick lists or submenus Refer to the next section for information about the structure of the menu system Example incrementing or decrementing the velocity demand in manual mode Use the up and down arrow keys to increment or decrement the desired velo...

Page 420: ... value of a parameter position press the right and left arrow keys to move to the next or previous position in the number to be edited This is required as opposed to using the number keys which automatically shift the underscore to the next digit in the number 4 Press the ENTER key to accept the new value or press SHIFT ENTER to abort the change Canceling the Current Security Mode Press the left a...

Page 421: ...rrent security level permits access to that item then the desired item will be displayed Note Accessing higher security level menus If you request access to a menu number that is assigned a higher security level than the current security level the drive will prompt for the appropriate security level code Within the menu structure when not in edit mode the right arrow acts like the ENTER key upon t...

Page 422: ...display is shown by default The default meter display is the starting point of the menu system This display remains active until keys are pressed Re displaying the Version Number Use the display version number 8090 function in Meter Menu 8 to re display the version number The version number is displayed on the identification version screen 1 727 9 76 530 0 02 Ve r s i o n D a t e S i e m e n s H a...

Page 423: ...llback RLBK Mode The following figure depicts the display in rollback mode L HG GLVSOD ILHOG LQH 8VHU GHILQHG GLVSOD ILHOGV 5LJKW FROXPQ RI GLVSOD VKRZV G QDPLF YDOXHV LQH 3 727 9 76 530 0 5 02 ILHOG Figure 9 77 Dynamic_Program_Meter_Display_Rollback The KYPD field displays the current operational mode of the system This field can have any one of the displays summarized in Table Line 2 of mode dis...

Page 424: ... this point you can select from the nine standard menus Use the up and down arrow keys to select the desired menu 3 Press the down arrow key twice The following figure shows the display prior to the selection of the Speed Setup Menu 2060 s u b m e n u s u b m e n u s u b m e n u 2 210 To r q u e r e f e r e n c e 2 0 0 0 D r i ve p a r a m e t e r s 2 0 6 0 S p e e d s e t u p Figure 9 81 Status d...

Page 425: ...nt or decrement the digit using the up and down arrow keys Use the up and down arrow keys to change the sign The parameter is written into memory once you press ENTER or the right arrow key 8 The following figure depicts the display when a number is entered and it is within the range of the system 6 S H H G I Z G P L Q O L P L W 6 S H H G I Z G P D O L P L W 5 D W L R F R Q W U R O Figure 9 85 Sta...

Page 426: ...ed edit is displayed again O U T O F R A N G E M o t o r f r e q u e n c y Figure 9 88 Status display upon entering a value beyond the range of the system Summary of Operation Mode Displays The following tables list the possible operational mode displays of line 1 and 2 of the display in order of precedence Table 9 15 Line 1 of mode field Order Code Meaning Description 1 FRST Fault reset Displayed...

Page 427: ...drive is operating in regen torque limit 17 BRKG Dual frequency braking Appears while drive is decelerating with dual frequency braking enabled 18 OVLT Regen Limit for 6 step Indicates that the six step regeneration torque limit is in effect It is set when the cell voltage gets too high and serves to reduce the regen torque limit to limit the energy flow from the output motor to the cells to pre v...

Page 428: ...drive is in a Auto Tuning mode used to determine motor character istics 19 FALT Drive fault active This mode is selected if any drive fault exists but is not usually displayed as the fault message is displayed instead This is shown if the Fault display override 8200 feature is enabled 9 6 10 ML Summary of Common Shift Key and Arrow Key Sequences T76 Menu System Structure The menu system consists o...

Page 429: ...meter display 3 6 7 Speed Menu to a context sensitive help menu Access from anywhere except the default meter display 1 6 7 17 5 Cancel the current action abort the current keystroke or exit the menu system RU Use individually to navigate through the menu structure In edit mode use to change the cursor position in the edit field of a parameter value It automatically jumps over a decimal point or f...

Page 430: ... display to restore the security level back to 0 6 7 Go to the bottom item of the currently selected menu submenu or pick list 6 7 When editing a value that has been changed from its factory default this key sequence returns the value to its factory default Software user interface 9 6 ML Keypad NXGPro Control Manual 428 Operating Manual A5E50491925A ...

Page 431: ...re 9 89 Multi Language Keypad and Display Interface The multi language keypad is intended as a direct replacement for the standard keypad The electrical connection and mechanical fit mounting are the same between the multi language keypad and the standard keypad Keypad Functions Use the keypad to navigate through the menu system activate control functions reset the system after faults have occurre...

Page 432: ...CEL key Assignment of functions to the keypad keys The keypad contains 20 keys Each of these keys has at least one function associated with it some keys have more functions The following sections give descriptions and uses of each of the keys on the keypad as well as the diagnostic LEDs and the built in display CAUTION Improper Keypad Operation Although the drive comes standard with a keypad inter...

Page 433: ...the drive operation where possible so that system response and I O configuration is configured for the application The SOP is used to define reference sources select a subset of operating parameters configure all I O and to define alarms and fault conditions as desired by the end user Note Internal drive generated faults defined for drive protection cannot be modified by the SOP NXGPro Control Man...

Page 434: ...dified by trained personnel for changing requirements SOP testing is performed at the Siemens LD facility The SOP file is downloaded to the drive in non volatile memory The operation of the SOP is similar to a PLC in that it reads from top to bottom and left to right on a cyclical basis The drive must be in an idle state that is with output disabled for a new SOP to be downloaded and started Opera...

Page 435: ...ic functions include Start stop control logic Input and output control logic for example annunciators interlocks etc Drive to machinery coordination The SOP is stored on the CompactFlash card Upon power up it is executed continuously by the drive s run time software in a repetitive fashion causing the intended logic statements to perform their functionality Operating the Software 10 3 SOP Logic Fu...

Page 436: ...ce an output variable is set to either true or false it is immediately available as an input to any subsequent logic statements within the context of the logic tables There is no limitation to how many times an output variable may change logic states within the context of the program However only the final evaluation is output to any assigned output flags or external I O Note Reassignment of outpu...

Page 437: ...s are identified by variable _I Input flags represent items such as digital inputs switches the state of a system process internal variables comparator flags a literal TRUE FALSE These input flags are combined using the unary and binary operators to form logic expressions Operating the Software 10 5 Input Flags NXGPro Control Manual Operating Manual A5E50491925A 435 ...

Page 438: ... Perfect Harmony drives have a set of pre defined symbols that describe control outputs or switches that can be controlled by the SOP These switches can control functions such as the source of the speed reference a selection for the system acceleration rate and many more In most cases to cause the system to perform in the intended manner the proper control switches must be set and others cleared b...

Page 439: ...he SOP via serial Ethernet connection Use the Drive Tool to download the program via the Ethernet connection You do not need to set up anything through the drive menu it is handled directly from the PC Once downloaded the file becomes the active SOP Refer to the NXGPro ToolSuite Software Manual A5E03086439 for details about the Drive Tool Operating the Software 10 7 Downloading the SOP NXGPro Cont...

Page 440: ...d to the DCR via Tool Suite Drive Tool via Ethernet Uploading the SOP via serial Ethernet connection Use the Drive Tool to upload the SOP via the Ethernet connection Once a connection with the drive is established select the Upload System Program function from the Configuration Menu Refer to the NXGPro ToolSuite Software Manual A5E03086439 for details about the Drive Tool Operating the Software 10...

Page 441: ...n creating and programming the slave files Once the files are created and enabled they are selected via the eight SOP flags SOPConfigFile1_O to SOPConfigFile8_O in the logic of the SOP file Ensure that only one valid flag is set true at a time within the SOP CAUTION Potential Drive Instability or Trip Switching SOP flags could cause drive instability and or a trip Do not switch SOP flags while the...

Page 442: ...o select a different active SOP the drive must not be running This could cause drive instability and or a trip Use the parameter Select system program 9146 to select from a pick list of all available SOPs To determine the SOP that is currently selected use the Display sys prog name 9140 function Find both parameters under the SOP and Serial Functions Menu 9110 Operating the Software 10 10 Selectin...

Page 443: ...t before attempting inspection or maintenance procedure WARNING Qualified service personnel Incorrect handling and maintenance may cause death or severe injuries Ensure that only qualified service personnel maintain SINAMICS PERFECT HARMONY GH180 equipment and systems Refer to Chapter NXPro Control Description for locations and details of major hardware components of the NXGPro control Refer to th...

Page 444: ...s you will not be able to count due to fast nature of blink pattern 3 Then Solid Red for next 15 seconds 4 Off for 1 2 seconds 5 Blink Yellow fast 2x then slow 1x 6 Off for 1 2 seconds 7 Alternating fast Green Yellow Red 4x about 2 3 seconds you will not be able to count due to fast nature of blink pattern 8 Solid Red for 5 seconds 9 Blink Yellow fast 3x 10 Off for 1 2 seconds 11 Solid Green indic...

Page 445: ... for the various fault and alarm conditions WARNING High Voltages Disabling the drive does not necessarily remove voltage form the motor terminals The motor especially if spinning may have residual voltage on the terminals and anything connected to them Always adhere to the five safety rules and safety measures in Chapter Safety Notes Table 11 1 Fault alarm type and drive responses Type Drive resp...

Page 446: ...nRequest_I is maintained at the value true The FAULT RESET key of the keypad is also used to acknowledge alarms Table 11 2 Auto resettable faults Over Speed Fault Keypad Communication Encoder Loss Under Load Fault Network 1 Communication Loss of Signal 1 to 24 Output Ground Fault Network 2 Communication Int AI1 to AI12 Loss of Signal IOC Motor Over Volt Fault Loss Of Drive Enable Menu Initializati...

Page 447: ...test point board 2 Use a voltmeter to check for common mode DC to neutral Line over voltage 1 A SOP Cause The drive input RMS voltage is greater than 110 of the drive rated input voltage Action Use a voltmeter to verify that the input voltages VIA VIB VIC are the expected value for the rated voltage NXGpro test point board VIA VIB VIC 3 8 Vrms Values greater than 4 2 Vrms will trigger this alarm N...

Page 448: ...d input volt age Action Use a voltmeter to verify that the input voltages VIA VIB VIC are the expected value for the rated voltage NXGpro test point board VIA VIB VIC values less than 2 66 Vrms will trigger medium voltage low conditions Medium voltage low Flt F Fixed Cause The drive input RMS voltage is less than 60 of the drive rated input volt age Note The fault will not occur even after the thr...

Page 449: ...if so equipped it is normal for phases to be imbalanced PreChrg M1 Contactor Flt F Cause This fault aborts pre charge and the message is issued in lieu of the pre charge fault Possible causes include No power to contactor coil Incorrect wiring of contactor and auxiliary contact and connection with system interface board Loose or defective cable between DCR and system interface board Defective syst...

Page 450: ...user I O module 1 3 Check fiber optic cable connection between DCR and NXGpro user I O module 4 Replace user I O module 5 Replace DCR PreChrg Breaker Opened A Cause This alarm indicates that the pre charge breaker was commanded to open when the precharge contactors M2 M3 or M4 failed to open This alarm is applicable to only pre charge Type 5 or Type 6 Possible causes include Incorrect wiring from ...

Page 451: ...ue to an output ground fault condition when the estimated ground voltage exceeds parameter Ground Fault Limit 1245 in the limits menu 1120 Action 1 Use an oscilloscope and the test point board to verify proper symmetry of the input voltages and currents VMA VMB and VMC If voltages are not a problem check the divider resistors in the motor sense unit or replace the system interface board 2 Disconne...

Page 452: ...r over volt alarm A SOP Cause If motor voltage exceeds 90 of the motor overvoltage limit in the motor limit menu Action Check menu settings for correct motor rating and limit setting Motor over volt fault F SOP Cause The measured motor voltage exceeds the threshold set by parameter Mo tor trip volts 1160 in the limits menu 1120 An improperly set up or tuned drive usually causes this fault This cou...

Page 453: ...er load alarm A SOP Cause The torque producing current of the drive has dropped below a preset value set by the user Action This alarm usually indicates a loss of load condition If this not the case verify the setting of parameter I underload 1182 in the limits menu 1120 Under load fault F Menu Cause This fault usually indicates a loss of load condition when the torque pro ducing current of the dr...

Page 454: ...ro speed setting or a low speed demand condition where speed demand is lower than the zero speed setting Action Increase motor torque limit 1190 1210 or 1230 if it is a stall condition or adjust the zero speed setting to avoid the desired low speed operating region Loss of field current F A SOP Cause This occurs only with synchronous motor control due to field exciter failure or loss of power to t...

Page 455: ...ce the motor is magnetized and run ning such an event is unlikely to occur Note Duringhighstartingtorque mode thetriptimeusedisthefluxramp rate Action 1 Increase the flux ramp time to give more time for magnetizing current to settle down at startup 2 Verify if parameter Stator resistance 1080 is set too high for the application reduce it if continuous operation at very low speed is not desired Che...

Page 456: ...t will cause an input protection fault if dedicated I O is used for IP faults This drive protection will not function properly if input CT s are instal led incorrectly This would be indicated by negative input power on a two quadrant system Carrier frq set too low A Fixed Cause The software detected a menu entry for carrier frequency menu 3580 was below the lowest possible setting based on the sys...

Page 457: ...s that are software set 2 Contact Siemens customer service CPU temperature fault F Fixed Cause CPU temperature is 103 C This fault is not logged because the board resets Action 1 Adjust temperature to the new NXGPro values that are software set 2 Contact Siemens customer service A D hardware fault F Fixed Cause A D board hardware error persists and cannot be cleared Action 1 Replace DCR M1 Permit ...

Page 458: ...tem has an output which is fed into the GLUE CPLD The FPGA CRC Error Fault is generated when the CRC error signal is received from the GLUE logic Action 1 Toggle control power 2 Contact Siemens customer service F O Exp Bd Not found F Fixed Cause The system has sense lines which indicate whether or not each of the four possible fiber optic expansion boards is installed A F O Exp Bd Not found fault ...

Page 459: ...the fault routine starts the cell diagnostic routine If no cell fault is found this fault displays The cell fault indication is from the modulator master fault register Action 1 Review grounding of the DCR 2 Replace DCR Cell fault modulator F Fixed Cause Modulator has an undefined fault from a cell Cell shows fault but the fault is undetectable Action Check fiber links and cell Bad cell data F Fix...

Page 460: ...tion 1 Reset drive control power 2 Check for proper grounding practices 3 Replace DCR Loss of drive enable F SOP Cause Modulator detected loss of drive enable Action 1 Reset drive control power 2 Check for proper grounding practices Troubleshooting Faults and Alarms 11 7 Drive Faults and Alarms Modulator Related NXGPro Control Manual 458 Operating Manual A5E50491925A ...

Page 461: ...I O is being used on the WAGO I O system Actions 1 Verify that the cable between the DCR and Wago communication alarm module is connected properly 2 Replace WAGO communication module 3 Replace the DCR 4 Contact Siemens customer service Wago communication fault F SOP Cause The software was unable to establish or maintain communication with the WAGO I O system The fault is triggered when the lack of...

Page 462: ...will indicate which module the system was trying to communicate with when the error occurred However this number may not always be the actual module which has a problem Noise on the fiber optic network may give cause an erroneous result Action 1 Replace affected user I O module 2 Contact Siemens customer service Int I O Internal Err F Fixed Cause This fault occurs when a module reports an error Th...

Page 463: ... Replace affected user I O module 4 Contact Siemens customer service Int I O Module Address F Fixed Cause This fault is generated when the system finds that a module s reported previous address does not match its current address Action 1 Check that the fiber optic chain is correct and the correct module is in the correct position within it 2 This condition can be corrected through the use of the S...

Page 464: ...t mes sage Action 1 Check the module voltage setting in the menus 2 Check that the module has the correct voltage rating Int IO Illegal Inp Type F Fixed Cause The software generates this fault if a module s analog input is set in the menus as a speed input and that analog input s type is set in the menus as 10 volts to 10 volts Normally the Internal I O Error Prevention func tion will prevent this...

Page 465: ... input line for voltage and distortion 2 Check status of InsufficientOutputVolts_O flag or the output voltage versus safe voltage to see if transfer is prohibited 3 Increase menu setting or set to zero to disable time out Down transfer failed A SOP Cause Time out has occurred from request to down synch transfer Action 1 Check feedback voltage waveform 2 Check status of InsufficientOutputVolts_O fl...

Page 466: ... Link F Fixed Cause The control system is not communicating with the MV bypass board i e the MV bypass board is either not receiving commands or is getting parity errors in the messages from the modulator Bypass is in use Action Refer to Cell bypass COM fail above Cell Bypass COM Alarm A Fixed Cause The control system is not communicating with the MV bypass board but the bypass system is not in us...

Page 467: ...on Check bypass system and contactor MV bypass board xx Bypass Ack Failed xx cell that is faulted F Fixed Cause Bypass contactor closure acknowledge failed Action Check bypass system and contactor MV bypass board xx Bypass Avail Warning xx cell that is faulted A Fixed Cause Cell level bypass unavailable alarm Only if bypass is used but not active Action Check bypass system fiber optic cable MV byp...

Page 468: ...his table lists faults that may occur in all SINAMICS PERFECT HARMONY GH180 drives unless otherwise noted All cell faults are initiated by the CCB located in each power cell Handling Specific Individual Cell Faults Table 11 13 Specific individual cell faults Fault display Type Enable Potential causes and corrective actions xx 2Q Diode shorted xx cell that is faulted F Fixed Cause The cell has sens...

Page 469: ...to have the cell repaired or replaced xx Ambient Temp Warn xx cell that has alarm A Fixed Cause The ambient temperature sensor reading has exceeded the alarm thresh old Action 1 Verify if the cooling fans are operating 2 Verify if the drive ambient temperature is above the ambient alarm level temperature 3 Verify if filters are clogged and or need to be replaced xx Ambient Temp Fault xx cell that ...

Page 470: ...Temp Fault xx cell that is faulted F Fixed Cause The IGBT2 NTC temperature has exceeded the fault temperature thresh old Action 1 Verify if the cooling fans are operating 2 Verify the load current doesn t exceed the cell current capability 3 Verify if the drive ambient temperature is above the ambient alarm level temperature 4 Verify if filters are clogged and or need to be replaced xx Humidity Al...

Page 471: ...el 20 duty cycle default setting Action 1 Check the condition of the cooling system 2 Check motor load conditions xx Over Temperature xx cell that is faulted F Fixed Cause Each cell sends a PWM signal to the modulator On AP cells water cooled 6SR325 LNG and HV AP the temperature is returned in a word of this protocol This signal represents the heat sink temperature The temperature has exceeded the...

Page 472: ...or the DC bus is low possibly due to power fuses Not all cells have control power fuses Action 1 Check and replace blown cell control fuse or input power fuses 2 Repair or replace the CCB xx IGBT OOS n n 1 2 3 4 xx cell that is faulted F Fixed Cause Each gate driver board includes circuits which verify that each IGBT has fully turned on This fault might indicate a bad gate driver an open IGBT or a...

Page 473: ...ced 3 Change fiber 4 Change CCB 5 Contact Siemens customer service xx Control Fuse Blown xx cell that is faulted F Fixed Cause Cell control power fuse blown This is rarely seen since the CCB has a dual source of power Action Check cell fuses replace if necessary xx DC Bus Low Warning xx cell that has alarm A Fixed Cause Cell DC bus is below alarm level This fault alarm applies to water cooled 6SR3...

Page 474: ...tching and blocking tests Refer to the Operating Instructions manual Table 11 14 Diagnostic cell faults Fault display Type Enable Potential causes and corrective actions xx Blocking Qn n 1 2 3 4 xx cell that is faulted F Fixed Cause During cell diagnostic mode the drive checks the voltage across each IGBT under gate off conditions A blocking failure is reported if insufficient voltage is detected ...

Page 475: ...P cells the returned data is not as expected EPLD status lower 4 bits does not equal Dh Action 1 Check fiber optic connections on both CCB and DCR end 2 Change CCB xx Cell Fault Modulator xx cell that is faulted F Fixed Cause Cell is showing a fault but no fault is able to be determined Action 1 Check fiber optic connections on both CCB and DCR end 2 Change CCB xx DC Bus Dischrge alrm xx cell that...

Page 476: ...lace if incorrect 2 Check Hall effect transducers and CCB 3 Study line conditions and reactive current demand at the time of the fault 4 Adjust AFE Sat filter parameter ID 3046 as necessary 5 Verify current loop tuning parameters are set correctly xx AFE Loss of Lock xx cell that has alarm A Fixed Cause This alarm occurs when the power cells AFE sync signal generated from the modulator is lost for...

Page 477: ...hat has alarm A Fixed Cause The over temperature switch alarm occurs if water flow to the power cell is insufficient to cool the cell The overtemperature switch alarm is applica ble to 600 AP AFE 750 AP and 750 AP 4Q cells Action 1 Check for restricted water flow to the cell and correct as necessary 2 Fix any loose connections 3 Replace CCB or replace cell xx ADC Fail xx cell that is faulted F Fix...

Page 478: ...s input reactor 2 Replace power cell xx Diff Temp Fault xx cell that is faulted F Fixed Cause 600 AP AFE 750V AP 750V AP 4Q and 1375 HV AP cells contain sensors that monitor the inlet and outlet water temperature to the heat sink within the cell This difference between the inlet and outlet water temperature is passed from each CCB to the modulator The main controller reads this difference in tempe...

Page 479: ...ed cells are installed This alarm is generated when humidity as detected at the celddl exceeds the setpoint of parameter 2534 Action 1 Verify that humidity in the area where drive is installed is within the operating conditions for which the drive operation is specified 2 If the drive is equipped with a space heater adjust the temperature of the thermostat in order to reduce the humidity Continuou...

Page 480: ...at proper cooling is provided for the drive Inspect and verify air filters are not clogged 2 Replace filters if needed 3 Verify that the ambient temperature in the environment in which the drive is operated is within the operating conditions of the drive 4 Verify the load does not exceed the maximum current capability of the drive 5 Reduce the load of the drive until the warning is reset xx AFE Te...

Page 481: ...not clogged 2 Replace filters if needed 3 Verify that the ambient temperature in the environment in which the drive is operated is within the operating conditions of the drive 4 Verify the load does not exceed the maximum current capability of the drive 5 Wait at least 5 minutes and then try to reset the fault If the fault doesn t reset and if there are no other faults bypass or replace the cell x...

Page 482: ...which the drive is operated is within the operating conditions of the drive 4 Verify the load does not exceed the maximum current capability of the drive 5 Wait at least 5 minutes and then try to reset the fault If the fault doesn t reset and if there are no other faults bypass or replace the cell xx AFE Not Ready Warn xx cell that has alarm A Fixed Cause This alarm only applies when AFE cells tha...

Page 483: ...ver temperature switch fault occurs if water flow to the power cell is insufficient to cool the cell The fault is applicable to 1375 HV AP cells Action 1 Check for restricted water flow to the cell and correct as necessary 2 Fix any loose connections 3 Replace CCB or replace cell 11 12 2 Troubleshooting General Power Cell and Power Cell Circuitry Faults This section may vary per product Refer to t...

Page 484: ...occur when the transistor junction is depleted of charge carriers resulting in a higher junction resistance This in turn created a larger voltage drop and more losses in the transistor which can lead to premature failure The cause of the OOS can be a defective gate driver board or a high di dt transition on the device The gate board is designed with circuitry to detect the larger voltage drop when...

Page 485: ... the root cause A faulty CCB or bad data from the CCB could give a faulty indication of this fault Action Replace damaged or defective parts Handling switching failure faults Switching failures occur when a device opens or fails to turn on It could also be caused by a defective gate driver or a damaged device Also a defective CCB or modulator could give a faulty indication Repetitive OOS failures ...

Page 486: ...V drives set regen torque limit parameters to 0 15 3 Reduce flux regulator proportional gain 3110 and flux regulator integral gain 3120 parameters in the flux control menu 3100 4 If the failure is occurring in bypass mode increase the energy saver minimum flux 3170 parameter in the flux control menu 3100 to at least 50 5 If the measured signals from the previous section seem to be correct change t...

Page 487: ...lly as faults although they can be programmed as alarms only Refer to Chapter Operating the Software for more information Table 11 16 MV Mechanical Bypass Board Status LEDs LED function Color Description CommOK Green Indicates active communication link established with modulator Fault Red Indicates that a bypass fault is active PwrOK Green This LED is hardware controlled and indicates that the 5 1...

Page 488: ...ansformer temperature is above the alarm 1 temperature the second set opens when the transformer temperature is above the alarm 2 temperature Two outputs one output corresponding to each set are read by the control logic A Xfrmr Temperature Alarm 1 is issued when one or more alarm 1 switches open A Xfrmr Temperature Alarm 2 is issued when one or more alarm 2 switches open When both these condition...

Page 489: ... connection to the MV supply in a timely manner The following inputs and outputs are dedicated to input protection System Interface Board Contacts TB1 51 C TB1 53 NC TB1 55 NO M1 permissive al lows the circuit to close M1 to be com pleted by the custom er This opens with an IP fault and closes after the IP fault is reset including the Latch Fault Relay LFR When opened this causes the TIMV to drop ...

Page 490: ...is release If an alarm is desired then the flag AllBlowersLostWn_O must also be set true This is triggered by the SOP when 2 of 3 cell banks or both transformer banks of blowers is not function ing This is primarily used as a trip alarm preceding an over temperature trip used on air cooled drives as part of the Standard SOP Action 1 Check physical input connected to SOP flag 2 Check for faulty blo...

Page 491: ...OP flag 2 Check for faulty pumps tripped CBs or obstruction Coolant Cond 3 uS A SOP Cause Drive initiated alarm when the CoolantConductivityAlarm_O SOP flag is set true and the CoolantConductivityAlarmEn_O flag is true to enable it The default is an alarm and it cannot be changed This is used in the Standard SOP for water cooled drives as an alarm Action 1 Check physical input connected to SOP fla...

Page 492: ...s as an alarm Action 1 Check physical input connected to SOP flag 2 Check coolant temperature 3 Check for flow Cell Water Temp High F A SOP Cause Drive initiated alarm when the CellWaterTempHigh_O SOP flag is set true and the CellWaterTempHighEn_O flag is true to enable it The default is an alarm but it can be changed to a fault by setting the CellWaterTempHighWn_O flag to False true is an alarm T...

Page 493: ...d to SOP flag 2 Check sensor Low Coolant Flow 20 F A SOP Cause Drive initiated fault alarm when the LowWaterFlowFault_O SOP flag is set true and the LowWaterFlowFaultEn_O flag is true to enable it The default is a fault but it can be changed to an alarm by setting the LowWaterFlowFaultWn_O flag true This is used in the Standard SOP for water cooled drives as a trip alarm Action 1 Check physical in...

Page 494: ...ion 1 Check physical input connected to SOP flag 2 Check sensor 3 Check for faulty fan 4 Check for obstruction All HEX Fans On A SOP Cause Drive initiated alarm when the AllHexFansOn_O SOP flag is set true and the AllHexFansOnEn_O flag is true to enable it The default is an alarm and it cannot be changed This is used in the Standard SOP for water cooled drives as an alarm Action 1 Check physical i...

Page 495: ...condition of the DB50 cable between the DCR and the sys tem interface board ensure continuity of conductors for pins 41 to 50 from one connector through to the other side 5 If the above steps do not resolve the issue contact Siemens customer service Power supply Note This feature will be re leased in a later software ver sion F Fixed Cause The DCR power supply has indicated a loss of power This ca...

Page 496: ... when the SOP flag RedMainPwrSupFailEn_O is set true This should only be done for systems which use redundant main power sup plies Action 1 Verify that both redundant power supplies to the DCR are operating correctly 90 to 264 VAC 47 to 63 Hz input 12 VDC no greater than 10 of specified output 2 Check the physical condition and connections of the power supply wiring harness 3 If the above steps do...

Page 497: ...system interface board has failed This fault will only be generated if M1 permissive is commanded to be closed Action 1 Verify that the system interface board M1 PWR LED is illuminated green 2 Check connection of DB50 cable at the DCR J3 and the system inter face board P1 3 Check the condition of the DB50 cable between the DCR and the sys tem interface board Ensure continuity of conductors for pin...

Page 498: ...on module 1 of the internal I O This also applies to drives with parameter Dedicated Input Protect 7108 enabled on Refer to Section Dedicated I O For Input Protection Troubleshooting Faults and Alarms 11 14 Drive Faults and Alarms Low Voltage Power Supply Related NXGPro Control Manual 496 Operating Manual A5E50491925A ...

Page 499: ...copy of the parameter configuration file that was created when the DCR was last rebooted When this occurs a log entry will be entered into the system log If there was subsequent file deletion zeroing due to ongoing internal system errors then the system will try to recover to the defaults file If the defaults file is not available then the original configuration file will be used In all instances ...

Page 500: ...en If this screen is shown Check the cable between the drive s control system and the keypad Make sure that drive s control system is functioning correctly Recycling the power to the control system may rectify the problem If these steps do not resolve the issue contact Siemens customer service Troubleshooting Faults and Alarms 11 16 Loss of Communication to Keypad NXGPro Control Manual 498 Operati...

Page 501: ...ivalent inertia from Wk to SI by dividing lb ft by 23 73 1 kg m 23 73 lb ft therefore J kg m J lb ft 23 73 Table A 1 NEMA Table 20 1 from NEMA Standard MG 1 1993 Part 20 42 converted to SI units Maximum Load Inertia for Polyphase Squirrel Cage Induction Motors in kg m Inertia from kW and speed in units of Kg m 23 73 lb ft 1 kg m Hp kW 3600 1800 1200 900 720 600 514 450 400 360 327 300 100 75 533 9...

Page 502: ...089 3 2309 3 4100 3 6523 4 9633 4 13480 8 18112 1 23556 7 29877 8 37126 0 4000 2984 66 2 398 7 1199 3 2557 9 4559 6 7273 5 10762 7 15086 4 20295 0 26422 3 33544 0 41677 2 4500 3357 68 6 426 5 1301 7 2793 9 5002 1 7998 3 11858 4 16645 6 22418 9 29203 5 37126 0 46144 1 5000 3730 70 0 451 7 1397 4 3021 5 5423 5 8697 9 12916 1 18154 2 24483 8 31942 7 40581 5 50484 6 5500 4103 70 7 473 7 1486 7 3232 2 ...

Page 503: ...900 720 600 514 450 400 360 327 300 14000 10444 2229 2 5533 1 10686 9 17943 5 27517 9 39570 2 54319 4 71934 3 92498 9 116224 2 15000 11190 2237 7 5667 9 11057 7 18664 1 28697 9 41424 4 56974 3 75558 4 97303 0 122376 7 NEMA Table NXGPro Control Manual Operating Manual A5E50491925A 501 ...

Page 504: ...NEMA Table NXGPro Control Manual 502 Operating Manual A5E50491925A ...

Page 505: ...ecorded historic log The event log includes the option to copy and record the historic log so that all fault events are recorded The historic log is stored in memory with a total of 512 records Non volatile memory is used to store the most recent 78 records Snapshots are recorded at the slow cycle update rate Most snapshots are recorded before a fault occurs 20 snapshots are recorded after a fault...

Page 506: ...e memory until the next fault occurs at which time the old information is overwritten To preserve multiple records of historical logs the user can enable default is enabled saving the historical logs into the event log file To prevent overrunning the event log with too much historical log information the number of pre fault samples is reduced to 57 samples The user defined variables are to be sele...

Page 507: ...t17 CPUTempFault bit18 CellOverTempAlarm bit19 Cells bit12 InTorqueLimit bit13 InTorqueLimitRollback bit14 InputPhaseLoss bit15 OutputPhaseOpen bit8 OutputGroundFault bit9 IOC bit10 MenuInit bit11 OverSpeedAlarm bit0 OverSpeedFault bit1 UnderLoadAlarm bit2 UnderLoadFault bit3 InputGroundFault bit40 EncoderLoss bit41 KeypadCommunication bit42 Network1Communication bit43 Network2Communication bit44 ...

Page 508: ...h bit16 LowWaterLevelAlarm bit17 LowWaterLevelFault bit18 LowWaterFlowAlarm bit19 CoolantConductivityFault bit12 InletWaterTempHigh bit13 InletWaterTempLow bit14 CellWaterTempHigh bit15 XformerOverTempFault bit8 OnePumpFailure bit9 AllPumpsFailure bit10 CoolantConductivityAlarm bit11 OneBlowerLost bit0 AllBlowersLost bit1 Insufficient Cooling bit2 ReactorTemperature bit3 LossOfSignal1 bit40 LossOf...

Page 509: ...9 bit18 UserFault20 bit19 UserFault13 bit12 UserFault14 bit13 UserFault15 bit14 UserFault16 bit15 UserFault9 bit8 UserFault10 bit9 UserFault11 bit10 UserFault12 bit11 UserFault1 bit0 UserFault2 bit1 UserFault3 bit2 UserFault4 bit3 UserFault41 bit40 UserFault42 bit41 UserFault43 bit42 UserFault44 bit43 UserFault45 bit44 UserFault46 bit45 UserFault47 bit46 UserFault48 bit47 UserFault49 bit48 UserFau...

Page 510: ...PoleSlip bit14 ReservedBit15 bit15 Input Frequency Alarm bit8 AfeCellDiffTempFault bit9 FieldExciterFault bit10 SMDCStartupFault bit11 InternalLossofSignal1 bit0 InternalLossofSignal2 bit1 InternalLossofSignal3 bit2 PrechargeFault bit3 IntIoInternalError bit40 IntIoConfigFault bit41 IntIoModuleAddress bit42 IntIoWatchDogFault bit43 InternalLossOfSignal4 bit44 InternalLossOfSignal5 bit45 InternalLo...

Page 511: ...Alg Analog AP Advanced protocol for cell communication avail Available BTU British thermal units C Centigrade or Capacitor cap Capacitor CCB Cell Control Board ccw Counter clockwise CE Formerly European Conformity now true definition CFM Cubic Feet per Minute CLVC Closed Loop Vector Control cmd Command com Common conn Connector CPS Control Power Supply CPU Central Processing Unit CSMC Closed Loop ...

Page 512: ...fwd Feed Forward FLC Full Load Current freq Frequency ft Feet fwd Forward gnd Ground GUI Graphical User Interface H Height hex Hexadecimal hist Historic Hp Horsepower hr Hour HVAC Heating Ventilation Air Conditioning HVF Harmonic Voltage Factor Hz Hertz I Integral PID ID Identification IEC International Electrotechnical Commission IEEE Institute of Electrical and Electronic Engineers IGBT Insulate...

Page 513: ... Minimum Minute msec Millisecond S Msl Mean Sea Level MV Medium Voltage mvlt Motor Voltage MW Megawatt NC Normally Closed NEMA National Electrical Manufacturer s Association NO Normally Open NVRAM Non Volatile Random Access Memory NXG Next Generation Control NXGpro Next Generation Control pro NXGPro Next Generation Control Pro Plus OLVC Open Loop Vector Control O M Overmodulation OOS Out of Satura...

Page 514: ...Q2 Q3 Q4 Output Transistor Designations rad Radians RAM Random Access Memory ref Reference rev Reverse Revolution S RFI Radio Frequency Interference RLBK Rollback rms Root mean squared RPM Revolutions Per Minute RTD Resistance Temperature Detector RTU Remote Terminal Unit RX Receive RS232 Communications s Second s SCR Silicon Controlled Rectifier sec Second s ser Serial SIB System Interface Board ...

Page 515: ...tions UPS Uninterruptable Power Supply V Voltage Volts VA Volt Amperes VAC Volts AC var Variable VDC Volts DC vel Velocity speed VFD Variable Frequency Drive V Hz Volts per Hertz vlts Voltage s Volts W Width Watts WAGO Expansion I O System brand name xfmr xformer Transformer List of abbreviations C 1 Symbols and Abbreviations NXGPro Control Manual Operating Manual A5E50491925A 513 ...

Page 516: ...List of abbreviations C 1 Symbols and Abbreviations NXGPro Control Manual 514 Operating Manual A5E50491925A ...

Page 517: ...Index D NXGPro Control Manual Operating Manual A5E50491925A 515 ...

Page 518: ...Index NXGPro Control Manual 516 Operating Manual A5E50491925A ...

Page 519: ...s are used to indicate either a true 1 or false 0 state within the drive s programming Boolean algebra A form of mathematical rules developed by the mathematician George Boole used in the design of digital and logic systems Carrier frequency Carrier frequency is the set switching frequency of the power devices IGBTs in the power section of each cell The carrier frequency is measured in cycles per ...

Page 520: ...rol modes of the drive This is a flux vector control for a synchronous machine utilizing an encoder for speed feedback and providing a field excitation command for use by an external field exciter DC link The DC link is a large capacitor bank between the converter and inverter section of the drive The DC link along with the converter establishes the voltage source for the inverter De Morgan s Theo...

Page 521: ...olerable electromagnetic disturbances to anything in that environment ESD ESD is an acronym for ElectroStatic Discharge ESD is an undesirable electrical side effect that occurs when static charges build up on a surface and are discharged to another When printed circuit boards are involved impaired operation and component damage are possible side effects due to the static sensitive nature of the PC...

Page 522: ...harmonic currents Harmonics are also found in uninterruptable power supplies UPSs rectifiers transformers ballasts welders arc furnaces and personal computers Hexadecimal digits Hexadecimal or hex digits are the numerals used to represent numbers in the base 16 hex number system Unlike the more familiar decimal system which uses the numerals 0 through 9 to make numbers in powers of 10 the base 16 ...

Page 523: ...ion and error checking embedded Inverter The inverter is a portion of the drive that changes DC voltage into AC voltage The term inverter is sometimes used mistakenly to refer to the entire drive the converter DC link and inverter sections Jog mode Jog mode is an operational mode that uses a pre programmed jog speed when a digital input programmed as the jog mode input is closed Jumpers Jumper blo...

Page 524: ... parameter change and setting H 1 hides the menu option from view until the appropriate access level has been activated Memory Memory is the working storage area for the drive that is a collection of RAM chips Microprocessor A microprocessor is a central processing unit CPU that exists on a single silicon chip The microprocessor board is the printed circuit board on which the microprocessor is mou...

Page 525: ...er PED PED is an acronym for pressure equipment directive a directive of the EU relating to pressure vessels Pick list A pick list is one of four items found in the menu system Pick lists are parameters that have a finite list of pre defined values from which to choose rather than a value range used by parameters PID PID is an acronym for proportional integral derivative a control scheme used to c...

Page 526: ...esired or optimal speed of the VFD to maintain process levels speed command Slip Slip is the difference between the stator electrical frequency of the motor and the rotor mechanical frequency of the motor normalized to the stator frequency as shown in the following equation Slip ωS ωR ωS Slip compensation Slip compensation is a method of increasing the speed reference to the speed regulator circui...

Page 527: ...nd downloading files over the RS232 connection See Tool Suite definition Speed Menu function Speed menu is a feature of the menu system that allows the operator to directly access any of the menus or parameters rather than scrolling through menus to the appropriate item This feature uses the Shift button in conjunction with the right arrow The user is prompted to enter the four digit ID number ass...

Page 528: ...via direct access to the Flash Disk Host Simulator used for monitoring programming and controlling a drive remotely from a PC over the built in ethernet port of the drive Parameter changes status display and graphing of internal variables are its main functions Debug Tool this tool is used to display the diagnostic screens of the drive for diagnosing drive problems or improving performance via the...

Page 529: ...is intended for multiple motors connected in parallel Therefore it disables spinning load and fast bypass This is essentially open loop vector control with de tuned smaller bandwidth obtained by reducing the gain current regulators Glossary NXGPro Control Manual Operating Manual A5E50491925A 527 ...

Page 530: ...Glossary NXGPro Control Manual 528 Operating Manual A5E50491925A ...

Page 531: ...overload setting 216 parameter 217 cell fault 67 cell trip 67 closed loop vector control 54 70 command generator 218 258 analog input sources 218 set point sources 220 Commissioning 23 communication interfaces 404 Communications Menu 167 Serial Port Setup Menu 168 SOP and Serial Functions Menu 168 TCP IP Setup Menu 169 communications protocol 265 Control Loops 60 control modes 257 summary 49 Contr...

Page 532: ... guidelines 29 ethernet 392 communications network 264 Ethernet port 229 Excessive drive losses implementation 209 internal threshold 210 inverse time curve 210 parameters 210 External and internal inputs configuring 138 external flux reference 242 parameters 242 external I O 75 configuring 112 External outputs configuring 144 F fast bypass 67 106 cell fault detection 182 limitations 183 number of...

Page 533: ...ring and resetting a fault 343 375 414 clearing and resetting an alarm 344 375 414 default meter display 355 366 381 405 420 diagnostic LED indicators 341 380 419 display interface 389 429 editing parameter values 351 379 418 enter key 348 fault LED conditions 342 374 413 fault reset key 342 373 412 front panel display 351 379 418 functions 340 390 429 hexadecimal values 346 manual start key 345 3...

Page 534: ...4 slave setup and configuration parameters 172 multiple drives in parallel 316 multiple motors 53 multiple networks 404 N network 339 network interface 404 neutral point shift 15 cell drive in which no cells are bypassed 186 after loss of 3 cells 188 after loss of 5 cells 189 Drive output with 2 cells bypassed 186 O One cycle protection 203 integral timer 205 transformer model 204 Open Loop Test M...

Page 535: ...al 215 under voltage 212 RS485 serial port 264 S safety electrical hazard 252 441 high voltages 231 443 scaling 139 Security default access codes 152 Security Edit Functions 151 menu 152 set point sources 220 Shielding 23 Signal Polarities 180 Single induction motors 50 slip compensation 236 calculations 236 disabling 237 motor speed 236 software version 33 355 367 381 406 420 SOP 431 speed demand...

Page 536: ...torque mode 319 parameters 320 torque reference 319 trained personnel 76 transformer 204 transformer model one cycle protection 204 Transport 23 troubleshooting 486 electrical hazard 441 high voltages 231 443 transformer over temperature loss of cooling 486 U up down transfer timeout 112 up transfer induction motor 262 synchronous motor 266 USB port 229 user I O 44 user I O board 77 V Variable Spe...

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