Application for Drive Technology

Transcription

1 Application for Drive Technology MICROMASTER 4 Application Description Conveyor Systems Hoisting Gear Engineering and Commissioning

2 Warranty, Liability and Support 1 Warranty, Liability and Support We do not accept any liability for the information contained in this document. Any claims against us based on whatever legal reason resulting form the use of the examples, information, programs, engineering and performance data etc., described in this document shall be excluded. Such an exclusion shall not apply in the case of mandatory liability, e.g. under the German Product Liability Act ( Produkthaftungsgesetz ), in case of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of a condition which goes to the root of the contract ( wesentliche Vertragspflichten ). However, claims arising from a breach of a condition which goes to the root of the contract shall be limited to the foreseeable damage which is intrinsic to the contract, unless caused by intent or gross negligence or based on mandatory liability for injury of life, body or health. The above provisions does not imply a change in the burden of proof to your detriment. The Application Examples are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. They do not represent customer-specific solutions. They are only intended to provide support for typical applications. You are responsible in ensuring that the described products are correctly used. These Application Examples do not relieve you of the responsibility in safely and professionally using, installing, operating and servicing equipment. When using these Application Examples, you recognize that Siemens cannot be made liable for any damage/claims beyond the liability clause described above. We reserve the right to make changes to these Application Examples at any time without prior notice. If there are any deviations between the recommendations provided in these Application Examples and other Siemens publications e.g. Catalogs then the contents of the other documents have priority. Copyright 25 Siemens A&D. It is not permissible to transfer or copy these Application Examples or excerpts of them without first having prior authorization from Siemens A&D in writing. For questions about this document please use the following -address: mailto:csweb@ad.siemens.de A&D SD Page 2/47

3 Definitions and Warnings 2 Definitions and Warnings 2.1 Qualified Personnel In the sense of this documentation qualified personnel are those who are knowledgeable and qualified to install, mount, commission, operate and service/maintain the products to be used e.g.: o Trained and authorized to energize and de-energize, ground and tag circuits and equipment according to applicable safety standards. o Trained or instructed according to the latest safety standards in the care and use of the appropriate safety equipment. o Trained in rendering first aid. There is no explicit warning information in this documentation. However, reference is made to warning information and instructions in the Operating Instructions for the particular product. 2.2 User group The application software and the application example were developed to support Siemens personnel in the generation of user programs for machines or systems. This is not intended to be directly passed-on or sold to persons/companies outside Siemens AG. Application software may only be passed-on as part of a complete machine or plant software. If application software, which is not integrated in a complete project, is passed-on to persons/companies outside Siemens AG, then the person or persons who transferred this information carry full responsibility for any liability or damage claims. Only qualified personnel may apply the application software and the application example. If this is incorrectly used, this can result in the plant or system being destroyed and/or injury to personnel. A&D SD Page 3/47

4 Definitions and Warnings 2.3 Applicable conditions The valid Edition for the General Conditions of Sale and Delivery for Products and Services for internal Siemens business applies. 2.4 Information regarding trademarks SIMOVERT is a Siemens registered trademark MICROMASTER is a Siemens registered trademark 2.5 Revision/Author Version Date/change Author 1/5 First edition M. Schmittele A. Bader A&D SD Page 4/47

5 Hoisting gear 3 Hoisting gear 3.1 Introduction These instructions are used to commission hoisting gear equipment. Please refer to the appropriate Operating Instructions and/or parameter lists if certain issues are not clear or the functionality is to be expanded. The frequency converter must be ready to operate. This means that the frequency converter must have been installed, mounted and connected-up according to the data in the Operating Instructions. In practice, difficulties are often encountered when using MM44 frequency converters for hoisting gear applications. Frequently, incorrect commissioning and engineering mistakes as well as unsuitable operating modes are the reasons. Generally, a hoisting gear doesn t tolerate any faults/errors. These Instructions are a guide for engineering and commissioning the MM44 for hoisting gear applications to allow you to quickly and reliably engineer conventional hoisting gear. 3.2 Hoisting gear applications MM44 frequency converters can be especially recommended for cranes with low and average performance requirements both as hoisting gear as well as traversing gear drive. Not only this, it can be used for hoisting applications in conveyor systems. Application examples include: o o o Cranes in halls e.g. in workshops and storage facilities/warehouses: Hoisting and traversing gear equipment Hoisting gear in conveyor systems with and without counter-weight Outdoor storage locations/warehouses cranes: Hoisting and traversing gear 3.3 Validity/ restrictions o o This application document describes the closed-loop control types V/f control and closed-loop vector control with encoder and KTY 84. Closed-loop vector control with encoder and KTY 84 is the preferred operating mode. It should be clearly pointed-out that at the present time, the MM44 does not reliably detect pulse encoder faults and when the motor stalls. A&D SD Page 5/47

6 Hoisting gear o o o Presently, we do not recommend additional operating modes as mentioned in this Section for example SLVC or VC with speed encoder without KTY. When using the parameter assignments recommended in Section Pre-control to prevent the load dropping/sagging when entering a uni-polar speed setpoint, CDS command data sets cannot be used. In this document, reference is made in the literature references to documents that are only available in the SD Intranet. 3.4 Information and instructions when selecting/dimensioning motors and frequency converters, definitions Selecting/dimensioning motors and frequency converters using SIZER Here, reference should be made to the SIZER program, that also provides engineering support when selecting and dimensioning hoisting gear Rough selection/dimensioning of motors and converters for VC with pulse encoder The rough selection/dimensioning described here has proven itself in practice and for most hoisting gear applications, provides good results. It assumes the following: The rated hoisting power P nh at the rated velocity of the hoisting gear is calculated. A maximum power that has been empirically determined of P max = 2 P nh is required for accelerating or a maximum torque, refer below. The motor is dimensioned for the rated hoisting torque M nh, if, starting from M nh, 2% overload is possible. Otherwise, the motor must be dimensioned corresponding to the overload or the ramp-up and ramp-down times of the hoisting velocity should be extended. For frequency converters up to 75 kw, 15% overload can be utilized and for frequency converters from 9 to 2 kw, 136% overload. We do not recommend that 2% overload is used. When the 2% overload is used, this results in a load duty cycle, that does not match the usual operating mode of cranes and hoisting gear. The formulas for the calculation example are shown below. The essential quantities of a hoisting gear are shown in Fig A&D SD Page 6/47

7 Hoisting gear Encoder Motor Gear Rope drum 3~ M d/2 n M ; M M i n T F' Distance s S v F S = 2 S = 1 m Load m Load m Load Fig : Diagram showing the essential quantities of a hoisting gear Calculation example: - Total load (load + load suspension equipment): m = kg - Rated hoisting velocity: v = m/min =.36 m/s - η mechanical =.9 (without η motor (!)) - Cable drum diameter d =.4 m - Gear ratio: i = 1 : 37 - Suspension/ reeving S = 2 a) Calculating the rated hoisting power P nh = (m g v) / η mechanical = (3141kg 9.81kg/ m².36 m/s) /.9 = W = 12.3 kw With P nh = rated hoisting power in [kw] g = 9.81 m/s 2, acceleration due to gravity v = rated hoisting velocity in [m/s] m = nominal mass of the load to be hoisted in [kg] A&D SD Page 7/47

8 Hoisting gear Note: The hoisting power can be quickly calculated with just few data and provides a rough basis for the hoisting gear power. Generally, it is not suitable for selecting/dimensioning the motor and frequency converter. To do this, the following formulas should be used. b) Calculating the shaft speed n M of the motor from: n M = i n T = (i S v) / (π d) = ( m/s) / (π.4 m) = / s = RPM With i = gear ratio n M = motor speed in [RPM] n T = cable drum speed in [RPM] S = reeving d = cable drum diameter in [m] c) Calculating the required rated hoisting torque M nh for v = constant: M nh = (m g d) / (2 i S η) = (3141 kg 9,81 m/ s^2,4) / (2 37 2,9) = 93 Nm With M nh = rated hoisting torque in [Nm] d) Selecting a motor: Starting from a rated torque of 93 Nm and a speed of RPM, a 1LA AA.. motor is selected. Check whether the motor can output the maximum required torque: M hmax = 2 M nh, as required: The motor supplies the following maximum torque: M maxm =,77 M k M nm =,77 3, 98 = 226 Nm A&D SD Page 8/47

9 Hoisting gear From c): M hmax = 2 M nh = 2 93 Nm = 186 Nm The motor can output the max. hoisting torque. With M maxm = max. motor torque in [Nm] M hmax = max. hoisting torque in [Nm] M k = stall torque/ rated torque = 3. from Catalog M11 M nm = rated torque = 98 Nm from Catalog M11 e) Calculating the max. motor current Imaxm: e1) Torque overload factor m: m = M hmax / M nm = 186 Nm / 98 Nm = 1,9 e2) Calculating the max. motor current Imaxm: cos φ =.84, from the Catalog I nm = 28.5 A (rated motor current), from the Catalog from e1): m = 1,9 I o = I nm (1 cos φ)½ = 28,5 A (1,84)½ = 11,4 A With I o = magnetizing current in [A] I w = (I n ² I o )½ = (28,5 A² - 11,4 A²)½ = 26, 1 A With I w = active current in [A] I maxm = (I o ² + (m I w )²)½ = (11,4 A² + (1,9 26,1 A)²)½ = 51 A A&D SD Page 9/47

10 Hoisting gear f) Selecting and dimensioning the frequency converter: From e): I maxm = 51 A When using the frequency converter overload, the rated frequency converter current I nfu is given by: I nfu = I maxm / 1,5 = 51 A / 1,5 = 34 A A 6SE644-2UD31-8AD1 frequency converter with 18.5 kw power and a rated output current of 38 A is selected. For information and instructions to set parameters P64, P152 and P1521, refer to function chart 771: o o o o Prerequisite: P35 = 28.5 A (rated motor current, from the rating plate already calculated, refer to e): I max = 54 A Overload factor P64 = 54 A / 28.5 A 1 % = 189 % or the maximum value from P64 Upper torque limit P 152 = 194 Nm or maximum value from P152 (M max =.77 M k ) Lower torque limit P 1521 = -194 Nm or minimum value from P1521 (M min = -.77 M k ) Roughly selecting and dimensioning motors and frequency converters for V/f The motor and frequency converter are selected/dimensioned the same as described above with the following restrictions: The rated motor torque may not be exceeded! A&D SD Page 1/47

11 Hoisting gear Others When using field weakening it should be carefully ensured that the torque taken from the motor is reduced corresponding to the square of the field-weakening speed. For hoisting gear equipment with heavy duty cycles and the appropriate overload when accelerating and decelerating, the load duty cycle should be used to check whether the motor and frequency converter selection/dimensioning is sufficient from the perspective of the RMS value of the current. The braking resistor should be dimensioned for the duration of the lowering and the load duty cycle. For more detailed information, refer to Document /5/. Further, the MM44 Operating Instructions should be taken into account. This information only includes special issues that have to be noted when engineering hoisting gear applications. The other rules that apply must also be carefully observed. 3.5 Closed-loop control technique The following closed-loop control techniques are available a) V/f characteristic (P13 = ) an encoder is not required either no overload or just a low motor overload is possible restricted dynamic performance of the hoisting gear as there is no torque reserve b) Closed-loop vector control (P13 = 21) and KTY 84 an encoder and KTY 84 are required when appropriately selecting and dimensioning the frequency converter the overload capability of the motor can be fully used. dynamic crane operation is possible A&D SD Page 11/47

12 Hoisting gear 3.6 Commissioning If a harmonized and coordinated parameter set is still not available for the frequency converter / hoisting gear, then before optimizing the closed-loop vector control or the V/f control, carry-out and observe the following steps: 1. Loads that are potentially hazardous a) Lower the load to the floor (secure the load), or b) Ensure that the frequency converter cannot control the motor holding brake (MHB) c) When commissioning the load, e.g. optimizing the controller etc., it must be possible to immediately stop the hoisting gear. This should be able to be done, for example, using an Emergency Stop button located close by that also directly acts on the hoisting gear brake. Before starting any work, the effectiveness of this function must be carefully checked to ensure that it is working perfectly. 2. Quick commissioning (refer to Chapter 4) Quick commissioning should always be carried-out.. 3. Motor holding brake (MHB) (refer to Chapter 5) For drives that must be secured in the powered-down condition against undesirable motion, the brake sequence control of the MM4 (this function is enabled using P1215) can be used to control the motor holding brake. Notes a. When controlling the MHB, the interaction between opening/closing the mechanical brake and the motor torque being established is decisive. This interaction in the frequency converter is instantaneous without any delay. This is the reason that the control implemented in the frequency converter itself is preferred over an external control (e.g. Simatic. b. If the motor holding brake is controlled from a higher-level control system (e.g. Simatic, crane control, etc.), then the brake control should be realized there! c. The term MHB of course includes for example, an external brake mounted on the brake drum, that, for example, is controlled from the frequency converter. d. If P1215 = (P1215: enable MHB), then r52.12 = 1 a brake controlled by the frequency converter opens. Therefore: The binary output, that controls the hoisting gear brake, may only be connected with r52.12 if P1215 = 1. A&D SD Page 12/47

13 Hoisting gear 4. Regenerative energy (refer to Chapter 6) If the frequency converter brakes a motor in a short time or a hoisting gear lowers a heavy load, the motor operates in the regenerative mode and feeds energy back into the frequency converter. The frequency converter DC link voltage increases. If this voltage becomes too high (overvoltage F2), the frequency converter inhibits the inverter and the motor coasts-down. By using the resistor brake, the regenerative energy is fed through the braking chopper to the external braking resistor where it is converted into heat. This means that the frequency converter can control the motor corresponding to the setpoint even in regenerative operation. 5. Motor data identification (refer to Chapter 7) a. P191 = 1 + ON command Motor data identification b. P191 = 3 + ON command Comment.: It is not absolutely necessary to determine the saturation characteristic, if the frequency converter is only used in the voltage control range. However, the saturation characteristic must be determined when operating in the field-weakening range 6. Magnetizing current (refer to Chapter 8) The value of the magnetizing current r331/p32 has aspecial influence on the accuracy of the motor model parameters. This value is estimated from the rating plate on SIEMENS standard motors. Especially for third-party motors, the determined magnetizing current should be again checked and if required corrected. The following criteria can be used for the magnetizing current: o Flux setpoint (r1598=1%) matches the flux actual value (r84=96..14%) of the motor model. o The Xm adaptation (r1787) of the motor model should, if possible, not intervene. Good values lie between 1-5%. o Please refer to /6/ and Section when setting the magnetizing current. A&D SD Page 13/47

14 Hoisting gear 7. Optimizing the closed-loop control Depending on the closed-loop control technique, the individual parameters for the hoisting gear application must be appropriately optimized. The important parameters can be taken from the following sequence diagrams: o V/f characteristic refer to Chapter 1.1 o Closed-loop vector control with encoder refer to Chapter Motor temperature (refer to Chapter 9) A KTY84 sensor is used to measure the motor temperature. Among other things, the motor temperature depends on the load level, load duration, speed and type of motor cooling. The motor temperature influences the stator and rotor temperature and must, as far as possible, be precisely emulated in the motor model of the drive converter. 3.7 Series commissioning If a harmonized, coordinated parameter set is available for the drive converter / hoisting gear, then please observe the following: 1. Potentially hazardous loads a) Secure the load, or b) Inhibit the MHB control (e.g. disconnect the connection between the drive converter and the motor holding brake) c) Under all circumstances, ensure that the hoisting gear motor does not unintentionally rotate (cable drum) in order to avoid mechanical damage. Then start the fast commissioning / parameter download using the PC tool (e.g. STARTER, AOP) A&D SD Page 14/47

15 Quick commissioning 4 Quick commissioning Note: Before starting any of the commissioning steps in Section 4, the hoisting gear motor must be secured so that it cannot unintentionally start and the holding brake of the hoisting gear must be locked-out so that it cannot be unintentionally opened (e.g. so that the holding brake cannot be intentionally released). o o o The steps shown in Section 4 should be carried-out for both closedloop control types (VC with pulse encoder and KTY 84 and V/f. With the fast commissioning, the drive converter is adapted to the motor and important technology parameters are set. The parameters designated with a * offer more setting possibilities than are listed here. Please refer to the parameter list for these additional setting possibilities. START P3 = 2 P1 = 1 P1 =... P1 = 1, 2 P1 = Note: Factory setting We recommend that before starting any commissioning work, all of the parameters are set to the factory setting. If required, settings should be made at Starter/ DriveMonitor and at the drive unit (P21, P212). Access stage * 1 Standard (basic/simple application) 2 Expanded (standard application) 3 Expert (complex application) Commissioning parameters * Ready 1 Fast commissioning 3 Factory setting NOTE P1 should be set to 1 in order to enter the motor rating plate data. Europe/ North America Select the power entry (kw / hp) and the rated motor frequency Europe [kw], rated motor frequency 5 Hz and DIP2(2) OFF (factory setting) 1 North America [hp], rated motor frequency 6 Hz and DIP2(2) ON 2 North America [kw], rated motor frequency 6 Hz Remove the I/O module access to DIP 2(2) DIP5/6 1 NOTE For P1 = or 1, the setting of switch DIP5/6 defines the value of P1. A&D SD Page 15/47

16 Quick commissioning P34 =... P34 =... Rated motor voltage FC spec. (the rating plate in V is entered) Check the rated motor voltage on the rating plate regarding the star/ delta circuit with the connections on the motor terminal board. P31 P34 P35 =... P35 =... Rated motor current FC spec. Input acc. to the rating plate in Amps P37 =... P37 =... P38 =... P38 =... P39 =... P39 =... P31 =... P311 =... P335 =... P64 =... P7 =... Rated motor power FC spec. (the rating plate in kw/hp is entered). If P1 = or 2, then the input is in kw, for P1 = 1, in hp. P37 P35 P38 P311 Rated motor power factor (the cos ϕ data on the rating plate is entered) For the setting, the value is automatically calculated. P1 = 1,2: P38 has no significance, an entry is not required Rated motor efficiency (input acc. to the % data on the rating plate) For the setting, the value is automatically calculated. P1 = : P39 has no significance an entry is not required Rated motor frequency (the Hz specified on the rating plate is entered) The number of pole pairs is automatically taken into account. Rated motor speed The input is acc. to the rating plate in RPM Motor cooling * (the motor cooling system is entered) Self-ventilated using the fan mounted on the motor shaft 1 Force-ventilated (separately-driven fan) Motor overload factor 15 % (entered as a % referred to P35) This defines the limit value of the maximum output current as a % of the rated motor current (P35). Note: Generally, the overload factor here is selected so that the motor can provide the maximum demanded torque when hoisting and lowering the load refer to Section 3.4 Selects the command source 2 Defines the command source with which the drive converter is controlled. Factory pre-setting 1 BOP (converter keyboard) 2 Terminal strip 4 USS at the BOP link 5 USS at the COM link 6 CB at the COM link BOP Terminals USS BOP link USS COM link CB COM link P7 = 2 Sequence control Setpoint channel FC spec. FC spec. 5. Hz 6. Hz FC spec. Closed-loop motor ctrl. A&D SD Page 16/47

17 Quick commissioning P1 =... Selects the setpoint source * 2 Defines the frequency setpoint source that is defined by the setpoint that has been entered. 1 Motorized potentiometer setpoint 2 Analog input 3 Fixed frequency 4 USS at the BOP link 5 USS at the COM link 6 CB at the COM link 7 Analog input 2 MOP ADC Sequence control FF USS BOP link USS COM link P1 = 12 P1 = 12 Additonal setpoint Main setpoint Setpoint channel Motor control CB COM link ADC2 P18 =... P182 =... P112 =... P1121 =... Minimum frequency. Hz (the lowest motor frequency in Hz is entered) The lowest motor frequency with which the motor can operate independent of the frequency setpoint is entered. The value set here applies for both directions of rotation. Note: P18 = Maximum frequency 5. Hz 6. Hz (the highest motor frequency in Hz is entered) The maximum frequency to which, e.g. the motor is limited independent of the frequency setpoint, is entered. The value set here applies for both directions of rotation. Ramp-up time (accelerating time) 1. s (the accelerating time in s is entered) The time in which, e.g. the motor should accelerate from standstill up to the maximum frequency P182 is entered. Ramp-down time (deceleration time) 1. s (input the deceleration time in s) The time in which e.g. the motor should brake from the maximum frequency P182 down to standstill is entered. Note: This time should not be set too long in order to avoid actuating a limit switch. Recommended setting: P1121 = P112 A&D SD Page 17/47

18 Quick commissioning P1135 =... P13 =... P39 = 1 ENDE OFF 3 ramp-down time 5. s (the fast stop ramp-down time in s is entered) The time in which e.g. the motor should brake from the maximum frequency P182 down to standstill for an OFF3 command (fast stop) is entered. Note: Generally, the value of P1135 is < the value of P1121 Closed-loop control type * (the required closed-loop control type is entered) V/f with linear characteristic 21 Closed-loop vector control with sensor End of fast commissioning (start of the motor calculation) 3 Only motor calculation. The remaining parameters are not reset. NOTE For P39 = 3 internally, P34 is set to 1 and the appropriate data calculated (refer to the parameter list P34). End of the fast commissioning/drive setting. A&D SD Page 18/47

19 Motor holding brake (MHB) and hoisting gear brake 5 Motor holding brake (MHB) and hoisting gear brake This Section applies both for V/f control as well as for closed-loop vector control with encoder. Series / commissioning for potentially hazardous loads proceed as follows Lower the load to the floor The hoisting gear motor must be inhibited so that it cannot unintentionally start. When replacing the drive converter, prevent the drive converter from controlling the MHB until the new drive converter has been completely commissioned. Secure the load, and ensure that the MHB cannot be controlled and then, and only then commission / download parameters using the PC tool (e.g. STARTER, AOP) Only connect the binary output (P731 P733) for the brake control to r52.12 if P1215 = 1. Generally, every hoisting gear has a brake. This brake is either the motor holding brake or is an external brake e.g. that is mounted on the cable drum. It makes sense if this brake is controlled by the drive converter itself. Generally, the hoisting gear brake is only designed as holding brake and not as operational brake. Pre-control to prevent the load sagging/dropping when the holding brake is opened (weight equalization) and delayed setpoint enable, refer to Section 1. Notes: The pre-control to prevent the load sagging depends on the weight of the suspended load that must be raised. In most cases, one setting is suitable for all load situations. The modified brake control can result in improved drive behavior when starting. A&D SD Page 19/47

20 Motor holding brake (MHB) and hoisting gear brake The application / release times (brake closing / brake opening times) can be taken from the appropriate documentation. The following typical values have been taken from the M11 Motor Catalog 23/24, Page 2/51 Motor frame size Brake type Release time [ms] Application time [ms] 63 2LM8 5-1NAxx LM8 5-2NAxx LM8 1-3NAxx LM8 2-4NAxx LM8 4-5NAxx LM8 6-6NAxx LM8 1-7NAxx LM8 26-8NAxx LM8 315-NAxx LM8 4-NAxx Table 3: Application/release times (M11 Motor Catalog) A&D SD Page 2/47

21 Motor holding brake (MHB) and hoisting gear brake P1215 =... Enables the motor holding brake Activates/de-actives the motor holding brake (MHB). Motor holding brake inhibited 1 Motor holding brake released fmin (P18) Note P1216 P1217 r52 The following applies when controlling Bit12 Point 1 Point 2 the brake relay via, e.g. digital output 1: 1 P731 = 52.C (or 52.12) t f t P731=52.C BI: Fct., digital output Defines the source for digital output 1. Note The brake relay can be controlled via one of the two other digital outputs. MM44 DOUT channel Functio n xxxx.y rxxxx.y BI: Fct. of DOUT 1 P731.C (52:3) P731 = xxxx.y 52. Ready to power-up closed 52.1 Ready closed 52.2 Drive running closed 52.3 Fault present closed 52.4 OFF2 active 1 closed 52.5 OFF3 active 1 closed 52.6 Power-on inhibit active closed 52.7 Alarm active closed 52.8 Setpoint/actual value deviation 1 closed 52.9 PLC control (PZD control) closed 52.A Maximum frequency reached closed 52.B Alarm: Motor current limiting 1 closed 52.C Motor holding brake (MHB) active closed 52.D Motor overload 1 closed : : Invert DOUTs... 7 P748 () 1-1 CO/BO: State DOUTs r747 r747. Relay : - max. load capability 3 V DC / 5 A 25 V AC / 2 A - max. opening / closing time 5 / 1 ms int. 24 V max. 1 ma T.9 COM NO NC T.2 T.19 o T.18 r T.28 P1216 = s Enable delay, holding brake This defines the time interval in which the drive converter runs with the min. frequency P18 after being magnetized before ramp-up. Recommendation: P1216 = A&D SD Page 21/47

22 Motor holding brake (MHB) and hoisting gear brake P1217 = s Ramp-down holding time, holding brake This defines the time during which the drive converter operates with the minimum frequency (P18) after ramp down to the minimum frequency. Recommendation: P1217 brake application (closing) time + relay closing time P ms + application (closing) time of the brake + the switching time of a braking contactor if a braking contactor is being used. A&D SD Page 22/47

23 Regenerative energy 6 Regenerative energy This Section applies both for V/ f open-loop control as well as for closed-loop vector control with encoder. The following settings should always be made: The Vdc_max controller de-activated P124 = - (def.: P124 = 1) The compound brake de-activated P1236 = - (def.: P1236 = ) Resistor brake activated P1237 > - (def.: P1237 = ) P1237 =... Resistor braking Resistor braking is activated using parameter P1237 and the nominal load duty cycle / power-on duration of the braking resistor defined. Inhibited 1 Load duty cycle 5 % 2 Load duty cycle 1 % 3 Load duty cycle 2 % 4 Load duty cycle 5 % 5 Load duty cycle 1 % Using the resistor brake, the regenerative energy is transferred through the chopper control (braking chopper) to the external braking resistor where it is converted into heat. This means that the drive can be braked in a controlled fashion. To select and dimension the braking resistor and set the load duty cycle, please refer to Resistor brake of the MM44 Operating Instructions and /5/ and /7/. The regenerative power when lowering P ns is obtained as follows (compare Section 3.4): P ns = (m g v) η with m = max. weight when lowering v = max. velocity when lowering η = total efficiency of the system and motor Braking resistor MM4 B+ B- ~ ~ = Chopper control = ~ A&D SD Page 23/47

24 Motor data identification 7 Motor data identification The motor data identification routine must be carried-out for all closedloop control types When carrying-out the motor identification routine, the motor temperature must approximately correspond to the value in P625 During the motor data identification routine, the motor can remain locked (the rotor locked). A&D SD Page 24/47

25 Motor data identification START P625 =? Motor ambient temperature (entered in C) 2 C Enter the ambient temperature of the motor at the time that motor data is determined (factory setting: 2 C). Motor temp. - P625 Yes 5 K? No Value in P625 ~ motor temperature Note: If the motor is equipped with an KTY 84 temperature sensor, then we recommend that the KTY 84 is parameterized using P61 = 2 and the value from r35 is entered into P625. Allow the motor to cool down P191 = 1 Selects the motor data identification routine with P191 = 1 P191 = 1: Identifies the motor parameters with parameter change. A541 ON OFF1 P191 = 3 A541 ON OFF1 End When p191 = 1 is selected, alarm A451 (motor data identification active) is output, and data calculation can be started after the measurement has been completed (P34 = 3). Note: The existing hoisting gear brake can remain closed. Starts the motor data identification routine with p191 = 1 The measuring operation must be started with a permanent ON command. The motor aligns itself and conducts current. Diagnostics is possible via r69 (CO: Phase currents). p191 is reset after the motor data identification routine has been completed (p191 =, motor data identification routine inhibited) and alarm A541 is withdrawn. In order to bring the drive converter into a defined state, an OFF1 command must be issued before the next step. Selects the motor data identification routine with p191 = 3 p191 = 3: Identifies the saturation curve with parameter change When p191 = 3 is selected, alarm A451 (motor data identification routine active) is output, and after the measurement has been completed, data calculation is started (P34 = 2). Starts the motor data identification routine with p191 = 3 The measuring operation must be started with a permanent ON command. After the motor data identification routine has been completed, p191 is reset (p191 =, motor data identification routine inhibited) and alarm A541 is withdrawn. In order to bring the drive converter into a defined state, an OFF1 command must be issued before the next step. A&D SD Page 25/47

26 Magnetizing current 8 Magnetizing current For V/f control, it is not necessary to determine the magnetizing current. The value of the magnetizing current - r331/p32 has a special effect on the closed-loop control. However, this value cannot be measured at standstill and for 4-pole standard 1LA7 SIEMENS motors, this is estimated using the automatic parameterization P34=1 (P32=; result in r331). If the deviation between the actual magnetizing current and the magnetizing current saved in the drive converter, then also the values for the magnetizing reactance and the rotor resistance cannot be precisely determined. The magnetizing current that is determined should, especially for thirdparty motors, be if necessary corrected. The following description describes how to proceed when manually determining the magnetizing current and re-calculating the equivalent circuit diagram when operating the drive in closed-loop vector control (P13=2/21). Note: For this measurement, the motor must be running under no-load conditions i.e. it must be de-coupled from the load. Also refer to /6/ A&D SD Page 26/47

27 Magnetizing current START Quick commissioning (refer to Chapter 4 Quick commissioning The drive converter is adapted to the motor using the fast commissioning procedure. Motor data identification (refer to Chapter 1 Motor data identification routine Using the motor data identification routine, measuring techniques are used to determine the equivalent motor circuit diagram data. Operation under no-load Determines the magnetizing current When determining the magnetizing current (P32/r331), the motor should be accelerated up to approx. 8% of its rated speed under no-load conditions. In so doing the following conditions must be carefully maintained: The closed-loop vector control must be activated, P13 = 21 No field weakening (r56.8=) Flux setpoint r1598=1% The efficiency is not optimized, P158=% No Criterion fulfilled? Yes No-load means that the motor is operated with the load decoupled (not coupled). A current r27 is obtained under steady-state conditions. This approximately corresponds to the rated magnetizing current r331 (the current is always lower than the no-load current for a pure V/f control). Measuring and entering the magnetizing current and the associated recalculation of the equivalent circuit diagram data of the motor are iterative procedures. It should be repeated at least 2-3 times until the following criteria have been fulfilled: The more accurate that the magnetizing current is entered, the better the flux setpoint (r1598=1%) matches the flux actual value (r84=96..14%) of the monitor model. The output Xm adaptation (r1787) of the monitor model should be as low as possible. Good values lie between 1-5%. The less that the Xh adaptation of the monitor must work, then the motor parameters are that much less sensitive after power failures. Note: To display r84 on the BOP/AOP, LEVEL 4 parameters must be enabled using the service parameter P395=46. P32 =... Calculating P32 From the flux-generating current component r29 that was determined, using the following equation the new value can be entered into P32. P32 = r29 * 1 / P35 P34 = 1 End Calculating the motor parameters The values of the motor equivalent circuit diagram data are calculated from the rating plate data that was entered. In addition, the parameters of the controls are pre-set (P34 = 3). A&D SD Page 27/47

28 Drive converter and motor overload 9 Drive converter and motor overload P29 =... This Section must be carefully observed both for V/f closed-loop control as well as with closed-loop vector control with encoder and KTY 84. In addition to the thermal motor protection, the motor temperature is also incorporated in the adaptation of the motor equivalent circuit diagram data. Especially for high thermal motor loads, this adaptation has a significant influence on the stability of the closed-loop vector control. For hoisting gear applications with closed-loop control mode VC with encoder (P13 = 21), presently, the motor temperature must be measured using a KTY 84 temperature sensor. The KTY 84 temperature sensor is not required when using a V/f closed-loop control; however, the motor must then be protected against overload in another way, e.g. using a thermo switch that is integrated in the winding overhangs of the motor. Parameter settings: P29 = 1 P61 = 2 shutdown with F4/ F5 KTY 84 is evaluated; mandatory for VC with encoder, practical for V/ f P61 =, 1 additional settings for V/ f r35 motor temperature Drive converter overload response This defines the drive converter response to an internal overtemperature condition. The output frequency is reduced 1 Shutdown (F4 / F5) 2 The pulse frequency and output frequency are reduced 3 The pulse frequency is reduced, then shutdown (F4) Monitoring, drive converter Overload response, drive converter P29 r36 r37 i 2 t P294 Heatsink temperature P292 IGBT temperature P292 i_max controller (V/f) current controller (SLVC, VC) Pulse frequency controller A54 A55 A56 F4 F5 A&D SD Page 28/47

29 Drive converter and motor overload P61 =... Motor temperature sensor Selects the motor temperature sensor. No sensor, only for V/ f 1 PTC thermistor, only for V/ f 2 KTY84 this is mandatory for VC with encoder When "no sensor" or PTC thermistor is selected, the motor temperature is determined using as basis the value estimated in the thermal motor model. 5 V Fault F15 P61 = 2 & r52 Bit13 ADC PTC KTY T 1 = 4 s Monitor signal loss P61 No encoder PTC 1 KTY 2 ϑ V 1 r Motor temp. response P61 Equivalent circuit Power loss P V,mot Thermal motor model r631 r632 r633 P64 A&D SD Page 29/47

30 Closed-loop control techniques 1 Closed-loop control techniques Information regarding commissioning: All of the previously mentioned safety information and instructions must be carefully complied with. It is especially important to ensure that the hoisting gear cannot unintentionally start (the load may not sag when the brake opens, controlled by the drive converter). An Emergency Stop, that must act directly on the holding brake, must be located in the immediate vicinity and its function must have been checked to ensure that it operates correctly. Note the information and instructions in Section V/ f open-loop control P13 =... P131 =... Closed-loop control mode * The closed-loop control mode is selected using this parameter. The ratio between the drive converter output voltage and the drive converter output frequency is defined for the "V/f characteristic" control mode V/f with linear characteristic Note: Only operating mode P13 = is permitted for sensorless operation Constant voltage boost (entered as a %) 5. % Voltage boost as a % relative to P35 (rated motor current) and P35 (stator resistance). At low output voltages, the ohmic active resistances of the winding can no longer be neglected. The reason for this is that the voltage drop results in a lower motor flux if it is not compensated. Note: We recommend P131 = 1 % V Boost voltage V/f linear Vmax Validity range Vn (P34) V ConBoost,1 V actboost V ConBoost,5 Output voltage Normal V/f (P13 = ) ON OFF f P131 active 1 t t t P1311 =... P1312 =... f Boost,end fn (P1316) (P31) Voltage boost when accelerating P1311 = Voltage boost when starting P1312 = f max (P182) f. %. % A&D SD Page 3/47

31 Closed-loop control techniques P1335 =... P1338 =... Slip compensation. % P1335 =, Refer to Sections , (V/ f) Resonance damping, gain V/f. Defines the controller gain to dampen resonance for operation with V/f characteristic Supplements to the brake control and slip compensation: The following parameterization is only valid for the V/ f open-loop control mode. The subsequently discussed parameterization is additionally used to that already described if satisfactory results are not obtained with the previously described standard setting at starting, and when The brake is controlled The load sags which is unacceptable behavior Extended brake control Overview, refer to Section Setpoint delay: P1142 = 2852 P1215 = 1 P1216 =, s P1217 =,1 s delayed enable for the ramp-function generator motor holding brake released release delay holding brake set the brake closing time (brake delay time) as short as possible. P732 = 52:12 control, e.g. DO 2 (terminals 21, 22), brake P28 = 1 enable free FBs P282. = 3 execution level 3 P2849 = 52:12 control the timer to open brake P2851 = switch-in delay mode P285 =,1 s delay n* enable A&D SD Page 31/47

32 Closed-loop control techniques Information regarding the setting of P285: Lowest effective value: 18 ms, effective stages: 18 ms Recommended setting for P285: P285 = -18 ms + brake release time + switching time of a braking contactor if one is used Usual release time of brakes, refer to Section 1 and Table 3 in the same Section Pre-control to prevent the load sagging when entering a bipolar speed setpoint Notes: It is assumed, as was declared at the start of this document, that hoisting requires a positive speed setpoint and lowering a negative speed setpoint and this is fed-in at parameter P17, main setpoint, function chart Page Monitoring parameters: r178 total setpoint, refer to the function chart Sheet -5- r117 setpoint after the ramp-function generator, refer to the function chart, Sheet -53- Parameterization without extended brake control: P1142 = 1 enable ramp-function generator (factory setting) P175 = 2889 pre-control, load sagging P2 = 5 5 Hz reference frequency P2889 = z. B (!) 6 % of 5 Hz corresponds to 3 Hz Parameterization with extended brake control: P17 = 2889 pre-control, load sagging P2 = 5 5 Hz reference frequency P2889 = z. B. 6 + (!) 6 % of 5 Hz corresponds to 3 Hz P1142 = 1 enable ramp-function generator (factory setting) P175 = 755 main setpoint is connected to the supplementary setpoint P174 = 2853 switch-in speed setpoint after brake is open. A&D SD Page 32/47

33 Closed-loop control techniques The slip frequency that prevents load sag, is fed-in via P17, main speed setpoint, function chart Page 5-. This slip frequency can either be calculated from the size of the load or should be empirically determined. A bipolar speed setpoint can, for example, come from PROFIBUS, the fixed frequencies or analog input 1 (r755.) and is fed-in via P175, supplementary speed setpoint, function chart Page Pre-control to prevent load sag when entering a unipolar speed setpoint Notes: The parameterization discussed in this Section is required if a unipolar setpoint is used and the reversing command (P1113) is used to changeover between hoisting (positive speed setpoint) and lowering (negative speed setpoint). The prerequisite to prevent load sag is, as described in this Section, the parameterization of Section Extended brake control. Monitoring parameters: r178 total setpoint, refer to the function chart, Sheet -5- r117 setpoint after the ramp-function generator, refer to the function chart, Sheet -53- The parameterization used in this Section is shown in the following diagram in the form of a function chart. This is then followed by the parameterization itself. A&D SD Page 33/47

34 Closed-loop control techniques P28=1 P282.=3 P285 =.1 P2851= Switch-in delay T MHB active r52.c P2849 Index P2849 = 52.C Switch-out delay T Switch-on/switch-out delay T T Pulse generator T MHB active r52.c MHB via DO2 P732 P732 = 52.C 1 Applications 2 Extended Brake Control and Preventing Load Sag 3 1 r2852 r2853 : P2816[] = 2853 P2816[1] = : P2816 Index Index1 P28=1 P281[3]=2 1 P81 = 2817 r2817 P81 P28=1 P281[]=2 Reversing r722.1 P281 Index Index1 P281[] = 2852 P281[1] = 54.B & P811 = 2811 r2811 P811 P17[] = 755 Main setpoint P17 P17[1] = P17[2] = 755 P175[] = 2889 Supplementary setpoint P175 P175[1] = 2889 P175[2] = V2. r2811 Reversing P1113 P1113 Hoist Hold P1113 = 2811 f set, MS 1 Lower 1 + x + f set Hoist Hold 1 f Lower set, SS 1 x 7 Function diagram MICROMASTER A&D SD Page 34/47

35 Closed-loop control techniques Parameterization Data set changeover: P81 = 2817 CDS changeover P281.3 = 2 enable OR 1, execution level 2 P2816. = 2853 OR 1 BI P = OR 1 BI P811 = 2811 CDS changeover Information regarding the drive data set changeover: P811 P81 DDS X 3 r5 = display, actual BDS Assigning slip values when hoisting and lowering P175. = 2889 slip, hoisting P175.1 = 2889 slip at setpoint = (brake release time) P175.2 = 289 slip, lowering P2 = 5 Hz reference frequency P1335 = slip compensation P2889 =? [%] slip, hoisting, e.g. 4 % P289 = -? [%] slip, lowering, e.g. 4 % Interlocking reversing (P1113) during setpoint = (brake release time) P281. = 2 enable AND 1, Level 2 P281. = 2852 AND 1 BI P72. = 99 (enable BiCo wiring) P281.1 = AND 1 BI P1113. = reversing Ramp-function generator P1142 = 1 A&D SD Page 35/47

36 Closed-loop control techniques Copy CDS - CDS1 must be copied into CDS2 and CDS3. : CDS1; 1: CDS2; 2: CDS3 Procedure: P89. = this data set CDS is copied, in this case CDS1 P89.1 = 1 copied into this data set, here CDS2 P89.2 = 1 start copying Note: CDS1: Data set that is used in crane operation when hoisting CDS2: Data set that is effective at setpoint = (brake release time) CDS3: Data set that is used in crane operation when lowering Main setpoint P17. = 755 here, e.g. analog input 1 P17.1 = P17.2 = 755 P175.2 = 289 slip, lowering Inhibiting reversing (P1113) at setpoint = (brake release time) P1113. = 2811 P = Closed-loop vector control (VC) with pulse encoder The operating mode described in this Section 1.2 is the preferred mode for hoisting gear. When commissioning the closed-loop vector control with encoder (VC), the drive converter should first be operated with V/f control (P13 = ). When the motor is rotating and the speed encoder is connected (activated using P4), then parameters r61 and r21 must correspond regarding the following quantities: sign absolute value (a deviation of a few percent is permissible) The closed-loop vector control with encoder (P13 = 21) may only be activated if both of these conditions are fulfilled (refer to Chapter 1.2.3). A&D SD Page 36/47

37 Closed-loop control techniques Limits P64 =... P152 =... P1521 =... P153 =... P1531 =... The limit values for the torque (P152, P1521) and the power (P153, P1531) can be set to the maximum value. This therefore avoids a possible limit that could result in instability in the closed-loop control. Calculating the values, refer to Section % Motor overload factor [%] Determines the motor overload factor as a [%] relative to P35 (rated motor current). Limited to the maximum drive converter current or to 4 % of the rated motor torque (P35), whereby the lower value is applied. min (r29, 4 P35) P64max = 1 P35 CO: Upper FC spec. torque limit Specifies the upper torque limit. Pre-setting (default): P152 = - 1,5 r333 Max. Value: P152 = -± 4 r333 Refer to section CO: Lower FC spec. Torque Limit Specifies the lower torque limit. Pre-setting (default): P1521 = - 1,5 r333 Max. Value: P1521 = -± 4 r333 Refer to section Resulting torque limit M r1526 r1527 FC spec. Limit value, power when motoring Specifies the maximum permissible power when motoring. P153 def = 2.5 P37 P153 max = 3 P37 Recommended: P153 = max Constant torque FC spec. Limit value, power when regenerating Specifies the maximum permissible power when regenerating. P1531 def = P37 P1531max = - 3 P37 Recommended: P1531 = - P153 Power limit P M = 2 π f Stall limit 1 ~ f P153 P1531 Constant power M 1 ~ f 2 Power limit (motoring, regenerating) P1531 P153 f stall P153 P1531 Torque limit Stall power f act f A&D SD Page 37/47

38 Closed-loop control techniques Pulse Encoder P4 =... Selects the encoder type 2 Two-track pulse encoder The following table indicates the values of P4 as a function of the number of tracks: Note: For hoisting gear applications (4- quadrant operation (!)), a 2-track encoder must be used! P4 = 2 Parameter Terminal Track Pulse encoder output P4 = 1 A Referred to ground (single ended) A AN Differential P4 = 2 A B A AN B BN Referred to ground (single ended) Differential The DIP switch on the encoder module must be set as follows depending on the encoder type (TTL, HTL) and the encoder output: P48 =... P491 =... P492 =... Type TTL (e.g. HTL 1XP81-2) (e.g. 1XP81-1) Output Referred to ground Differential (single ended) Number of encoder pulses 124 Specifies the number of encoder pulses per revolution. For pulse encoder 1XP81: 124 pulses/ revolution Response, speed signal loss Defines the calculation method. No transition 1 Transition into SLVC Permissible frequency difference 1. Hz Parameter P492 defines the frequency threshold for encoder signal loss (fault F9). P494 =... P492 = (no monitoring): With P492 =, the loss of the encoder signal both at a high frequency and also at a low frequency is de-activated. This means that the system does not monitor for loss of encoder signal.. Delayed response to speed signal loss 1 ms P492 is used to detect the loss of the encoder signal at low frequencies. If the motor speed is lower than the value of P492, then the encoder signal loss is determined using the appropriate algorithm. P494 defines the delay time after detecting the speed signal loss until the appropriate response is initiated. P494 = (no monitoring): With P494 =, the loss of the encoder signal is de-activated at a low frequency. This means that when the encoder signal is lost at these frequencies then it is not detected (the loss of the encoder signal at a higher frequency remains active as long as parameter P492 > ). A&D SD Page 38/47