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Commissioning Common Functions

Comm_Common page 01SITRAIN / METAL ACADEMY

Siemens AG 2011 - all rights reserved

DR-SM150

page 02

List of Contents

1.1 Required Software-Tools ........................................................................................ 6

1.2 Drive Firmware ....................................................................................................... 8

1.3 Structure and Content of the CFC ......................................................................... 10

1.4 Getting the PG/PC Installation ready to handle the SM150-project ...................... 12

1.5 Registering Library FBA121 .................................................................................. 14

1.6 Getting the Project ready for the download to the CFC ........................................ 18

1.7 Downloading the Project ........................................................................................ 20

1.9 Exemplary SM150 Application ............................................................................... 22

1.10 Drive Devices, Components and Topology of a typical Project ............................ 24

1.11 Project with three Power Sections in parallel ........................................................ 26

2.1 Checking Cabling and Voltage Supplies ............................................................... 28

2.2 Checking the Communication Network in HW-Config ...................................... 30

2.3 Rebooting the Controllers ...................................................................................... 32

2.4 Checking the Communication Network in NetPro ............................................ 34

2.5 Setting the IP-Address on the PG/PC .................................................................... 36

2.6 Assigning the PG/PC to ETHERNET in NetPro .................................................... 38

2.7 Going Online to D445 and Downloading the Drive Devices ................................. 40

2.8 Defaulting the DC-Master and setting the Node-Address via PMU ...................... 44

2.9 Going Online and Downloading the Project Data via Drive Monitor ..................... 46

2.10 Adapting Parameters to particular Plant Conditions ............................................. 52

2.11 Loading the OP177 ................................................................................................ 56

2.12 General Content and Structure of the DCC-charts ................................................ 66

2.13 Assigning the Code to activate DCC-charts ........................................................ 68

2.14 Clearing faults and alarms on behalf of the DC-Master ........................................ 78

2.15 Clearing faults and alarms (on behalf of the ET200 stations) ............................... 84

2.16 Forcing a control command via ET200 .................................................................. 922.18 Adding field messages to the fault monitoring ....................................................... 104

2.19 Selection of the active cooling pump ..................................................................... 108

2.20 Defining properties for the ET200 analog modules ............................................... 112

2.21 Controlling the drives operation via OP177 .......................................................... 114

2.22 Stamping the Power Stack Adapters (PSA) .......................................................... 116

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Training Rack

ET200 Motor

ET200 Auxiliaries

Control

Electronics

Synchronous Motor

with Induction Motor

DC-Master

Motor

Module

G120 Load Generator Infeed

OP177

Bus Coupler

DR-SM150

page 04

Preface

This training section covers all essential steps of commissioning a SM150 medium voltage converter as used in

rolling-mill applications.

With the inevitable exception of the medium voltage hardware the SM150 training unit is equipped with the same

components as will be found in typical rolling-mill applications of SM150:

- individually controlled power sections for Active Line Module and Motor Module

- original control electronics (processor boards, option components) including the Power Stack Adapters

- separate ET200 stations for the motor periphery (MOT-ET) and the auxiliaries (HIB-ET)

- DC-Master to provide the excitation current for the synchronous motor

- OP177 for local control of the SM150

The programming within the project used for this training is based on an original site project with very few exceptions;

in consequence all steps of commissioning a SM150 converter with synchronous motor can be carried out on the

training unit in quite the same way as at site.

Naturally, the commissioning of the medium voltage hardware cannot be included in this training.

Apart from the training for which this material is prepared it can well be used as guideline and reference material for

plant commissioning. In this case, however, the particular link of the plant periphery to the drive controllers (via PLC,

TMxx, ) has to be considered and the plant periphery has to be included in the commissioning sequence as well.

Wherever you do any commissioning work, please strictly observe the five safety rules.

- Switch off the power supply on all poles- Verify the de-energized condition

- Ensure against unauthorized re-energizing (lock-out, tag-out)

- Ground and short circuit the power terminals on all poles

- Cover or fence off adjacent live components

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Software Tools and Licenses

Simotion CFCActive Line Module

and Motor ModuleDC-Master OP177

SIMATIC Manager

SIMOTION SCOUT

STARTER integrated

DRIVE ES

DriveMonitor

WinCC flexible

DR-SM150

page 06

1 Preparatory Steps

1.1 Required Software-Tools

To have access to the programming of a SM150-converter as used in rolling-mill applications a number of software-

tools and their respective licenses have to be installed on the PG/PC. At the PG/PC used for the training these tools

and licenses are installed already.

Verify that all the required software-tools are installed and that the respective licenses are available.

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Matching the Software Tool to the Firmware

Content of the Compact Flash Card

Version of the Tool SIMOTION SCOUT

DR-SM150

page 08

1.2 Drive Firmware

As a general rule, the versions of the software-tools have to match the drives firmware. This applies in particular to

the version of SIMOTION SCOUT in relation to the firmware of the SM150.

Create file directory SCOUT: > Temp_Trainee; if it should already exist, delete all its content.

Using Explorer and a card reader, copy the entire content of the Flash Card of SIMOTION D445 to directory

SCOUT:\ Temp_Trainee\D445_CFC.

Execute the routine remove hardware safely (button at the right end of the bottom line) before removing the CFC and

the card reader; put the D445 CFC back into controller D445.

Open tool SCOUT and verify that the version of SIMOTION SCOUT and the firmware of the SM150 are a matching

pair.

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Hardware Description Data, Ident-Files and User Data

Vector-related ACX-data and Ident-file for the Motor-Module Power Stack (PSA)

Infeed-related ACX-data and Ident-file for the Line-Module Power Stack (PSA) / port X105

Vector-rela

teduserdata

Infeed-rela

teduserdata

DR-SM150

page 10

1.3 Structure and Content of the CFC

Check the content of the Compact Flash Card to identify the Hardware Description Data, the Ident-files both for the

Infeed and for the Motor Module and the User Data:

A) Hardware Description Data (DESCxxxx.ACX) define converter properties such as power section data (voltage,

current) and the actual value monitoring on the PSA

B) Ident-files (ident_xx.bin) assign the allocation of the PSA to its application as Infeed for SM150, Motor Module

for SM150, Motor Module for GM150 etc.

C) User Data (PSxxxxxx.ACX) contain the parameterization of the individual objects of the drive devices Infeed,

Motor Module and Simotion programming (PSxxxx00.ACX to PSxxxx99.ACX).

In case of parallel Infeeds, the data for the second Infeed (port X104) respectively the third Infeed (port X103) are

located in \Data\14\... respectively in \Data\13\...Check whether file fba121V23_0_simotion4_1_1.zip is available on C:\Programme\Siemens\Step7\u7umc\data\dcc

(file fba has to be installed on the same drive as SCOUT; SCOUT must be installed on drive C only!).

If this library already exists on your PG/PC, then please delete it to be able to go through the steps required for its

registering (not a normal approach, just for the sake of training).

,

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Running the Project on the PG/PC

deletes the old compilation in full

deletes modifications only

left

mouse

click

right mouse click >

open object

DR-SM150

page 12

1.4 Getting the PG/PC Installation ready to handle the SM150-project

As (typically) found in plant commissioning the SM150-project is provided as a zipped file (project archive) for the

training as well. Here it is part of the CFC-content by the name Yas_syn0.zip in file 0_Training.

Open the SIMATIC Manager and delete project Yas_Syn0 if it should already exist (File > Delete > Yas_Syn0 > OK).

Now retrieve project Yas_syn0.zip from file Temp_Trainee > 0_Training into the prompted directory

(SCOUT:\Programme\Siemens\Step7\S7Proj).

Select any one of the three SM150 drive devices you find via Yas_Syn0 > Obermotor G2 (Yask_CX32 / Infeed,

Yask_SINAMICS_Vector / Motor Module, D445_Master / SIMOTION program) and open SCOUT:

- left mouse click (lMC) on the drive device in the navigator-section and

- right mouse click (rMC) on the drive device in the worksheet-section > Open Object

In SCOUT start the routine Save project and REcompile all. You will observe that the compilation output lists a

considerable number of error messages. These error messages indicate that a library required for the compilation of

DCC-charts used in the project is missing. Specifically it is the library FBA121 which contains DCC functions used in

rolling-mill applications.

The project for the SM150 can only be compiled and downloaded if this library is available (registered) on the PG/PC.

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Registering the DCC-Library FBA121

before

inserting

the

library

Enter

Enter

Enter

after

inserting

thelibrary

DR-SM150

page 14

1.5 Registering Library FBA121

Exit SCOUT to be able to register library FBA121 (processes u7bt04ax.exe or u7wwbfax.exe must not be running!).

Register the library as follows:

- copy the library fba121V23_0_simotion4_1_1.zip from your source to directory

Programme\Siemens\Step7\u7umc\data\dcc

- call up the DOS-prompt (Start > Programme > Zubehr > Eigabeaufforderung)

- call directory programme\siemens\step7\u7umc\data\dcc

- ask for the content via dir

- request the registry of the library via inst_dcc_lib fba121v23_0_simotion4_1_1

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Importing required DCC-Libraries

mark library TPfba121 library is imported

DR-SM150

page 16

After the successful installation close the DOS-prompt and select the library in SCOUT:

- right mouse click (RMC) on D445 > Select technology packages

- in addition to already marked technology packages select fba121_SIMOTION. and dcblib_SIMOTION. > OK

Now update the DCC-libraries in SCOUT > DCC:

- open any of the DCC-charts in D445 > PROGRAMS

- access the import of libraries via Options > Block Types > OK

- mark library TPfba121_SIMOTION, transfer it to Imported libraries ( button >> ), mark library

TPdcblib_SIMOTION, transfer it to Imported libraries and Accept the request of the Import of the two libraries

- ignore the warning messages

- exit the DCC-chart

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Getting the Project Ready for the Download to the CFC

deletes the old

compilation in full

DR-SM150

page 18

1.6 Getting the Project ready for the download to the CFC

In SCOUT again start the routine Save project and REcompile all. Once finished without errors, initiate the step

Check consistency.

If no consistency errors are signaled, the project (the user directories for the Infeed rsp. the Motor Module and the

Simotion programming) is ready to be downloaded to the CFC either via D445 with the CFC inserted or directly to the

CFC via card-reader.

For either of the two approaches, the CFC has to have a Simotion specific boot section (invisible via card-reader)

and the firmware for Sinamics SM150. At this step of training these preconditions are satisfied.

In the given situation user files for the Infeed and the Motor Module already exist on the CFC; they will subsequently

be overwritten by the download of the project (with no user files on the CFC these files will appear only after having

them loaded to the file system followed by a power-on initialization).

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Downloading the Project to the CFC

only for Simotion technology,

irrelevant for SM150

DR-SM150

page 20

1.7 Downloading the Project

Insert the CFC in the card-reader and connect it to one of the USB-ports of the PG/PC; identify which directory is set

up for the Compact Flash Card.

Directory for SIMOTION_D: . . . . . . .

Download project Yas_Syn0 to the CFC:

- in SCOUT, RMC on D445 > Load to file system > Save normally

- button Select target > select the drive identified for the CFC > OK

- acknowledge the request to overwrite the existing user data

Verify that the ACX-data and the Ident-files are located on the CFC (\ADDON\DATA\...) both for the Infeed and for

the Motor Module; else copy them from a suitable source to their respective location.

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Single Line Diagram of a Typical SM150 Rolling Mill ApplicationDR-SM150

page 22

1.9 Exemplary SM150 Application

The single line diagram above serves as an example for a setup of a SM150 in rolling mill applications :

- Synchronous motor with external DC-excitation and encoder

- DC-excitation provided by a Simoreg DC-Master

- Stator winding fed by Sinamics SM150 (Infeed, Motor Module)

- Signal interface to the field via ET200-S (group Auxiliaries, group Motor)

- Local control via OP177

- Process control via MRG, Basic Automation

- Data link via Profibus and Profinet

The above setup is true for a motor which can be supplied by a single SM150 unit.

For larger power ratings the Infeeds and Motor Modules will be paralleled. Motors of large power ratings mostlyfeature two or three groups of stator windings; the number of Infeeds and Motor Modules is then adapted accordingly.

A typical rolling mill stand comprises two motors, an upper motor (Obermotor) and a lower motor (Untermotor). The

above setup will then be found twice, one serving the Obermotor and one serving the Untermotor. An example of

such a project is shown on the next slide.

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Drive Devices, Components and Topology of a Typical Project

SINAMICS_Vector_OM_G2

SIMOTION_CX32_OM_G2

HB-A11

HF-A11

HC-A11

HD-A11

HD-A31

HP-A11

HG-A11

HD-A51

DR-SM150

page 24

1.10 Drive Devices, Components and Topology of a typical Project

The control of the Obermotor G2 requires a number of drive devices as shown in the Simatic project:

- Simoreg DC-Master (to provide the DC-excitation for the synchronous motor)

- Simotion CX32 (to control the Infeed of the SM150)

- Sinamics_Vector (to control the Motor Module of the SM150)

- D445_Master (to provide technological control for the individual motor)

Sinamics drive devices consist of a number of components; these are listed separately for the Infeed (CX32) and for

the Motor Module (Sinamics_Vector).

These components are interconnected via Drive-CLiQ; the respective Topology Trees indicate the wiring. (The training

rack is wired identically to a plant application; some additional components are built in but are not connected.)

Verify that the DRIVE-CLiQ wiring as listed in the project topology is set up identically in the SM150 training rack.

Communication networks via Profibus and Profinet are used to link other non-Sinamics components such as OP177,

ET200-S and DC-Master to the overall system (refer to slides in sections to come).

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Project with Three Power Sections in ParallelDR-SM150

page 26

1.11 Project with three Power Sections in parallel

To increase the power rating up to three power sections are paralleled both on the line side (Active Line Modules) and

on the motor side (Motor Modules).

While all three power stack adapters for the motor side power sections are controlled by the D445_SINAMICS

controller, one SIMOTION CX32 controller each is assigned to the three power stack adapters of the line side power

sections.

As a standard, each of the three Infeed power sections has its own Voltage Sensing Module.

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Voltage Supplies and Signal Check

Motor

Fan Group

Converter

Cooling

ET200-S

Motor

SM150

Cooling Fans

Control

Voltage

DR-SM150

page 28

2 Basic Commissioning

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HW-Configuration of the Project for the Training Rack

6432

16

8

4

2

1address-coding

of ET200S;

i.e. address 17

PROFIBUS-addresses are set

- via switches on the ET200S-stations

- via parameter on the DC-Master

- via interface definition on the MoMo

- via DRIVE-CLiQ port on the ALM

DR-SM150

page 30

2.2 Checking the Communication Network in HW-Config

Open the HW-Configuration (i.e. in SCOUT) and compare the communication network of the project to the actual

connection of the PROFIBUS- and ETHERNET-nodes: RMC on D445 > Open HW configuration.

Note down the PROFIBUS-addresses assigned to the nodes:

- HIB-ET200: . . . . . . . . . . - MOT-ET200: . . . . . . . . . . - DC-Master: . . . . . . . . . .

Verify respectively set these addresses via hardware where possible.

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Rebooting the Controllers / Connecting the Ethernet Ports

X120IE1/OP

X130IE2/NET

An Ethernet port is defined by its IP-address, by a Subnet mask

and (if networked) by the definition of a Standardgateway.

The definition of the Subnet mask depends on the applicationclass; Subnet mask and IP-address range have to match.

Subnet mask IP-address range class networks / hosts255.0.0.0 1 to 126 A 126 / 1677721255.255.0.0 128 to 191 B 16384 / 65534

255.255.255.0 192 to 223 C 2097152 / 254

DR-SM150

page 32

2.3 Rebooting the Controllers

Using the routine Safely Remove Hardware remove the card-reader from the PG/PC and insert the CFC in the D445.

Put all switches on the auxiliaries rack to their lower position and switch on the 24VDC supply to all Simotion and

Sinamics components on the SM150 rack by closing the line-side auxiliary supply breaker Q11 (this reboots the

controllers of the components). Allow approximately 3 minutes for the initialization. If the Drive-CLiQ topology of the

project matches the physical wiring the RUN-LEDs of the Drive-CLiQ components will turn green.

Now also switch on the supply to the auxiliaries rack via its main breaker Q1.

To analyze the nature of fault or alarm messages on the SM150, an online connection with the PG/PC has to be set

up next.

The PG/PC can be connected to the D445 via PROFIBUS or via ETHERNET; presently the ETHERNET connection to

port X130, IE2/NET will be used.

Connect an ETHERNET cable between port IE2/NET of the D445 and an available port of the PG/PC.

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Communication Network as seen via NetProDR-SM150

page 34

2.4 Checking the Communication Network in NetPro

Open the NetPro view (i.e. in SCOUT) and compare the communication network of the project to the actual connection

of the PROFIBUS- and ETHERNET-nodes: Project > Open NetPro.

In addition to the existing hardware NetPro shows a SIMATIC PC Station and a SIMODRIVE 611U. Remove the

SIMODRIVE 611U from the network: (rMC) SIMODRIVE 611U > Delete > Yes > Yes.

Note down the PROFIBUS- and ETHERNET-addresses assigned to the nodes

(via right mouse click on node connection > Object Properties):

- HIB-ET200: . . . . . . . . . . .

- MOT-ET200: . . . . . . . . . . .

- DC-Master: . . . . . . . . . . .

- PG/PC_MPI: . . . . . . . . . . .

- PG/PC_DP: . . . . . . . . . . .

- PG/PC_ETHERNET: . . . . . . . . . . . . . . . . . . . . . . .

- OP177_ETHERNET: . . . . . . . . . . . . . . . . . . . . . . .

- OP177_MPI, DP: . . . . . . . . . . .

- D445_DP1: . . . . . . . . . . .

- D445_DP2/MPI: . . . . . . . . . . .

- D445_IE1/OP: . . . . . . . . . . . . . . . . . . . . . . .

- D445_IE2/NET: . . . . . . . . . . . . . . . . . . . . . . .

- D445_CBE30: . . . . . . . . . . . . . . . . . . . . . . .

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Setting the IP-Address on the PG/PC

Enter

DR-SM150

page 36

2.5 Setting the IP-Address on the PG/PC

Follow the sequence Start > Einstellungen > Netzwerkverbindungen and doubleclick on LAN-Verbindung; open the

properties menu via button Eigenschaften. Scroll down to Internetprotokoll (TCP/IP), mark it and again continue via

button Eigenschaften.

Now assign the subnet-mask and the IP-address to a setting compatible with the definition of the ETHERNET port

IE2/NET of the D445 :

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

Test the communication by pinging the D445 in the DOS-prompt: ping IP-address.

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Assigning the PG/PC to ETHERNET in NetPro

Network > Save and Compile

DR-SM150

page 38

2.6 Assigning the PG/PC to ETHERNET in NetPro

In NetPro the PG/PC is connected both to an MPI-network and to an ETHERNET-network.

To enable an online connection to the D445, the link to the ETHERNET-network has to be activated:

- right mouse click (RMC) on PG/PC > Object Properties

- acknowledge the change of assignment via button Yes

- in tab Assignment of menu Properties PG/PC, section Configured Interfaces select

Ethernet Service Noteboo

- in section Interface Parameter Assignments select TCP/IP Intel 825666MC Gigab...

(this selection has to match the device name for the LAN-Verbindung selected above)

- define this selection as Assigned via button Assign > OK

- mark the assigned interface, verify that the checkmark next to Active is inserted and terminate the assignmentby pressing button OK

The assigned connection of the PG/PC to the D445 is highlighted in yellow.

Any change of assignment in NetPro will become effective only after NetPro has been Saved and Compiled: Network

> Save and Compile (the warning message points at missing ET200-hardware for the Obermotor which is not used

in the training rack; close the warning message).

Exit program NetPro by Network > Exit

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Finding the Reference address / module / terminal / bit

address references in I/O-container

any DCC-chart

DR-SM150

page 42

To easily find the blocks of chart U2COMCBE which use the variables pn_drv, open any DCC chart, select menu

Chart Reference Data and open the listing of Cross Reference Chart Elements Address.

Search for one of the variables pn_drv_piw and double click on it; the chart page showing this variable and its wiring

to a DCC-block is opened automatically.

Now delete all 8 inputs to block RCB100 (left Mouse Click on input signal line > Delete Interconnection). Follow the

same approach to delete the chart output to the variables pn_drv_pqw.

Compile the modified chart U2COMCBE: Cart > Compile > Chart as program > Compile individual chart > OK.

Once more Save and Compile the project and check its consistency. If consistency is still not given, follow the above

approach once more to delete the offending links to the variables in question.

Again Save and Compile the project, check its consistency and then download the D445 again. Be sure to have the

function Copy RAM to ROM executed for device D445_Master.

Reboot the drive (power off/on) and continue by downloading the Motor Module and the Infeed. After completion of the

downloads all three drive devices have to indicate data-consistency (green-green). Dont forget to have a Copy RAM

to ROM executed at the end of the download of devices SIMOTION_CX32 and SINAMICS_Vector.

If a drive device changes to disconnected (red-red) in the sequence of downloading, reconnect it as follows:

- mark the drive device in question

- open the function menus via right mouse click

- left mouse click on Connect online

device changes to offline requested (white-white)

- again open the function menus via right mouse click

- left mouse click on Connect online device changes to online mode (green-green)

Open the Alarm-tab in SCOUT and try to acknowledge all faults. You will notice that fault Excitation group signal fault

(this fault is quite logical as the DC-Master has not yet been commissioned) persists.

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Defaulting the DC-Master and Setting the Node-Address via PMU

Increasing / decreasing

- the parameter number

- the index number

- the value

/

Change from parameter level to

value indication and vice versa

Change from parameter level to

index level and vice versa

Change from index level tovalue indication and vice versa

P234 17.20

P150 i 001

56.37i 001

Acknowledging a fault lastindication

F036

P

P

P

P

P +Shifting fault or alarm

messages to the background

P +

Recalling fault or alarm

messages from the background

F036

P0623

o11.0

A537

P0623

o11.0

DR-SM150

page 44

2.8 Defaulting the DC-Master and setting the Node-Address via PMU

As a standard, the DC-Master for the SM150 synchronous motor application is pre-commissioned at SIEMENS and

the parameter file provided within the project will require only minor modification at site (i.e. the optimization of the

armature current controller for the synchronous motor excitation).

Start by defaulting the DC-Master to factory settings using its ParaMeterizing Unit (PMU):

- shift eventual fault and alarm messages to the background

- scroll to parameter P051 (access level) and set the value to P051 = 21 (default request; after execution of this

routine an internal offset tuning is carried out automatically (indication P051 = 22) and

- after some seconds delay P051 reads P051 = 40 service level for commissioning)

- scroll to P918 to set the PROFIBUS address as defined in NetPro: P918 = . . . . . . . . .

- scroll to P927 to extend the parameterization authority to SST1 + PMU + PROFIBUS: P927 = 7Switch the power supply for the DC-Master (F001) off and on again to activate the new PROFIBUS address;

acknowledge eventual fault messages.

Profibus alarm A83 will persist since settings for the Profibus communication still have to be parameterized.

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Tool Drive Monitor

offline online

RAM

online

EEPROM

tracer

parameter list as used

to open Drive Monitor

complete

parameter list

complete

parameter list

empty

parameter list

upload

download

upload download

left mouse click

right mouse click

online

RAM

online

EEPROM

Copy RAM to ROM

P971 = 1

DR-SM150

page 46

2.9 Going Online and Downloading the Project Data via Drive Monitor

Within the project view of the SIMATIC Manager the DC-Master is listed in addition to the three drive devices.

Navigate to the parameter list (or lists) provided for the DC-Master:

- in the navigator-section successively doubleclick on DC-Master CBP2, SIMOREG DC MASTER and

Parameter

- right mouse click on the parameter list DC_Yas_Trainee_Delta in the worksheet-section > Open Object

The tool for the DC-Master, Drive Monitor, is opened.

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Messages: Differing Firmware and Missing Data Base

The FW-release of the DC-Master used

in the project differs from the FW-version

of the Control Unit.

(FW 3.1 cannot be run on CU-HW 2.2)

Unless the very latest release of Drive Monitor

is used, a missing data base has to be added.

DR-SM150

page 48

In Drive Monitor, click on the list of all offline parameters: a list of the parameters defined in project parameter list

DC_Yas_Trainee_Delta opens and indicates the offline values of these parameters.

Request operating mode online EEPROM (to have changes of parameter values saved in non-volatile fashion);

acknowledge an eventual device identification message.

If the message Device Identification pops up, ignore it by pressing the SW-button OK.

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Downloading the Parameter File with Drive MonitorDR-SM150

page 50

Now download the project file DC_Yas_Trainee_Delta to the EEPROM (the download of a complete file takes

considerably longer than the download of a delta file, which contains only those parameters whose values are other

than default values); close the eventual device identification message with button Download.

If the download is executed with only a very small number n of errors (indicated by [OKxxx: E]), call up the

Details with the respective button. Analyze the reason for the error; mostly the errors result from different versions of

the tool Drive Monitor and the Firmware of the DC-Master and can be ignored.

On the DC-Master programming numerous Free Function Blocks are used. These Free Function Blocks have to be

enabled either temporarily (for test operation with a maximum test time of 500 operating hours) or permanently via

PIN-code.

For a temporary enable parameter U977 is set to U977 = 1500 (the parameterized value 1500 is reset to 0

automatically). Parameter n978 indicates the remaining hours of test operation in its last three digits(e.g. n978 = 1372 372 h of test operation still available).

For a permanent enable parameter U977 is set to U977 = PIN-number; in this case n978 indicates n978 = 2000.

Check whether the training racks DC-Master is enabled temporarily or via PIN.

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Uploading the Parameterization as Delta-FileDR-SM150

page 54

Upload the parameterization of the DC-Master as a delta file by the name DC_Yas_Trainee_Delta_1.

Copy file DC_Yas_Trainee_Delta_1 to your listing of DC-Master files in explorer as follows:

SIMATIC Manager > (rMC) DC_Yas_Trainee_Delta_1 > Export parameters > Drive Monitor > C: > Temp_Trainee >

0_Training > DC_Master_Files > Save.

Go offline with the DC-Master and exit the tool Drive Monitor (View > Offline / File > Exit).

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F7

F7 / System

Preparing the OP177 to load Data via ETHERNETDR-SM150

page 56

2.11 Loading the OP177

PROFIBUS messages Alarm A083 / Fault F82 cannot be cleared as a consequence of the still persisting Excitation

group signal fault of the Motor Module. To follow up on this fault, Simotion messages have to be analyzed which is

most comfortably done via OP177.

To load the OP177 via one of the available interfaces, the interface in question has to be assigned to the PG/PC. As

the current interface assignment of the PG/PC reads ETHERNET, the OP177 will be loaded via ETHERNET. Since

the online connection to the D445 will no longer be maintained in this situation, disconnect the SCOUT project from

the target system (go offline).

Connect the PG/PC to the OP177 both physically and in NetPro; note down the IP-Address on the PG/PC:

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

The selection of the type of interface, the interface settings and the preparation of a data transfer are done in the

menu Transfer of the OP177.

If the OP177 has been used already, the previously defined faceplate opens up; in this case press HW-button

F7/System and then the SW-button System Control.

Scroll down to menu Transfer, double-click on it and adapt the Transfer Settings on the OP177 to enable the

communication with the PG/PC via ETHERNET.

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Loading the Project to the OP177 (WinCC via SIMATIC Manager)DR-SM150

page 58

Set the OP177 to the state Transfer > Connecting to host.

In SIMATIC Manager, start WinCC flexible, select Project > Transfer > Transfer Settings, define Mode =

ETHERNET and the IP-Address of the OP177.

Start the transfer with the assigned button; select the existing password list to be overwritten (else the password list

has to be overwritten via WinCC flexible by a separate command).

If the data transfer is finished, close WinCC flexible without saving the changes to the current project.

Now connect an ETHERNET cable between D445, port IE1/OP and OP177 : the feedback values for Nact, TQact, etc.

on the OP177 screen read 0 (instead of the #### as before the connection to the D445).

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Loading the Project to the OP177 (direct Call of WinCC)

called up via Project > Transfer > Options

DR-SM150

page 60

As an alternative, the OP177 data can also be transferred if WinCC flexible is opened by itself. In this case some

definitions for the interface have to be entered in a menu accessed via Project > Transfer > Communication Settings.

The MPI connection between PG/PC and OP177 is then tested using a menu called up via Project > Transfer >

Options. Additionally the project data for the OP177 have to be selected by separately opening the project containing

the OP177 settings before starting the data transfer via Project > Transfer > Transfer Settings as above.

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Updating the OP177

called up via Project > Transfer > OS Update

DR-SM150

page 62

If the versions of the OP177 and of the project are not compatible, the download is rejected. In this case the OP177

has to be updated using a menu called up via Project > Transfer > OS Update.

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Excitation Group Signal Fault

PROFIBUS

Communication error

x

DR-SM150

page 64

To get a definite idea about the state of the entire system, first switch off the main supply both for the SM150 rack and

the auxiliaries rack and then back on again; the following state should be observed:

- the DC-Master signals F082

- several analog modules of the MOT-ET indicate System Failure

- the D445 reads RDY = red

(as interface DP1 and board CBE30 are part of NetPro but not participating in communication the assigned LEDs

read DP1 = red and OPT = red)

Use another cable to connect the D445, port IE2/Net to the PG/PC and adapt all settings required for the ETHERNET

link between the PG/PC and the D445; verify that an online connection is successful.

necessary steps 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Close the pop-up window Online/Offline comparison without uploading or downloading any of the drive devices) and

in rough identify the persisting fault message:

persisting fault: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Try to acknowledge the fault indicated for the D445: fault Excitation group signal fault persists.

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General Content and Structure of the CFC-charts

I/O-Container Signals between drive devices and interfaces

MRG (Basic Automation)

I O INAUX Auxiliary inputs via ET200 I/O

I O AUXCU Auxiliaries Cooling Unit

I O AINF1 Control of Infeed

I O COMCBE Communication to other CPU

I O TMONI Temperature monitoring

I O CPU CPU System Functions

I O AUX1 Start-up Sequence Control

I O DOPAR Parameter Read/Write Logic

I O AUX2 Auxiliaries Control

I O MOPRO Rotor protection

I O MSG Messages to OP177

I O PANEL Communication to OP177

I O OUAUX Auxiliary outputs

INPUT Communication and scaling I O

LCOMRG Commissioning functions I O

CECO Coil eccentricity compens. I O

POSIT Spindle spotting I O

LBCON Load balancing I O

DRVMG Drive Manager I O

OUTPUT Communication and scaling I O

internalcommunicationbetween

functioncharts

DRIVE (Infeed / Motor) PDA ET200S (Mot / Aux) DC-Master (Field)

DR-SM150

page 66

2.12 General Content and Structure of the DCC-charts

Additionally to the control of the Infeed ( CX32) and of the Motor Module ( D445_SINAMICS_Integrated) extensive

additional functionality is provided in D445_SIMOTION via DCC-charts. The diagram above lists the majority of DCC-

charts; to view the entire list, refer to SIMOTION Program > Plne.

The data exchange between the DCC-programs, the Basic Automation / MRG, the Drives Functions / Infeed,

Motor Module, Exciter and the Periphery / ET200 is carried out via System Variables which are assigned to the

process data address codes in the I/O-container.

A detailed list of contents of the individual DCC-charts, each chart containing a large number of sheets (A, B, ) with

six assigned pages is always given on the first page of sheet A.

,

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Cross-Reference from OP177-Messages to DC-Charts

A reference to the related page of the DCC-

charts is shown on the OP177 in column

Text once an alarm or a trip is monitored.

The reference (=.WA01) related to the fault is

given in column Text and can be identified

as Comment in the list of all charts assigned

to Plne (charts) of SIMOTION D445.

DR-SM150

Al

armd

isplayOP177 actual messages X

Date Time Text

29/03/11 06:12:33 =.WA01/C1

Error Software Protection

page 68

2.13 Assigning the Code to activate DCC-charts

Checking the indication on the OP177 you will find a message indicating the existence of SEVERAL alarms or faults.

Identify the nature of these alarms or faults by clicking on the symbol :

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

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

If the messages are in German, change the language to English via key F7/System and the assigned SW-button.

Return to the main faceplate via key F1/Start or [ X ] within the menu.

You will notice that one of the messages reads Error software protection.

Many of the function blocks used in the DCC-charts are especially designed for rolling-mill applications. These blocks

are software-protected and the DCC-charts using these blocks are processed by Simotion only if the correct code isregistered (this code is generated by Siemens on the basis of the serial number of the compact flash card).

The code has to be registered in one of the DCC-charts. Use the information on the OP177 / alarm display to find out

to which chart you have to go to enter the code:

chart: . . . . . . . . . . . . . . . . . . . . . . . . . . .

!. . . .. . .

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Assigning the Code to activate the CFC-charts

Chart Reference DataCompile Download

Test Mode Overview Sheet View

Watch On Watch Off

DR-SM150

page 70

Open DCC-chart CPU, sheet C1 (the project specific name of the chart is U2CPU; U2 is an identifier valid for this

project, CPU is the block name in general).

Select Test Mode, mark block SWP100 and set Watch On. Presently the wired output QKF respectively

BM_ERR_SWP reads value 1 which means Error software protection.

Take a note of the serial numbers SN1 and SN5 (as an example; at site you have to record all serial numbers if the

Code still has to be generated by Siemens):

block U2CPU, serial number SN1: . . . . . . . . . . . . . . . . . . . . . . . . . .

block U2CPU, serial number SN5: . . . . . . . . . . . . . . . . . . . . . . . . . .

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Customizing I/Os by assigning CommentsDR-SM150

page 72

Inputs and outputs of function blocks are identified by names which are factory set and cannot be redefined. To

customize these I/Os, however, self defined comments can be assigned. The changeover from I/O-name to I/O-

comment is activated via Options > Customize > Layout. By positioning the cursor on any I/O a tool tip text

providing additional information pops up.

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Changing Block Values in DCC-Offline

menu to change block valuesin DCC-offline

consistency is restored after the download

DR-SM150

page 74

Set Watch Off, discontinue Test Mode and assign the code numbers for the CFC you are using (refer to the list

below) after a doubleclick on the individual I/O:

Possibility 1) internal serial numbers generated for the Compact Flash Card ST0B8222290000062553 :

SN1: 38423054 SN2: 32323232 SN3: 30303039 SN4: 32363030 SN5: 00333535 SN6: 4F4E5241

Code numbers to be entered in U2CPU / C1 / SWP100

CW1: 16#AC15B40D CW2: 16#FC340A1F CW3: 16#29240982

CW4: 16#17915EA5 CW5: 16#AED72302 CW6: 16#5B34724F

Possibility 2) internal serial numbers generated for the Compact Flash Card ST0BKM02-0000006456 :

SN1: 54534643 SN2: 304D4B42 SN3: 30302D32 SN4: 30303030 SN5: 36353436 SN6: 4F4E5241


CW1: 16#42F36528 CW2: 16#A0109EB5 CW3: 16#B4949D5E

CW4: 16#55B498FA CW5: 16#B4C5726E CW6: 16#DF9D3DF9

Possibility 3) internal serial numbers generated for the Compact Flash Card ST0B822220000062551 :

SN1: 38423054 SN2: 32323232 SN3: 30303039 SN4: 32363030 SN5: 00313535 SN6: 4F4E5241


CW1: 16#AC15B40D CW2: 16#FC340A1F CW3: 16#29240982

CW4: 16#17915EA5 CW5: 16#671D3513 CW6: 16#1981C50C

To activate these changes, the DCC-chart has to be compiled and downloaded (to download any DCC-chart,

D445_SIMOTION has to be downloaded; the inevitable change from RUN to STOP and back to RUN is requested by

the system whenever applicable).

A few seconds after the download the output BM_ERR_SWP of block SWP100 reads value 0 ( no code error)

and fault F082 on the DC-Master clears automatically. The D445 fault Excitation group signal fault, however, still

persists.

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Changing Block Values in DCC-Online

menu to change block values in DCC-online

(Test Mode and Watch On)

saving data on Compact Flash Card

saving data on PG/PC

close all charts / save and compile the project

DR-SM150

page 76

Contrary to the sequence just followed, most of the modifications of the CFC-programming you might have to carry out

during commissioning will typically be done in online mode (Watch On state; i.e. changing input values). These

changes become effective in the D445_SIMOTION RAM immediately and they are stored in the PG-RAM

automatically.

To save these changes in the non-volatile memory (on CFC), the function Copy RAM to ROM has to be carried out

for D445_SIMOTION.

To update the PG/PC-project with the modifications introduced while in DCC-Online, the function Compile Chart

(saving data of the compiled charts in the PG/PC-project) has to be carried out for all concerned charts.

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Clearing Faults and Alarms on behalf of the DC-Master

Some faults within the exciter circuit are monitored both on the DC-Master and on the OP177 (via DCC-charts)

DC-Master

OP177

DR-SM150

page 78

2.14 Clearing faults and alarms on behalf of the DC-Master

The OP177, which is now indicating the operating state of the hardware components (circuit breakers, exciter unit,

infeed, motor module, motor and auxiliaries) now indicates a good number of faults or alarms.

These faults and alarms now have to be cleared one by one.

Start by following up the fault Trip overvoltage protection excitation DC-side.

PLEASE NOTE that faults and alarms of the drive hardware such as DC-Master, Infeed and Motor Module are

indicated by the respective hardware (Fxx messages for the DC-Master, Alarms via SCOUT for Infeed and Motor

Module) but are also sent to Simotion and are finally displayed on the OP177.

Faults of the exciter hardware are (in part) evaluated by the DC-Master (without being indicated on the DC-Master

itself) and then sent on to Simotion where the fault is picked up to trigger the required action and from where the

message is sent to the OP177.

Refer to the plant function diagrams for the DC-Master and find out which external monitoring device generates the

message Trip overvoltage protection excitation DC-side:

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

Find out which switch on the training rack is assigned to simulate this condition:

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

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Measuring Values of Binectors and Connectors (DC-Master)

measuring Binectors

measuring Connectors(accuracy of 0.1%)

selection: P046.3 = B0210

indication on: r045.03 = 0 / 1

selection: P044.4 = K0193

indication on: r043.04 = xx.x%

DR-SM150

page 80

Go online to the DC-Master and check the logic state of the binector which picks up this external monitoring device:

P . . . . . . . . . . . . = . . . . . . . . . . . .

If you switch on the assigned simulator switch S4 the logic state of the binector still reads a constant L-state.

Adapt the related BiCo-connections for the SICROWBAR considering the fact that the simulator switch is connected

to CUD1, terminal X171:39 instead of CUD2, terminal X161:214:

U350 .1 = . . . . . . . . . . . . . U . . . . . . . . . . . . . = . . . . . . . . . . . . . U . . . . . . . . . . . . . = . . . . . . . . . . . . .

Clear the (simulated) hardware fault by switching on the assigned switch on the auxiliary rack:

the fault is automatically cleared on the OP177; the overall number of faults is decremented by one.

Find the source of the fault Trip overvoltage protection excitation AC-side by referring to the plant function

diagrams for the DC-Master and identifying the I/O-terminal and the assigned binector:

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

Assume the I/O-board CUD2 temporarily missing (which it actually is) and program a software substitute for the

(temporarily) not available binector to the EEPROM:

U . . . . . . . . . . . . . = . . . . . . . . . . . . .

After acknowledging with key F8/ACK fault Trip overvoltage protection excitation AC-side is cleared.

. . . . .

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Clearing Faults and Alarms on behalf of the DC-Master

Some faults within the exciter circuit are monitored ONLY on the OP177 (via DCC-charts)

OP177

DR-SM150

page 82

Follow the same approach to clear the alarm Alarm earth fault monitoring rotor:

- I/O-terminal and assigned binector: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- temporary substitute: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The alarm Alarm earth fault monitoring rotor is cleared automatically.

Again follow this approach to clear the alarms

- CB earth fault monitoring rotor tripped U . . . . . . . . . . . . . . .

- CB excitation converter fan 1 tripped U . . . . . . . . . . . . . . .

Both alarms are cleared automatically.

Assign the fault Trip earth fault monitoring rotor to the same I/O-terminal through which the DC-Master fault

F021 is generated (simulated via switch S3):

U . . . . . . . . . = . . . . . . . . .

Test the function and clear the indicated faults.

The last message on behalf of the DC-Master reads Overload overvoltage protection excitation DC-side. Once

more refer to the plant function diagrams for the DC-Master and follow the message Overload overvoltage protection

excitation DC-side.

Find out which switch on the training rack is assigned to simulate this condition (this switch simultaneously acts as

E-Stop indication o10.3 on the DC-Master):

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

Switch on the identified simulation switch and verify that a.m. message can be acknowledged on the OP177; also

verify that the operating state of the DC-Master changes from o10.3/E-Stop to o7.1/Waiting for the On command,

that the D445 fault Excitation group signal fault finally clears and that the RDY-LED of CU320-2 turns green.

Save the parameterization you have made in the DC-Master as a delta file by the name DC_Yas_Trainee_Delta_2.

.lta

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Clearing Faults and Alarms on behalf of the ET200-Stations

ET200S / Auxiliaries (HIB)

01

PM

02

DI

03

03 . 10

8 x DI

04 . 11

11

DI

12

12

DO

13

16

DO

17

17

DI

18

18 . 31

14 x DI

19 . 32

32

DI

33

33

TM

slot

IM

AX

13

DO

14

14

DO

15

15

DO

16

- A11 - X13 module AX13

Q . 2 Output . Bit 2

terminals 2 (signal)

4 (common)

bit 4 0 5 1

1 5

2 6

bit 6 2 7 3

nibble high low high low

ET200-

terminal

nibble L H H L H L L H

- A11 X18 module AX18

I . 0 Input . Bit 0


3 (common)

The first module after a change of type starts with the Low- nibble.

- A11 X23 module AX23

I . 4 Input . Bit 4


3 (common)

DR-SM150

page 84

2.15 Clearing faults and alarms (on behalf of the ET200 stations)

By now the list of fault or alarm messages has been reduced to 7:

- Switch Off fault cooling pump 1

- Stator transformer 1 oil temperature alarm - Stator transformer 1 oil temperature trip

- Stator transformer 1 Buchholz relay alarm - Stator transformer 1 Buchholz relay trip

- Delayed trip TC7 fast stop request

- Delayed trip TC8 stop rolling request

The last two messages listed are Tripping Combination messages (TCxx). TCxx-messages represent a

summary message which will clear only once the individual messages which are part of the summary message are

cleared.

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Cross-Reference from OP177-Messages to Circuit Diagrams

A reference to the related page of the circuit

diagrams is shown on the OP177 in column

Text once an alarm or a trip is monitored.

E.g. = D 01/ 02 . 2 the terminal of the

ET200S for the alarm/trip is shown on

page D01, sheet 2, column 2.

actual messages X

Date Time Text

29/10/09 08:45:17 =.D01/02.2

Stator Xformer 1 alarm oil temperature

Al

armd

isplayOP177

DR-SM150

page 86

In the next step, message Stator transformer 1 oil temperature alarm will be cleared. Use the circuit diagrams for

the mill stand and the information provided on the OP177 to find out by which ET200 module and by which of its

inputs the message Stator transformer 1 oil temperature alarm is picked up (follow main transformer system 1).

information of OP177 . . . . . . . . . . . . . . . . . . . . . . . . . circuit diagram / sheet no . . . . . . . . . . . . . . . . . . . . . . . . . . .

ET200 module no. . . . . . . . . . . . . . . . input terminal . . . . . . . . . . . . . . Low nibble, bit no. . . . . . . . . . . . . .

Use the circuit diagram of the Auxiliaries Rack to find out which switch is used to simulate the message above:

switch S . . . . . . . . . .

Switch this switch on to clear message Stator Xformer 1 oil temperature alarm ; the message acknowledges

automatically.

Follow the same procedure to find out which switch simulates message Stator transformer 1 oil temperature trip:

switch S . . . . . . . . . .

Clear the message Stator transformer 1 oil temperature trip; this message has to be acknowledged via OP177

(key F8/ACK).

. .. .

. . . . .

.

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Signal Routing from Charts to Field-HardwareDR-SM150

Signal to be followed:e.g. No-Load contactor open command (L-byte, H-nibble, bit 4)

bit 4 0 5 1

1 5

2 6

bit 6 2 7 3


ET200-

terminalX

X

page 88

Since the Auxiliaries are switched off, Cooling Pump1 has to switched off as well.

Check the feedback message of Cooling Pump 1 on the OP177 via F14/Start up > button Cooling Unit.

You will notice that the status of Cooling Pump 1 reads ON; this mismatch between control and status is also

indicated by message Switch Off fault cooling pump 1.

Use the information on the OP177 to find the chart which processes this message:

information of OP177 . . . . . . . . . . . . . . . . . . . . . . . . . chart . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the Table of Content for this chart to find the chart section related to this message: chart section . . . . . . . . . .

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DR-SM150

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0bit

Status word

7 6 5 4 3 2 1 0bit

H-byte

X13

7 6 5 4 3 2 1 0bit

L-byte

3 2 1 0bit

L-nibble

7 6 5 4bit

H-nibble

3 2 1 0

7 6 5 4

X14

X15

X16

0 1

2 3

1 5

2 6

4 5

6 7

1 5

2 6

0 1

2 3

1 5

2 6

4 5

6 7

1 5

2 6

AX16 AX15 AX14 AX13

01

PM

02

DI

03

03 . 10

8 x DI

04 . 11

11

DI

12

12

DO

13

slot

IM

AX

13

DO

14

14

DO

15

15

DO

16

nibble L H H L H L H

Relation of DCC-Word to Terminal-No. / Word Byte Nibble

page 90

Which input reads a logic state not in tune with the required control state Cooling Pump 1 = OFF:

block . . . . . . . . . input . . . . . . .

Follow this signal upstream by double-clicking on the signal connection to the left of the block assigned to the signal

line until you reach the variable linking this message to the I/O-container:

variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use the information at the input of block DETM200 to find the page of the circuit diagrams of the mill stand showing

the ET200 input for the (incorrect) message Cooling Pump 1 = ON:

information on block DETM200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

first page in circuit diagram / sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

second page in circuit diagram / sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use this circuit diagram to find out whether the feedback message Cooling Pump 1 = ON corresponds to the control

command Cooling Pump 1 = ON.

feedback message at AX26, terminal 1: logic state = . . . . . . .

control command at module AX . . . . . . . . ., terminal . . . . . . . . ., logic state = . . . . . . .

Check the switching state of contactor K15 (substituting K11 and K13 of the mill stand) in the back of the training rack;

please dont pull any wires!

Tell your trainer what you think is wrong (he will fix it !): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Signal Transfer between ET200 and SIMOTION via I/O-Container

signal from

ET200

address references in the I/O-container

1 (3)

AX13, terminal 2

L-byte, L-nibble, bit 2 PQ 1600.2

DR-SM150

page 92

2.16 Forcing a control command via ET200

For a clearly defined condition please select Local Mode and Auxiliaries off on the OP177 and acknowledge fault

Switch Off fault cooling pump 1. If necessary press key K9/Local (LED = green) and press key K11/AUX OFF

(LED = green).

Since several alarms and faults still persist, the control of the Auxiliaries (i.e. Cooling Pumps) is blocked. To force

Cooling Pump 1 to ON, ET200 module A11-X16, terminal 2 has to be activated.

To find the chart in which to force Cooling Pump 1 = ON, follow the procedure as follows.

Open the HW-Config and find out which address is assigned to this ET200:

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

Any signal exchange from ET200 to Simotion is carried out via variables. Use the I/O-container to identify the name of

the variable assigned to the address found above:

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

Supplement the table below to create a cross reference between address, module number, output terminal, bit

number and nibble (refer to the information relating the ET200 terminal numbers to the bit numbers, page 94):

address: 1601. 7 6 5 4 1601. 3 2 1 0 1600.7-4 1600.3-0

module number: X16 X15 X14 X13

bit number:

nibble (H, L): .. ..

output terminal:

Which byte (H, L), nibble (H, L) and bit of the assigned variable represents Cooling Pump 1?

byte . . . . . . . . . . nibble . . . . . . . . . . bit . . . . . . . . . .

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Finding the Reference address / variable / chart

1600.0 1600.3

address references in I/O-container

any DCC-chart

AX13, terminal 2 L-byte, L-nibble, bit 2 PQ 1600.2

2 (3)

DR-SM150

page 94

Find out on which DCC-chart and on which page the variable representing Cooling Pump 1 is processed as output:

circuit diagram / page nr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(open any DCC-chart > Options > Chart reference data > View > Cross-ReferencesAddress > select variable >

double-click on this variable to open the DCC-chart showing the variable).

Analyze which bits of the variable in question are on H-state:

hex-value: . . C 0

binary-value: 1 1 0 0 0 0 0 0

The identified ET200 word (for modules X13-X16) is output from block OUP130 (chart OUAUX, sheet C1).

Which hex-value has to be OR-wired in input I2/VM_HMEXFC to permanently switch on the cooling pump:

current binary-value of output QS: 1 1 0 0 0 0 0 0

required binary-value of output QS: 1 1 0 0 0 0 0 0

necessary OR-word at input I2: 0 0 0 0 0 0 0 0

necessary OR-word in hex: .... . 0 0

Activate the Test Mode, set Watch On for blocks OUP150 and OUP130, change input I2/VM_HMEXFC of block

OUP130 to the hex-value you have defined and verify that output Q15 of block OUP150 (Converter cooling pump 1

on command) reads logic H.

Discontinue the forced operation of Cooling Pump 1 by changing input I2, block OUP130 back to 16#0.

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Control via PG/PC in parallel to Base Automation (MRG)

X14: high-nibble X13: low-nibble

current hex-value 7 2

current binary value 0 1 1 1 0 0 1 0

required binary value 0 1 1 1 0 1 1 0

necessary OR-word 0 0 0 0 0 1 0 0

dto. In hex 0 4

resulting hex-value 7 6

Correlation of I/Os of ET200 to bits

to be set to high to switch on

the anti condensation heater:

bit 2 (low-nibble) / low-byte

high-byte

16#3B72

16#0000

16#3B72 16#3B

16#72

16#7616#0004

low-byte

low-nibble high-nibble

ON-command for the anti-condensation heater:

via -X13, terminal 2 = H

via bit 2 (low-nibble) / low-byte

bit 4 0 5 1

1 5

2 6

bit 6 2 7 3


ET200-

terminal

3 B 7 2

bit 15-12 11-8 7-4 3-0

3 (3)

DR-SM150

page 96

2.17 Clearing faults and alarms (on behalf of the ET200 stations); continued

As next step of clearing faults and alarms the still indicated individual messages Stator transformer 1 Buchholz

relay alarm and Stator transformer 1 Buchholz relay trip will have to be followed up.

Use the information provided on the OP177 and the circuit diagrams for the mill-stand to find out by which ET200

module and by which of its inputs Stator Transformer Buchholz Alarm and Stator Transformer Buchholz Trip are

picked up.

first page in circuit diagram / sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

second page in circuit diagram / sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ET200 module nr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

input terminal for Alarm: . . . . . . . . . . . . . . for Trip: . . . . . . . . . . . . . .

Find out whether the related hardware inputs are connected to the Buchholz relay (respectively to simulation

switches).

Buchholz alarm: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Buchholz trip : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

If some components which are part of the evaluation by Simotion are temporarily not available, the concerned inputs

of the ET200 modules can be temporarily connected to P24V simulating an OK feedback.

If some components will permanently be missing (i.e. a stator transformer without Buchholz relay is used), an

adaptation of the related DCC-chart might be reasonable.

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Identification of Fault and Alarm Messages sent to OP177

16#0

16#8040

16#0

16#0

16#0

16#0

16#0

16#0

16#8040

16 # 8040 8 0 4 0

1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0

bit number 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

bit

0

1

2

3

4

5

6

7

89

10

11

12

13

14

15

DR-SM150

page 98

Fault and alarm messages coming in from the plant (via ET200 stations) are evaluated and processed to initiate

further actions on a larger number of DCC-charts.

In chart MSG, on sheets D4, D5 all messages which are sent to the OP177 are listed; without any fault or alarm

all outputs of the three related blocks have to read 16#0.

Find out which outputs on which block read other than 16#0 and take a note of the value:

block . . . . . . . . . . . . . . . . . . . . . . . . . . output . . . . . . . . . . value . . . . . . . . . .

output . . . . . . . . . . value . . . . . . . . . .

Follow the identified output with the smallest output number all the way to a sheet showing a table with details of the

fault word; proceed as follows:

- single click on the line at the input of the block which corresponds to the output (verify the signal value via tool tip

text to find the matching input)

- double click on the destination reference for the follow-up sheet

Analyze output QS of block FWH210 to find out which bits read a logic H: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Which messages are identified by these bits: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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16# 8 0 4 0

enabling

bit 0 - 3

16#FFFF

16# 7 3 B F

enabling

bit 4 - 7

enabling

bit 8 - 11

enabling

bit 12 - 15

1

1

0

1

from upstream: 16 # 73BF 0 1 1 1 0 0 1 1 1 0 1 1 1 1 1 1

definition NO/NC 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Enabling 1 1 1 1 0 0 0 0 1 1 1 1 1 1 1 1

message to OP177 1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0

dto. In hex 8 0 4 0

*

from page 101

condition from field contact definition signal to OP177 alarm/fault state

H n.o. H L no message

H n.c. L H message

L n.o. H H message

L n.c. L L no message

Enabling / Blocking Groups of FaultsDR-SM150

page 100

Which field messages are evaluated if the group of messages belonging to bit 0 to 3 is enabled:

by bit 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

by bit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

by bit 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

by bit 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exclude all these field messages from being evaluated as messages on the OP177 by blocking the entire group

(nibble) to which they belong.

On block DEN200 (chart AUX1, sheet D2) you can either follow I1 which will eventually lead you to a selection of oil

transformer / dry transformer or you can follow I2 which defines the existence of a stator transformer in general.

In the present step please follow the approach via I2.

Once you have blocked the entire group all messages on the OP177 either reset automatically or can be

acknowledged.

Which field messages are no longer be evaluated in addition to the messages Stator transformer 1 Buchholz relay

alarm and Stator transformer 1 Buchholz relay trip by having blocked the entire group:

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

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

.. . . . .. . .

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Blocking (Enabling) Individual Faults

6

15

16#016#F3FF

16#8040

1

1

1

1

1

1

0

1

1

1

0

0

1

1

1

0

1

1

1

1

1

1

1

1

1

1

0

0

1

1

1

1

6

15

16#73BF

from upstream: 16# 73BF 0 1 1 1 0 0 1 1 1 0 1 1 1 1 1 1

transfer to OP177 1 1 1 1 0 0 1 1 1 1 1 1 1 1 1 1

OR-word binary 1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0

OR-word in hex 8 0 4 0

16#73BF

messages of bits 10, 11 are blocked downstream via /enable bit 8-11

messages of bits 6, 15 have to be blocked individually

- blocking (output = H no message) is effected by OR-linking the

respective bits with H in case of n.o. contacts

- or by AND-linking the respective bits with L in case of n.c. contacts

*

to page 99

DR-SM150

page 102

If these two messages must not be suppressed, the blocking of an entire group is not permissible. In this case the

messages to be suppressed have to be blocked individually.

To follow this approach, enable the group of messages you have just blocked: the messages Stator Buchholz alarm /

trip show up again.

To find the source of the field messages, follow the input of block FWH210 (chart AUX1, sheet E2) upstream all the

way to a sheet showing a table which lists the individual field messages.

Check the state of the field messages Stator Buchholz alarm / trip on block ETA250 (chart INAUX, D2):

- stator transformer Buchholz no alarm . . . . . . . . .

- stator transformer Buchholz no trip . . . . . . . . .

Assign a suitable word to the OR-gate (block ETA230) to suppress only the a.m. two messages.

required word at OR-gate binary

hex

Again all messages on the OP177 either reset automatically or can be acknowledged.

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Enabling (Groups of) Field Messages

enabling

bit 0 - 3

enabling

bit 4 - 7

enabling

bit 8 - 11

enabling

bit 12 - 15

99

DR-SM150

page 104

2.18 Adding field messages to the fault monitoring

Find out which conditions are simulated by switches S13 and S15 on the auxiliaries rack at the input of ET200:

- ET200 module number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- terminal number for S13: . . . . . . . . . . . . . . . . . . . . . . for S15: . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- circuit diagram / page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- simulated condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

In the next step the DCC-programming has to be adapted to have these two messages shown on the OP177 (if the

respective simulation switches are off).

Start on chart AUX1, sheet E2 by analyzing the change of Faultword Hardware 2 at the input of block FWH210 while

simulating the two messages (each message by itself).

S13: change from 16 # . . . . . . . . . . to 16 # . . . . . . . . . . S15: change from 16 # . . . . . . . . . . to 16 # . . . . . . . . . .

Which bits are controlled by the switches? S13: ET200-view bit . . . . . . . DCC-fault-word-view bit . . . . . . .

S15: ET200-view bit . . . . . . . DCC-fault-word-view bit . . . . . . .

Follow the signal upstream to a sheet showing a table which lists the individual field messages.

On block ETA250 (chart INAUX, D2) check the state of these two field messages when switching S13 and S15.

Which setting is presently blocking these two messages from being indicated on the OP177:

responsible nibble in chart AUX1, E2, block . . . . . . . . . . . . . . for the group of messages belonging to bits . . . . . . . . .

Follow this input upstream and enable the nibble for this group of messages.

- setting in chart . . . . . . . . . . . . sheet . . . . . . . . . . block . . . . . . . . . . . . . to value . . . . . . .

- setting in chart . . . . . . . . . . . . sheet . . . . . . . . . . block . . . . . . . . . . . . . to value . . . . . . .

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Enabling / Blocking Individual Control Signals

1 + 0 = 1

fans group 1 onfans group 2 off

16#9F81

16#FFFD

16#9F83

16#9F81

16#FFFF

16#9F83

16#9F83

incoming control request: 16 # 9F83 9 F 8 3

binary coded: 1 0 0 0 1 1 1 1 1 0 0 0 0 0 1 1

required outgoing control request (bin): 1 0 0 0 1 1 1 1 1 0 0 0 0 0 0 1

required outgoing control request (hex): 9 F 8 1

required AND-word (binary): 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 1

required AND-word (hex): F F F D

3

0 0 1 1

0 0 1 1

3

1 1 1 1

F

1 + 2 = 3

fans group 1 onfans group 2 on

- the incoming control word requires both fan

groups to run

- AND-gate OUP120 can be used to block a

control bit from being handed on downstream

- OR-gate OUP130 can be used to force a

control bit acting downstream if not set in the

incoming control word

DR-SM150

page 108

2.19 Selection of the active cooling pump

Set all switches on the auxiliaries rack such that no alarm or trip is indicated on the OP177; also switch on S10 and

S11 to disable the simulation of yet other fault conditions.

On the OP177 call up the main faceplate (key F1/Start), select Local Mode (key K9/Local) and verify that the

Auxiliaries are switched off (key K11/AUX OFF).

You will observe that the Auxiliaries are off, but ready to be switched on (information about the color code assigned

to the power hardware units on the Start-menu of the OP177 can be accessed via key F5/Help).

Now switch on the Auxiliaries (key K3/AUX ON): you will notice that the LED next to switch S10 lights up (which

indicates Motor fans group 1 = ON) and that after a delay of 10s the ready state of the auxiliaries is indicated on

the OP177.

The DCC-controlled sequence activates Cooling Pump 1 simultaneously with Fan Group 1 once the Auxiliaries

are switched on. As you notice, however, the LED next to S11 doesnt light up (Cooling pump 1 is not switched on)

even though the Auxiliaries are switched on.

Open chart OUAUX and find out whether an ON-command is generated for Cooling Pump 1. You will notice that

Cooling Pump 2 is switched on instead.

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Global Device Variables as Link between OP177 and SIMOTIONDR-SM150

page 110

Follow the control signal Converter cooling pump 1 on command upstream to find out how you can manually switch

over from pump 2 to pump 1. (OUAUX, C1 OUAUX, B2 OUAUX, B1 AUXCU, T1 AUXCU, Q1 < follow

changeover from pump 2 to pump 1> AUXCU, Q4 AUXCU, D1).

You will observe that the operation of Cooling Pump 1 respectively Cooling Pump 2 is defined via variable

selcp1_2. Since this variable is defined in the group Global device variables, the source for the control of the

Cooling Pumps is found to be the OP177.

To activate one of the two cooling pumps via OP177 proceed as follows:

- access menu Cooling Unit via key F14/Start up > button Cooling Unit

- in line selection of mode use button AUTO in column Selection to get the status MANUAL

- in line selection of pump 1/2 use the blank button in column Selection to get the status PUMP 1.

If the Auxiliaries are switched on, the LED next to switch S11 will now light up, which indicates that Convertercooling pump 1 is switched on.

Crosscheck this state on the respective DCC-chart as well.

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Defining Properties for the ET200 Analog ModulesDR-SM150

page 112

2.20 Defining properties for the ET200 analog modules

As you will have noticed, the Motor ET200 station still indicates system fault (message SF on several analog input

modules).

This message typically appears if the analog inputs are fed by signals other than defined as object property for these

modules.

Open the HW-Configuration and set the object properties of an AI-module reading system fault as shown above

(right mouse click on module > Object Properties > tab parameters > click on the right end of line Measuring type >

select required type > OK).

Set the Measuring type of all concerned modules to match the given signal wiring.

To activate these changes in the project, start the routine Save and Compile,

to activate these changes in the D445, download the HW-Configuration: PLC > Download.

After you have followed all steps the system requests you to do the SF-message for the Mot-ET200 station will have

cleared.

Since some changes in the DCC-charts have been carried out in online-mode, they still have to be saved in the

project:

- exit test mode

- compile the DCC-charts (Chart > Compile > Charts as Program > Compile all)

- close all DCC-charts

- Save and Compile the SCOUT-project

Save all your modifications on the Flash Card for - D445_Master . (SIMOTION programming)

- Yask_CX32 (Infeed)

- Yask_SINAMICS(Motor Module)

Save your project by the nameYas_Syn1 and archive this project by the nameYas_syn1 as a zip-file.

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Controlling the Drives Operation via OP177

standard ON-sequence: 1 5

standard OFF-sequence: A E

1 2 3 4 5

A

BCDE 5

DR-SM150

page 114

2.21 Controlling the drives operation via OP177

If the Auxiliaries are switched on, the operating state shown on the OP177 indicates ready to switch on for the main

CB, the exciter CB, the Infeed, the Motor Module and the DC-Master; only the motor still reads not ready to be

switched on.

In the fault free condition an interlocking sequence is predefined for Local Control.

PLEASE NOTE: DONT FOLLOW THESE STEPS AS YET other than suggested! In a plant side commissioning a

good number of measurements, settings and tests still need to be done before the drive can be switched on in full.

- Auxiliaries = ready Exciter, Infeed, Motor Module, Motor = ready

Main CB, Exciter CB = not ready

- K3/AUX ON additionally: Main CB, Exciter CB = ready, but Motor = not ready

- K4/Power ON after pr

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14 Common Syn0 s