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Comm_Motor page 01SITRAIN / METAL ACADEMY

Siemens AG 2011 - all rights reserved

Commissioning the Motor Module

DR-SM150

List of Contents

4.1 Opening Cabinet Doors / Grounding Make Proof Switch ...................................... 4

4.2 Verifying Essential Settings on the Excitation Unit (DC-Master) ........................... 4

4.3 Deleting Faults in the message buffer ................................................................ 6

4.4 Energizing the DC-Master ..................................................................................... 8

4.5 Measuring the Exciter Current ............................................................................... 22

4.6 Substituting the Automation via DCC-Chart, LCOMRG .................................. 24

4.7 Automatic Optimization and Identification of Current Loop Data (in the DC-Master) 30

4.8 Optimization of the Exciter Current Controller (in the DC-Master) ..................... 32

4.9 Tracing Signals at the Input- or Output-Channels of DCC-Blocks ........................ 38

4.10 Verifying Essential Settings on the Motor Module ................................................. 44

4.11 Rotor Position Detection ........................................................................................ 48

4.12 Operation of the Motor in I/f-Mode ...................................................................... 544.13 Operation of the Motor in Speed Control ............................................................ 62

4.14 Transition Current Model Voltage Model .................................................. 66

4.15 Setting the Scaling of the Magnetizing Inductance, d-axis ................................ 68

4.16 Excitation Current Adaptation (Balancing-Factor / G-Factor) .............................. 70

4.17 Optimization of the Current Controllers (via ISq ) ................................................... 74

4.18 Optimization of the Flux Controller ....................................................................... 86

4.19 Optimization of the Speed Controller via Step of Setpoint ................................. 92

4.20 Optimization of the Speed Controller via Step of Load ....................................... 98

4.21 Setting the Infeed Pre-Control ............................................................................... 102

4.22 Adjusting the Instrumentation Meters .................................................................... 106

4.23 Final Steps .............................................................. 108

page 02

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Comparison of Essential Settings for the Excitation

r072 * P076 p390

P101 p388

- P100 serves as scaling reference and

as excitation current limit

(along with P171: I.exc.max = P100 * P171).

- P78 acts as scaling reference for the

line input voltage.

- p390 defines the HW-rating of the DC-Master and the scaling reference on SIMOTION/SINAMICS.

- p388 represents the maximum armature voltage available for a line input voltage as set in P101; P101.max = 1.35 * P78).

- p389 acts as exciter current setpoint in no-load condition (i.Sq = 0).

Exciter setpoint from SIMOTION DCC via

PROFIBUS and Free Blocks of DC-Master

P820

Unless the exciter winding is equipped with temperature

sensors, the I2t-monitoring should not be deactivated.

DR-SM150

page 04

4 Commissioning the Motor (Motor Module)

4.2 Verifying Essential Settings on the Excitation Unit (DC-Master)

Basic commissioning of the DC-Master has already been carried out by downloading the assigned file (via DriveMonitor). Furthermore a number of faults which were due to some minor mismatch between the required

parameterization of the DC-Master and the settings assigned to it via download already have been cleared by

adapting the respective parameters.

Before the DC-Master is switched on for the first time, some essential parameters should be checked to verify that

the download file which has been used matches with the given set-up:

- P079 = 1, P601.3 = K9210 (particular settings, if the DC-Master is used for excitation)

- P171 = 120%, P172 = -10% (current limits; unless required differently)

- P150 = 100 (training rack: 600), P151 = 1500 (alpha_G limit, alpha_W limit)

The parameters for Rated excitation voltage and Rated excitation current have to be functionally identical both in

the DC-Master and in the Motor Module; verify that this requirement is given in the current parameterization (refer to

the information in the slide).

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Excitation-specific Settings of the DC-MasterDR-SM150

page 06

4.3 Deleting Faults in the message buffer

During commissioning a large number of alarm and fault messages have been indicated and acknowledged; all alarm

and fault messages are stored in the message buffer and can be viewed on the OP177 via key F4/MSG Buffer.

Have a look at the message buffer and delete its contents as follows:

- HW key F6/Diagn.

- SW button Delete Old Messages

- User = ADMIN or User = 0100

- Password = 100

- SW button Delete Old Messages

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Status Word 2 ExcitationDR-SM150

page 08

4.4 Energizing the DC-Master

To test the function of the DC-Master, its line breaker has to be switched on (key K5/Exc. Breaker ON), followed by

the on command to enable its pulses via key K6/Excit. ON.

Response to the command exciter line breaker on is enabled only if the Infeed signals ready (if it is switched on).

Select Local Mode, switch on the Auxiliaries, switch on the Infeed and switch on the Exciter line breaker: you will

observe that the assigned contactor (K1 on the auxiliaries rack) closes but trips again nearly immediately.

Which alarm message is (temporarily) displayed:

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

Refer to the mill stand function diagrams of the DC-Master and find out whether the feedback message exciter

breaker On is indicated on the PMU while contactor K1 is closed (use the PMU to read the message, because DriveMonitor is too slow to indicate a signal of such short duration).

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Source of Excitation Breaker Control

excitation breaker control via

D445 / ET200

0

1

DC-Master

1

0

DR-SM150

page 10

You will observe that no feedback signal is identified. The reason could be a true fault in the feedback circuit, but this

signal will also be missing (not being wired to the DC-Master to terminal X171:36 at all) if the exciter breaker is

controlled from external, typically via ET200 as true on the training rack.

(To avoid additional trouble later on, close switch S16 which actually simulates an exciter contactor feedback fault.)

The definition control via DC-Master respectively control from external is set on blocks TPH949 and TPH943 in

chart AUXS, sheet B1; assign the correct control request to the related blocks.

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Definition: Continuous Signal or Pulse Signal

excitation breaker

control via

pulse

signal

0

continuous

signal

1

DR-SM150

page 12

On repeating the test you will notice that the excitation breaker is still tripping after a short delay. On chart AUXS,

sheet E2, block EXB150 the switching characteristic of the exciter breaker control has to be defined (continuous

signal or pulse signal).

Check the wiring scheme of the training rack Auxiliaries to find out whether a continuous signal or a pulse signal is

used; adapt the programming of the DCC-chart accordingly.

Verify the success of this modification: the exciter breaker K1 closes and remains closed.

(A lead to chart AUXS, E2 is given by the temporarily displayed OP177 message =.WA75/E2, Self tripping excitation

breaker.)

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Control Word 1 Excitation

r000

S1

S2

DR-SM150

page 14

Now switch on the exciter via key K6/Excit. ON. You will observe no function whatsoever.

To find the very basic reason, check the drives status via missing enables and set the responsible parameter to its

required value:

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

You will notice that a fault is signaled. Identify the fault message indicated for drive device VECTOR:

current fault: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Open the expert list for object Vector and analyze the settings in p405 (this parameter was indicated to have a

parameterization error) under the aspect of using an HTL-encoder in the given hardware. Crosscheck the respective

settings in p404 and adapt them to the requirements of the HTL-encoder:

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

Remove the 24VDC supply from component SMC30 and put it back on again: after a short delay the SMC30 reads

RDY = green.

Upload these changes to the PG/PC, save the changes in the project and save these changes on the CFC.

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Adapting the Encoder SettingsDR-SM150

page 16

Again switch on the exciter via key K6/Excit. ON. Now you will observe the following:

- the command is accepted but the pulses are not enabled

- after elapse of the monitoring time, the Motor Module and the Motor signal Fault

(red symbols on the OP177) and

- the excitation circuit breaker is tripped.

Analyze the indication shown on the PMU of the DC-Master before and after the command key K6/Excit. ON.

Refer to the supplied circuit diagrams of the training rack and to the function diagrams of the DC-Master to find the

reason of the still observed malfunction.

Take the appropriate action to eliminate this cause:

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

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Fault Messages of the DC-MasterDR-SM150

page 18

Again switch on the exciter via key K5/Ex. Breaker ON and key K6/Excit. ON. You will notice that presently the

Motor Module, the Motor and the Exciter indicate Fault immediately.

Find out which fault message and which fault value is shown for the DC-Master:

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

Assign the correct parameter value on the DC-Master ( EEPROM) and again switch on the exciter via

key K5/Ex. Breaker ON and key K6/Excit. ON.

Once again, the Motor Module, the Motor and the Exciter indicate Fault immediately.

As before, find out which fault message and which fault value is shown for the DC-Master:

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

Detailed information about the line voltages of the DC-Master is provided via connectors K301 to K303.

Assign the correct parameter value on the DC-Master ( EEPROM) and again switch on the exciter via

key K5/Ex. Breaker ON and key K6/Excit. ON.

You will notice that:

- the command is accepted but the pulses are not enabled (the LED assigned to K6 flashes)

- after elapse of the monitoring time, the Motor Module and the Motor signal Fault

(red symbols on the OP177).

Again analyze the indication shown on the PMU of the DC-Master before and after the command key K6/Excit.

ON; refer to the circuit diagrams of the training rack and to the function diagrams of the DC-Master to find the reason.

Take the appropriate action:

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

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Cross-Reference from OP177-Messages to Charts to Periphery

chart

CPU

SIMU

AINF1

LCOMRG

DOPAR

COMCBE

INPUT

POSIT

chart

MOPRO

INAUX

INAUXD

AUX1

AUX2

TMONI

AUXCU

AUXS

chart

AUX2D

AUX1D

TMONID

PANEL

MSG

OUAUX

OUAUXD

OUTPUT

=.WA

01

03

05

06

07

10

11

12

=.WA

53

61

62

71

72

73

74

75

=.WA

77

78

79

81

82

97

98

99

actual messages X

Date Time Text

29/10/10 09:55:45 =.WA11 / I3 (=.DA/1.9)

Switch on fault excitation converter fan 1

>display OP177 0 ( I on PMU)

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Definition of the Pulse-Width of the Test Signal

EXC_SETP1

Flashing

duration

EXC_SETP2Flashing

duration

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

DR-SM150

page 28

Record the value of the exciter current e.g. on the DC-Masters PMU at r020:

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

Calculate the values for EXC_SETP1 and EXC_SETP2 as follows (100% = p390_Vector):

- EXC_SETP1 = 50% of the rated exciter current (generally used);

select 50% of the rated armature current of the DC-Master (P100)

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

- EXC_SETP2 = 70% of EXC_SETP1

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

Verify your settings by measurement: r020 = 35% / 50% / 35%, (100% = P100_DC-Master).

Follow the signal of the exciter current setpoint in the DCC-charts to find out where to set the pulse-width of the test

signal:

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

Change the pulse-width to 1s.

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Automatic Identification of Current Loop Data

Excitation Startup Mode

Auxiliaries = On

Power = On

Excitation Breaker = On

Test Signal = Off

EXC_STARTUP

BM_AUXON

POW_ON

ON

EXC_ENREF

Excitation = Off/ On BM_STC_ON

LCO_CONTROL

3

2

4

5

7

6

DR-SM150

page 30

4.7 Automatic Optimization and Identification of Current Loop Data (in the DC-Master)

The exciter winding resistance and the exciter winding inductivity are typically preset by Siemens in parameters P110

(armature winding resistance) and P111 (armature winding inductivity). They can, however, also be crosschecked or

identified by an automatic Optimization and Identification (manual tuning will not improve the settings beyond the

result of the automatic identification).

First take a note of the presently set values of following parameters (left column):

- armature resistance P110 = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- armature inductivity P111 = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- proportional gain P155 = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- integral action time P156 = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

In LCOMRG, switch off the test signal (EXC_ENREF = L) and switch off the excitation (BM_STC_ON = L), set

P51 = 25 (request to auto-tune the pre-control and the current controller) and start the routine by switching the

excitation back on again (BM_STC_ON = H).

You will notice that the DC-master issues F50. Analyze the prompted fault value, note down the current value of the

responsible parameter and TEMPORARILY adapt the setting to carry out the identification routine.

P . . . . . . . . . . = . . . . . . . . . . . . . . . / . . . . . . . . . . . . . . .

current setting temporary setting

On completion note down the automatically identified values in the column on the right. Armature resistance and

armature inductivity have to match fairly well; values for the current controller may differ and will be manually

optimized in the next step.Set the parameter you have temporarily adapted back to its original value.

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Trace-Tool of Drive Monitor

Start of trigger by command Start of trigger as specified

Selection of

signals to

be recorded Sampling rateand pre-trigger

recording of signal samples processing of signals transfer of samples to PG/PC

DR-SM150

page 32

4.8 Optimization of the Exciter Current Controller (in the DC-Master)

To optimize the exciter current controller the exciter current actual value has to be recorded and its response to a

step of setpoint has to be evaluated.

To correctly analyze any optimization, none of the variables of the closed loop in question must be limited; in the given

situation this applies for the firing angle.

The trace recording can be done both within the DC-Master (Drive Monitor) and within Simotion (Scout).

To optimize the PI-controller, the exciter current actual value, the step of exciter current setpoint and the firing

angle will be recorded using the tool Drive Monitor.

Refer to function diagrams G162 and G163 and assign the a.m. signals to be recorded (as close to the current

controller as possible):

- exciter current setpoint K . . . . . . . . . . . .

- exciter current actual value K . . . . . . . . . . . .

- firing angle current controller K . . . . . . . . . . . .

- firing angle pre-controlK . . . . . . . . . . . .

To be able to identify a limiting of the firing angle, relate the percent reading of K100 representing the currently set

limit of the firing angle to its degree reading (refer to the given characteristic):

r018 = . . . . . . . . . . . . . . . degrees

K100 = . . . . . . . . . . . . . . . %

[%] (K100)

[degr] (r018)

+100

-33.3

12060

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Pre-Control and PI-Controller

P154 = 0 I-controller blocked

1 I-controller active

P164 = 0 P-controller blocked

1 P-controller active

DR-SM150

set as

P111*

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

P153 = 0 no pre-control

3 pre-control

for field windings of SYN-motors

page 34

(Armature) Current Pre-Control and (armature) current PI-Controller act in parallel.

To manually optimize the PI-controller, first deactivate the Pre-Control (P113 = 0); the response must show no visible

overshoot.

The PI-controller will be optimized in its classical way by starting with a P-controller with a small proportional gain

(P155) and then increasing the gain such that the current steps up to its setpoint value without overshoot and without

developing noticeable noise (in doubt, select the smaller value rather than the larger).

Optimized proportional gain, P155 = . . . . . . . . . . . . . .

To optimize the integral property the integral component is activated, a large integral action time (P156) is selected

initially and then reduced to get a response with an overshoot of close to 15 % with the pre-control contributing to the

transient; with the PI-controller by itself an overshoot of about 4 % would be expected.

Optimized integral action time, P156 = . . . . . . . . . . . . . .

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Optimization of the Exciter Current Controller (in DC-Master)

1.0 / 10.0sk.P = 0.5/ 10.0s OPT0.2 / 10.0s

Optimization of the gain (k.P)

Optimization of the integral action time (T.N)

k.P = 0.5 / T.N = 0.01s OPT 0.5 / 0.003s0.5 / 50 ms

DR-SM150

page 36

Having added Pre-Control in parallel to the PI-controller a significant overshoot results.

Improve the transient response to avoid the overshoot while keeping the dynamic setting of your optimization as

follows:

- check the impact of P191 by looking at the controller output (K110)

- set this filter to get a minimum overshoot of the current actual, P191 = . . . . . . . . . . . . . .

(Note: P191 is not adjusted by the autotune function; it has to be set manually).

All settings on the DC-Master have now been completed. Make sure that you have made these settings on the

EEPROM and save the parameterization by uploading the data (i.e. as a delta-file, type changed parameters only).

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Trace-Tool of Scout

chart OUTPUT

block SFLD20

signal Y

chart OUTPUT

block SFLD30

signal X

signal to be traced

DR-SM150

page 38

4.9 Tracing Signals at the Input- or Output-Channels of DCC-Blocks

The exciter current setpoint originates from Simotion DCC, the exciter current actual value is fed back to Simotion

DCC; therefore both signals can also be traced using the Scout tracer.

These variables can be picked up in their nature as process data words; equally though they can be recorded at the

output Y or at the input X of any block within the DCC-charts.

Open the I/O-container and find out which variables are assigned to the following:

- exciter current setpoint: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- exciter current actual value: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Via Chart reference data localize the DCC-chart and sheet where the a.m. signals originate:



Follow both of these values until you come to a block which is referencing the signal; take a note of the name of the

block and of its input / output at the remote end of the I/O-variable (select the unscaled value):



Select the recording properties of the Scout tracer as suggested in the slide.

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Assigning DCC-Signals as Pins to the TracerDR-SM150

page 40

Inputs and outputs of DCC-blocks can be picked up as Pins of the DCC-chart.

Define the Scout trace tool to record the two exciter current values.

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Analyzing the Step Response

OUTPUT._dcc_instances._output_sfld30.x

INPUT._dcc_instances._input_rfld210.y

OUTPUT._dcc_instances._output_sfld30.x

INPUT._dcc_instances._input_rfld210.y

trise = 33ms (typical value 20 30ms)

tdead = 17ms (typical value 10 15ms)

DR-SM150

page 42

Analyze the step response of the exciter actual current as regards:

- overshoot . . . . . . . . . . . . . . % of step (must be no more than 15%)

- dead time . . . . . . . . . . . . . . ms (typically 10 to 15ms)

- rise time . . . . . . . . . . . . . . ms (typically 20 to 30ms)

Discontinue the Excitation Startup Mode by reversing your steps on LCOMRG:

- Test Signal = off EXC_ENREF = 0

- Excitation = off BM_STC_ON = 0

- Excitation Breaker = off ON = 0

- Infeed = off ALM_ON = 0

- Excitation Startup Mode = off EXC_STARTUP = 0

.. . .

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Essential Siemens-Set Values for the Motor

to be set as per Siemens-data

to be set in accordance

with site measurements

to be set as per

motor rating plate

to be set as per motor data

sheet or as per Siemens-data

DR-SM150

page 44

4.10 Verifying Essential Settings on the Motor Module

SM150 drive projects as supplied by Siemens will typically already contain all relevant Motor Data. The rating plate

of the motor has to be checked against the data set in the project. If any differences are found, the reason has to be

thoroughly investigated before taking an appropriate action.

Equivalent Circuit Diagram Data and Motor Characteristic are preset as well and should not have to be modified.

The slide above indicates the parameters involved; the values are relevant for the training unit and will only

coincidentally correspond to site settings.

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Encoder Data

track A

track B

zero

mark

zero mark

. . . . . . . . .

00 3620

3600position by adding pulses

DR-SM150

page 46

Encoder Data have to be set in accordance with to the encoder used; these data are preset as well.

As indicated in the slide above, parameters for the voltage level and for the encoder pulse number have to be

parameterized to identical settings in two different pairs of parameters.

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

If the transition from current model to voltage model (this topic is dealt with later) becomes irregular with time, the

rotor position adaptation, p430[0].22 should be set to Yes.

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

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Principle of Rotor Position Detection

UL1

UL2UL3

IEUL1

IE.set

UL2

UL3

E

S

torque

To achieve maximum torque at a given stator current ( stator flux) the

stator flux vector has to be positioned perpendicular to the rotor flux vector;

in consequence the rotor position has to be known at any time:

- initially it is identified via rotor position detection (after switching on I.E)

- from here on it is calculated by counting the encoder pulses while

in current model operation (low speed)

Detection of the rotor position by trigonometric evaluation of the voltages

induced in the stator (Ures in direction of UL1 is defined as zero degrees).

UL1

UL2

UL3

Ures

DR-SM150

page 48

4.11 Rotor Position Detection

When switching on the exciter current, the diE/dt generates a voltage pulse in the stator windings; the individual values

of the induced voltage depend on the respective angles. The trigonometric evaluation provides information about the

currently valid rotor position.

The phase voltages UL1 to UL3 can be picked up on parameters r089[0] to r089[2], the actual flux is available on

r084[0], parameters r1626[0] / r1641[0] indicate the excitation current setpoint / actual value and the pole position can

be monitored by parameter r93.

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

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Rotor Position Identification

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

The persisting voltage originates from the ripple of

the exciter current (6 current pulses per 20 ms at

line frequency = 50 Hz 3.3 ms per current pulse).

The long time view (1 s) reveals the different

voltage values generated by the gradient di.E/dt

u.L1

u.L2

u.L3

rotor position

i.exc.set

i.exc.act

flux

All signals are shown in their true physical relation

DR-SM150

page 50

Monitor these values as a result to switching on the exciter current (either via LCOMRG or via OP177).

The rotor position detection indicates the identified rotor position after evaluation of the motor voltages

( unsymmetrical initial values) induced by the di/dt of the exciter current.

Even after the exciter current has reached its steady state value, its ripple still generates motor voltages.

With exception of the first tens of ms the flux increases with PT1-property.

Please note that the signals shown in the above slide are shifted on the time axis to represent their true physical

relation.

(For the values one can record, different delay times of the internal algorithms apply. In analyzing these signals

relative to each other you would conclude that motor voltages are induced with the exciter current still zero and that

the rotor position is identified directly by switching on the exciter current setpoint; neither of these conclusions is

physically possible!)

Note down the identified Pole position angle, turn the shaft by a self estimated number of degrees and verify that the

now identified position reads:

new value = previous value +/- degrees of movement.

After you have changed the rotor position you will notice that the three motor voltages show a difference of values and

polarity (which of course is the input information for the calculation of the rotor position).

n

h

a 4

0 .

p r in

h

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Actual Flux and Ready for Operation

current

model

(IMO)

flux setpoint

p1579 (100%)

100%

motor model

UE

iS iE

i

US Up

LHd

- motor magnetizing

inductance, p360

- scaling factor, p655LHd acti

iE.set

iE.actflux actualr0084

act

iE.act

act

flux characteristic DC-Master p655 = 135

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

flux.act

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

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

flux.act

p655 = 170

L.Hd (motor model) >> L.Hd ( real motor)

85 %

DR-SM150

page 52

Trace following signals:

- exciter current setpoint r1626

- exciter current actual value r1641

- actual flux r84

You will observe that the actual flux increases up to 85% and then is substituted by 100%. This changeover to the

substitute value will always occur at 85% and acts as an internal enable signal inevitably required to run the motor.

You can monitor this essential response of the flux on the OP177 via key F13 / Graph.

If the actual flux doesnt reach the 85% value, one/several of the motor data or the voltage scaling (parameters p6753

to p6755) are likely to be set incorrect.

The setting of the magnetizing inductance (p360 * p655) for the motor circuit substitute diagram defines the exciter

current setpoint to generate the requested flux.

[A large magnetizing inductance (X.Hd) requires only a small exciter current (i.Exc) to generate flux.]

The actual exciter current is converted to the actual flux via the i.Exc / Flux characteristic up to 85%. If this value has

been reached the actual flux is defined 100% until changeover from the current model (IMO) to the voltage model

(UMO).

[If the i.Exc / Flux characteristic is matched to the real motor, the small exciter current will be calculated into a

sufficiently large actual flux, provided that the magnetizing inductance of the real motor is large. If, however, the

magnetizing inductance of the real motor is smaller than programmed as substitute circuit value, the generated

exciter current will be rather small and will in consequence be calculated into a small actual flux only.]

r

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Operation in I/f-Mode via OP177

K9

Local

K3

AUX

ON

K4

Power

ON

K5

Exc.

Breaker

ON

F1

Start

K11

AUX

OFF

K12

Power

OFF

K13

Exc.

Breaker

OFF

I/f-mode is selected / deselected automatically

if requested via the Start-up menu of the OP177

Sequence of OP177 commands to go into operation

Sequence of OP177 commands to quit operation

to force (even large) current

(excess current reactive)

- speed setpoint via

Start-up menu

of the OP177

- acceleration and

deceleration via

ramps of the

setpoint channel

for details refer to next slide

DR-SM150

page 54

4.12 Operation of the Motor in I/f-Mode

Before changing to an operating mode which evaluates current and voltage feedback values, verify that the Actual

Value Offset Correction is enabled and check the identified offset value (follow the procedure as suggested for the

Infeed on pages 33/34; parameters p6902 and p6903 have to be set to Enable Offset Calculation; the values of the

related read parameters have to float around zero).

Trusting that current and voltage evaluation are correct further tests (speed feedback evaluation, transformation angle)

can be carried out in I/f-mode, where the stator current is directly set. In case of doubt about correct current and

voltage evaluation V/f-mode has to be used for analysis. In V/f-mode the current is defined via stator voltage, so

great care has to be used not to have the current shoot up.

In I/f-mode the stator current will be forced by the direct setting, possibly even to large values (taking all excess

current as reactive current). To tolerate this condition, the tolerance monitoring of the exciter current has to beincreased; verify that parameters p3201 and p3202 are both set to 100% (this value should actually be set already).

As in V/f-mode, the rotor position calculation is not active in I/f-mode either. As logical consequence, the rotor has

to be given ample time to follow the stator field.

Due to control via OP177, the ramp settings of the Vector setpoint channel now determine the rate of change of

speed unless you exclusively use the [ /\ ] or [ \/ ] buttons to control the speed. In this case ramps set to 60s within the

OP177 Motorpot overrule the ramp settings in the setpoint channel.

Set the ramp-up and the ramp-down time to 50s each (p1120, p1121).

To operate the drive in I/f-mode, Auxiliaries, Infeed and Exciter have to be switched on beforehand; these control

operations can be performed comfortably via OP177.

t

o

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E .

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Operation in I/f-Mode

F14

Start

up

K6

Excit.

ON

I/f-Control

Selection

Start up menu

pops up

I/f-Control ispreselected

Status I/f-control changes to ON,

I/f-Control is set automatically

Exciter current builds up

(OP177: 20%);

Stator current is enabledOFF-sequence

ON-sequenc

e

K14

Excit.

OFF

Selection

one 0.5s pulse

Exciter current

is switched off

Stator current is disabled;

I/f-control is deselected

Stator Current

Setpoint (020%)

Stator Frequency

Setpoint (0100)

Stator Current

Setpoint (200%)

with =2.5% up to 20% with =2.5% down to 0%fmax = 10 Hz via DCC

in steps of =1Hz

F14

Start

up

Changeover to

Local Speed Control

N_REF_LOCALSpeed setpoint for

Local Speed Control

DR-SM150

page 56

Now follow the sequence suggested above to activate the I/f-mode;

with Stator Current Setpoint = 0 the Actual Stator Current already reads a small percentage

Increase the Stator Current Setpoint in steps of 2.5% to initially 20% (the response to the setpoint is noticeably

delayed) and verify the following:

- the torque generating actual current (r78) oscillates around 0%

- the actual stator current on the OP177 oscillates around 20% (Stator Current Setpoint)

Now increase the Stator Frequency Setpoint in steps of 1Hz to 5Hz. You will observe the following:

- the drive accelerates; Stator Frequency Setpoint and Actual Stator Frequency read 5Hz,

- several alarms are indicated.

In small steps decelerate the drive to 0Hz, in small steps reduce the current setpoint to 0 %, discontinue I/f-control,

analyze the alarm messages, check related parameters and assign the correct settings:

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

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

:r

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Current Measurement with Clamp-on Probe

Measuring small currents

(up to 10 A, e.g. gating current of SCRs)

DC to MHz, typically monitored on scope

Measuring moderate currents (up to 100 A)

DC to kHz, typically monitored on scope

Measuring large currents (up to 1000 A).

DC to kHz, monitored on display.

DR-SM150



Current Measurement with Rogowski Coil

Coil

IntegratorIf necessary, use open coil.

With half a turn, just double

the measured values.

www.sirent.de

rearch term: Rogowski

DR-SM150

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Verifying the Symmetry of Currents and Voltages

UL1

UL2-L1

UL3-L1

UL2

r89[0]

r89[1]

5% / div 10ms / div5% / div 10ms / divcurrent voltage

phase L1

phase L2

phase L3

1200

1200

PSA

raw

values

Power

Stack

Adapter

DR-SM150

page 60

Resume operation in I/f-mode, verify that no alarms are signaled and check the matching of the speed setpoint

value to the speed feedback value.

Run the drive at 10Hz and record the phase currents, r69[0 to 2] with Sinamics tracer 1 and the phase voltages,

r89[0 to 2] with Sinamics tracer 2 to get a recording similar to the one above.

(Suggested settings: endless trace, ring buffer, cycle clock = 2ms, recording time = 250ms.)

A missing or unsymmetrical feedback value of phase voltages or phase currents would easily be identified.

In case of some faulty feedback value it may prove helpful to check the raw actual values as picked up by the PSA

from the AVT-Cs via fiber optic on sockets X72 toX75 after having been assigned to r-parameters.

Find out which assignment is true between socket, parameter number and physical quantity:

socket physical quantity parameter no.

X72 . . . . . . . . . . . . . . . . . . . . . . . . .

X73 . . . . . . . . . . . . . . . . . . . . . . . . .

X74 . . . . . . . . . . . . . . . . . . . . . . . . .

X75 . . . . . . . . . . . . . . . . . . . . . . . . .

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

,f

.

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Operation in Speed Control (with Encoder)

K9

Local

K3

AUX

ON

K4

Power

ON

K5

Exc.

Breaker

ON

F1

Start

K11

AUX

OFF

K12

Power

OFF

K13

Exc.

Breaker

OFF

K6

Excit.

ON

K14

Excit.

OFF

K2

N*=0

K10

K18

F14

Start

upN_REF_LOCAL

direct entry of

speed setpoint

Increase of speed

towards positive

Increase of speed

towards negative

Request of

speed = zero

ON-sequence

OFF-sequence

DR-SM150

page 62

4.13 Operation of the Motor in Speed Control

At the training drive, consider the maximum speed to be 2400 rpm ( 80%). Using the control keys and buttons of the

OP177, run the motor in responsible steps up to the maximum speed presently possible (Training Center: 80%).

If the drive should trip before reaching 80% speed, evaluate the fault messages and set the responsible parameter to

a sufficiently large value:

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

e

r

i

l l

. =

a 61

ATERI

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Equivalent Circuit and Vector Diagram of the Synchronous Motor

LDq

p0350

p0361

US

p0356

p0355UP

RS

RDq

LS

LHq

p0359

LDd

p0350

p0360

US UE

p0356

p0354UP

RS

RDd

LS

LHd

p0358

ECDd-axis

ECDq-axis

d-axis

q-axis

p652

p659

p660

p653

p657

p658

p655

p656

scaling parameters

simplified ECD of synchronous motor

uS uP

LS LHdiS

emf

iS*(X S

+X Hd)

emfuS uP

iSiSq

iSd

iS * (XS + X Hd)

iS iSq

emfuS uP

iSiSq

iSd

iS*(X

S+XHd)

emfuS uP

DR-SM150

page 64

In the basic example above of the salient pole machine the magnetic field is set up by the permanent magnets. The

magnetic field is positioned in the d-axis and changes its position once the rotor starts to rotate.

The stator windings have to generate another magnetic field (in the q-axis) which is perpendicular to the field in the d-

axis to create a maximum of torque for any given current.

Depending on the data of the equivalent circuit components and the counter-emf (which is proportional both to speed

and to magnetic flux) a stator voltage has to be generated such that the motor doesnt develop a stator current

component i.Sd.

By changing the relation between the values of u.S and emf the stator current i.S can be shifted out of its vertical

position. A positive component i.Sd will increase the flux of the motor, a negative component i.Sd will decrease the flux

of the motor.

The data of the equivalent circuit components are defined in parameters (p350 p361) and scaled (multiplied by a

percent value) via p652 p660. An adaptation of a set motor value is commonly carried out via the assigned scaling

parameter.

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.

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Transition Current Model Voltage Model

Current Model (IMO)

flux angle via rotor angle;

actual flux via characteristic,

then substituted by 100%

Voltage Model (UMO)flux angle and actual flux

via actual values of iS, uSand substitute circuit data

flux

speed

100%

flux value

r84

act

motor model

UE

iS iE

i

USUp

LHd uS.act

iS.act

iE.actrotor angle

flux angle act IMO UMO

p1752 * p1756 p1752

enable voltage model

and flux controller

act

iE.act

flux characteristic

LHD small

LHD large

voltage model (UMO)

current model (IMO)

hysteresis

DR-SM150

page 66

4.14 Transition Current Model Voltage Model

In Vector Control Modes the position of the vector of the rotor flux is permanently available on the basis of following

relations:

- when the excitation current is enabled, the rotor position is identified by trigonometric

evaluation of the induced stator voltages

- up to the next zero pulse the position is calculated by evaluation of the A/B-track pulses

- at the next zero pulse the A/B-track pulse counter is reset and starts a new count

(the number of A/B pulses to the next zero pulse is monitored).

This flux angle is calculated by a Current Model (IMO) at lower frequencies and by a Voltage Model (UMO) at

higher frequencies.

While the current model calculates the flux angle initially on the basis of the rotor position and the flux value on thebasis of exciter current and flux characteristic, the voltage model uses the actual values of stator current components,

stator voltage and the substitute circuit diagram data of the motor to determine both the flux angle and the flux value.

Using actual values for the calculation gives more accurate results once a certain minimum frequency is reached

(typically: 10 20% of the rated frequency) if the substitute circuit diagram data of the motor are programmed

correctly.

The transition between the models is set by parameters changeover speed, p1752 and changeover hysteresis,

p1756 (refer to above slide).

If the substitute circuit diagram data of the motor are known, the transition parameters are preset by Siemens.

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Setting the Magnetizing Inductance

p655 = 175% p655 = 145%

p655 = 205%

settings for these traces of exciter current (r1626) and actual flux (r84):

p1752 = 40 % of nrated, p1756 = 50% / speed setpoint = 40 %

uS

up

emf

iS*RS

iS*XS

iS*XH

iS iSq

iSd

iE

i

iS

100%

8%

100%

8%

DR-SM150

page 68

4.15 Setting the Scaling of the Magnetizing Inductance, d-axis

The design and evaluation of the vector diagram shows that a smaller magnetizing inductance (X.H) requires a larger

magnetizing current (the smaller the inductivity the more magnetizing current is required to generate the same flux).

The larger magnetizing current is provided by a near proportional increase of the exciter current.

At the moment of enabling the voltage model (UMO), the flux as calculated by the evaluation of the actual stator

current, stator voltage and magnetizing inductance X.H is output as actual flux (r84).

If the magnetizing inductance is programmed to a value smaller than actually true in the motor, too much exciter

current will result. The evaluation of exciter current and stator current in the vector diagram will conclude a large

magnetizing current and a flux value larger than 100% in consequence.

If this value of the actual flux as calculated is other than the setpoint (typically 100 %), the flux controller changes theexciter current to reach a calculated value of 100% of actual flux (once activated; even if X.H is programmed

incorrectly).

Ramp the drive up to e.g. 40% (1200 rpm) of speed and read the values for actual flux (r84) and exciter current

(r1641) via expert list. Find a setting for the Scaling of the Magnetizing Inductance, p655 such that the actual flux

reads 100%.

p655 = . . . . . . . . . . . . . %

The Scaling of the magnetizing Inductance d-axis (p655) has to be optimized in the no load condition. The Scaling

of the magnetizing Inductance q-axis (p656) is related to load and has to be optimized once load is available.

r

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Excitation Current Adaptation / Magnetizing Inductance

-iSd +iSd

idealresponse

rated flux

(100%)

at iSd = 0

flux increases with - reduction of p655

- increase of p1625

-iSd +iSd

ideal

response

p1625

flux increases for negative iSd when increasing p1625

p655

p1625

p0655 scaling magnetizing inductance d-axisp1625 excitation current setpoint calibration

site recording

DR-SM150

page 70

4.16 Excitation Current Adaptation (Balancing-Factor / G-Factor)

The flux of the synchronous motor is defined both by the magnetizing stator current component, isd and by the

excitation current in the exciter winding, iExc.

Since the physical influence on the flux is different for each of the two currents, their relative effects are taken into

account by the implied algorithms of Vector Control.

As you can see in the diagrams above, the two parameters used in the definition of the flux setpoint (p1625, via DC-

Master exciter current) and in the calculation of the actual flux (p655) both influence the value of the flux at iSd = 0.

The example of a site-recording in the above slide shows the variables recorded by the PDA recording system as

response to a testing sequence commonly applied.

The settings of a.m. parameters has to match statically (parameters set such as to get 100 % flux). Additionally,however, these parameters have to be set such as to have the flux increase slightly if the stator operates with a

negative field generating current component (negative iSd).

The mutual influence of these parameters has to be balanced (balancing-factor / G-factor).

Note down the currently set values for the parameters listed below:

p1625 [%] = . . . . . . . . . . p655 [%] = . . . . . . . . . . r84 [%] = . . . . . . . . . .

step 1 increase the field generating current component iSd (p1620) in steps of -5 % to -25 %

observing the flux which should not exceed 140 %

step 2 reduce p1625 to get a flux of 105 %

step 3 in steps, set p1620 to zero the flux will drop to less than 100 %step 4 reduce p655 to again have a flux of 100 %

step 5 repeat the sequence (step 1 to step 4) until the flux reads 100 % with p1620 = 0 % and 105 % with

p1620 = -25 %.

Note down the values finally set: p1625 [%] = . . . . . . . . . . p655 [%] = . . . . . . . . . .

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Verification of the Setting of the Balancing-Factor

Interaction between stator flux current and rotor exciter current

change of the stator flux current

from 0% to -25% in steps of -5%

field generating stator

current component / r76

excitation current

DC-Master / r1641

actual flux / r84

DR-SM150

page 72

Verify the correct settings by studying the expected interaction between ISd (r76), Iexc (r1641) and flux (r84) by carrying

out a test as follows (e.g. at 750 rpm):

- assign r76, r1641 and r84 to be recorded by the tracer (suggested recording: endless trace)

- start the tracer and set ISd via p1620 successively to following values (in %):

0 / -5 / -10 / -15 / -20 / -25 / -20 / -15 / -10 / -5 / 0 (steps are in % of the rated motor current; p323)

- stop the tracer and verify that the exciter current (r1641) increases whenever the field generating stator current

(r76) decreases and that the flux increases slightly (up to 105 % at p1625 = -25 %).

Please note: the exciter current (r1641) must never become zero since this corresponds to an open exciter circuit

and bears the risk of resulting in high voltage on the exciter circuit.

To allow the ISd controller a fair margin of positive control, define a minimum stator current:

p1620 = -10 % (ISd = -10%).As observed in the previous test, this setting increases the exciter current of the DC-Master but keeps the flux

constant.

r t

t

t

s

I

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:

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Principle of Generating a Step of ISq-Setpoint / Torque Limit

speed

controller

.

.nset

nacttorque

limit

p1520

N_SET = steady state speed

TQ_LIM = torque limit (pos + neg)torque limit (from SIMOTION)

Profibus

Integrated

DR-SM150

page 74

4.17 Optimization of the Current Controllers (via ISq )

In this step the response of the ISq-Controller to a step of ISq-setpoint will serve to verify respectively to improve the

optimization of the current controllers which has been carried out in the previous step.

A common practical procedure to generate an ISq-setpoint step is to step up the speed setpoint by a fairly large value

(i.e. 10%) but limit the torque setpoint to the value intended as ISq-setpoint step (this step acts temporarily only until

the actual speed has reached the speed setpoint; for the short rise time of the actual current, however, this time is

more than required).

Even though the torque limit could be set at the output of the speed controller directly (by parameter) a preferred

approach is to manipulate the torque limit as it is requested from Simotion-DCC via Profibus.

Alternatively to the technological limit a manual limit can be set in LCOMRG, sheet C2, block SETPOINTS_010.

The value at the input TQ_LIM is used to define the effective torque limit.

(Please remember: a value of 1.0 in DCC represents 100%.)

Follow the torque limit TQ_LIM downstream through the charts to find out which PZD word transfers the torque limit to

object Vector:

- PZD word for torque limit: . . . . . . . . . . . . . . . . . . .

In Starter, follow this PZD word to the menu where the torque is limited and find which parameter could be used

alternatively:

- parameter for torque limit: . . . . . . . . . . . . . . . . . . .

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Generating a Step of ISq-Setpoint via LCOMRG

request for

continuous steps

steady state

speed

torque limit

(pos + neg)

generalcontrol of

the drive

* p.77

DR-SM150

page 76

To operate the drive via LCOMRG, set the operating mode to Remote (K17/Remote).

For the current test the drive will be run at a base speed (set via block SETPOINTS_010, input N_SET) to which an

additional step of speed will be added.

For this purpose LCOMRG offers a continuous step generator which is activated on block LCO_CTL_010 via input

CONT_STEP_RE.

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Continuous Step Generator

a (ms)

0.5 * cycle time

cycle time adjustment

step value Inevitable requirement: c > a / the settings of a and b define the symmetry of the generated signal

b

2 * c

a, b

c (ms)

request: continuous steps*p.75

DR-SM150

page 78

Activate the continuous step generator and follow the request to the next chart. Use input Factor of block OPTI_050

to define a (symmetrical) signal with a sweep time of 5s.

Define a step of speed of 10% (setting: 0.1 !) and roughly estimate the result of your settings on output

STEP_RESONSE of block OPTI_100.

If satisfied, deactivate the continuous step generator.

Now define the intended ISq-setpoint step by setting the torque limit TQ_LIM to 10% (setting: 0.1 !), assign a base

speed of 30% (setting: 0.3 !) and start the drive via LCOMRG (after each command wait for the feedback information):

STARTUP / BM_AUXON / ALM_ON / ON / BM_STC_ON / CNTR_EN

The drive will run up to a steady speed of 30%.

Activate the continuous step generator and verify that the speed is changing between 30% and 40%.

q

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General View of the Step-Response of ISq

+10%

-10%

+5%

40%

30%

nsetpoint

nactual

ISq-actual

ISq-setpoint

short sampling time recording

for analysis and optimization

DR-SM150

page 80

Prepare the tracer to record following variables:

- ISq-setpoint, r77 - ISq-actual value, r78

- speed setpoint, r60 - actual speed, r63

Suggested trigger settings

- initially, to get a general view: endless trace, recording time = 8s

- for the optimization: sampling rate = 0.125ms / pre-trigger = 50ms / recording duration = 255ms /

trigger condition = current setpoint > 10%

You will observe that the torque generating current component steps from an average of +5% to the set value of +10%

respectively -10% (the base torque of 5% is required to overcome friction).

Increase the torque limit to get a change of ISq-setpoint of about +20%.

i

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Optimization of the Current Controller (via ISq-setpoint)

0.25 / 1000ms 0.35 / 1000ms

0.25 / 8ms 0.25 / 6ms OPT 0.25 / 3ms

0.1 / 1000ms

DR-SM150

page 82

The current controller settings as already set by optimizing the controllers via steps of i.Sd have to prove to be correct

by applying steps of i.Sq.

For training purposes, follow the standard procedure to optimize the PI current controller once more:

- start with a large integral action time ( P-controller) to optimize the gain

- set the gain to get a fast response but no overshoot

- reduce the integral action time to again get a fast response but no overshoot

Find the optimum values for the current controller settings (they must be very similar to the values found by

optimization i.Sd):

gain, p1715 = . . . . . . . . . . . . . . and integral action time, p1717 = . . . . . . . . . . . . . .

Analyze the resulting rise time; you should find a value in the range of 5ms 10ms. If in doubt as to the correct setting,

the less dynamic setting should be preferred.

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Step Response of the ISq-Current Controller

site recording

rise time: 6ms

rise time: 3ms

DR-SM150

page 84

To give you a feeling of a site-recording, the above slide also shows the signals as they are found at site using the

PDA recording system.

Once you have finished the verification of your current controller properties, set the torque limit to a sufficiently large

value, i.e. TQ_LIM = 0.75 (LCOMRG, C2, SETPOINTS).

ITR

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Flux Control Loop [6726, 6723, 6728]

[%]

[%]

p1643[D] (0.40)

via EMF; on basis of actual values

of iS, uS and substitute circuit data

set

100%

base speed

typ. 60%

max speed

100%

example for

rolling mill

application

dynamic

support

main control

of the flux

p1590[D] (0.5) p1592[D] (200)

to verify the G-factor

about zero in

steady state

for correct X.H

r1624

DR-SM150

page 86

4.18 Optimization of the Flux Controller

Within the motor the flux is generated mainly by the excitation winding (via DC-Master, IExc) but additionally by the flux

generating current component (ISd) of the stator.

Flux control is accordingly assigned to two flux controllers, a PI-controller defining the setpoint for IExc and a

P-controller for the setpoint of ISd.

For the optimization of the two flux controllers a step of flux setpoint acting simultaneously on both controllers will be

used. By alternatively assigning a value of 0% respectively 5% as supplementary flux setpoint (parameter p1572) a

setpoint step is generated. The controller settings will be adapted to obtain an optimized step response.

Since the actual flux is calculated on the basis of the EMF, the drive has to be run at a speed where the voltage

model is active (for the given situation: n > 30%).

Prepare the tracer to record following values:

- actual flux, r84

- ISd-actual value, r76

- IExc-actual value, r1641

Suggested trigger settings:

sampling rate = 0.625ms / pre-trigger = 400ms / recording duration = 1700ms / trigger condition = actual flux > 104%

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Optimization of the PI-Flux Controller

0.4 / 10000ms 1.4 / 10000ms1.0/ 10000ms

1.0 / 200ms

OPTIMUM

1.0 / 75ms 1.0 / 50ms

IExc, actual (r1641)

actual flux (r84)

DR-SM150

page 88

The optimization of the the two controllers has to be done one by one (one controller is deactivated while the other

controller is optimized).

Note down the controller settings valid at the moment:

p1600 = . . . . . . . . . . . . . p1590 = . . . . . . . . . . . . . p1592 = . . . . . . . . . . . . .

To carry out the optimization of the PI-controller, the P-controller has to be deactivated by setting p1600 = 0.

Run the drive at a speed of 40% (either via LCOMRG or via OP177).

As for other PI-controllers, follow the standard procedure to optimize the PI flux controller:

- start with an integral action time of 10 000ms ( P-controller) to optimize the gain


- reduce the integral action time to get next to none overshootFind optimized values for the flux controller settings:

gain, p1590 = . . . . . . . . . . . . . . and integral action time, p1592 = . . . . . . . . . . . . . .

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Optimization of the P-Flux Controller / Final Result

1.0 3.0

OPTIMUM

2.5

ISd, actual (r76)

actual flux (r84)

50 ms/div

actual flux

(r84)

OPTIMUM

PI-controller: 1.0 / 75ms

P-controller 1.2

rise time:

60ms

DR-SM150

page 90

To optimize the P-controller, set its gain to its initially valid value (p1600 = . . . . . . . . . . . .), deactivate the PI-controller

by assigning the gain to p1590 = 0 and optimize the gain of the P-controller to again get a next to none overshoot:

gain, p1600 = . . . . . . . . . . . . . .

Set p1590 back to its optimized value (previous page) and analyze the resulting transient of the actual flux.

You will notice that the added influence of both flux controllers results in a too large overshoot.

Reduce the gain of the P-controller to half of its current setting: gain P-controller, p1600 = . . . . . . . . . .

The transient should now show only a slight overshoot. Analyze the rise time; you should find a value in the range

of 50ms to 100ms.

Finally monitor the actual flux for a down-step of the flux setpoint from 105% to 100% (via changing p1572 from 5%

to 0%). The resulting overshoot will be larger than for the up-step.If it is too large (or oscillating) the P-controller gain should be reduced still further to avoid the possible risk of DC-link

overvoltage.

When running the drive at constant speed also verify that the flux setpoint at the output of the PI-flux controller (r1593)

reads about zero. Any noticeable deviation results from either an incorrect setting of the magnetizing inductance;

i.e. its scaling parameter p655 or an incorrect evaluation of the actual values of motor voltage or motor current.

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Speed Controller

Kp

Tn

natural frequency

damping

dead time

reference modeloff

on

tsame rise time

DR-SM150

page 92

4.19 Optimization of the Speed Controller via Step of Setpoint

Any controller optimization is based on the consideration of the system properties of the respective control loops.

Unlike all the other controllers where the system properties are (at least to a very large extent) constant for any kind

of load or speed, the system properties of the speed control loop may change considerably with a change of speed

or with a change of dynamic load (moment of inertia).

For this reason the optimization of the speed controller should not be based on one single operating point but it has to

be valid for the entire range of operation. If the system properties change considerably (i.e. proportional to the speed

or in relation to the number of revs of the shaft like for a winding stand) the speed controller settings have to be

(automatically) adapted as necessary ( menu Adaptation).

DCC-chart LCOMRG, sheet C2 offers essentially following functionality to optimize the speed controller or to test

speed control loop properties:

1) ramping the speed up to a constant value with subsequent setpoint steps

(step up, step down at regular intervals)

2) performing reversing runs with defined ramp times within defined speed limits

3) stepping the speed up to maximum speed (preset step: 2%)

4) simulating a step of load (adding a step of torque)

Adaptation: if the moment of inertia changes along with the speed or with time, the controller properties have to be

adapted to the change of the controlled system.

Reference model: the reference model converts a step of setpoint to a signal comparable to the actual speed

feedback value. In consequence the set-actual deviation is nearly zero; the Integral-controller channel is not

contributing to the PI-controller output which makes the PI-controller functionally a P-controller with Value OptimumProperties no overshoot.

Steps of load are controlled with the high dynamic property of the PI-controller.

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Functionalities to Optimize the Speed Controller

CONT_STEP_RE continuous step response generator

activated additionally to N_SET

HIN und HER the speed setpoint is ramped from

plus N_SET to minus N_SET

ENABLE_OPT I steps the speed up to maximum speed

with a fixed step value

ENABLE TOPT provides for steps of torque

downstream of the speed controller

nactual

ISq,set

speed is ramping up;

controller properties

cannot be analyzed!

ISq, actual (r77)

nactual (r61)

nset (r1438)

must not be limited !

DR-SM150

page 94

Functionality Cont_Step_Re will be used first to optimize the speed controller at a constant base speed which is

preferably selected to correspond to the dominating operating speed (or at a speed at which basic controller settings

apply which will be adapted in operation i.e. with the change of speed).

At the training rack the system properties of the speed loop are the same at any speed.

Select a base speed of initially 60% (N_SET = 0.6 !) and define the step of speed to be 2% (LCOMRG, sheet D1,

block OPTI_100, input X2 = 0.02).

[The step value has to be small enough not to have torque or current limited; so start with a really small value initially.]

Switch on the drive via LCOMRG, have it run up to the set speed of 60% and activate continuous setpoint steps

(CONT_STEP_RE).

Prepare the tracer to record following values:

- speed setpoint, r1438

- actual speed, r61

- ISq-setpoint, r77

Suggested trigger settings:

sampling rate = 1.0ms / pre-trigger = 200ms / recording duration = 2000ms / trigger condition = speed setpoint > 61%

Analyze the recorded signals.

In particular have a look at the peak value of the torque generating stator current component (r77):

peak value of r77: . . . . . . . . . . . . . .

This peak value has to be noticeably smaller the set torque limit (p1520) to allow for the optimization

(when the gain is optimized it may be increased well beyond its initial value; the larger the gain, the larger the ISq peak

value for the same value of step).

=

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Optimization of the Speed Controller via Step of Setpoint

18/ 10000ms 25 / 10000ms8 / 10000ms

18 / 100ms OPTIMUM18 / 40ms

t.rise = 25ms

18 / 25ms

DR-SM150

page 96

The PI speed controller is optimized following the same sequence as has been used for other PI-controllers. The

typical aim of the optimization, however, is to find a step response featuring a considerable overshoot (details will

follow).

Start the optimization by following the standard procedure:

- set an integral action time of 10 000ms ( P-controller) to optimize the gain


- reduce the integral action time to get only one undershoot of the actual speed (the resulting overshoot will

range within 20% to 50%; the value depends on the mechanical properties of the load).

[The noise of the actual speed may make it difficult to identify the undershoot; looking at the current setpoint in

comparison an identification of the correct setting will be successful.]

Note down the optimized values for the speed controller settings and the resulting rise time:

proportional gain, p1460 = . . . . . . . . . . . . . . rise time = . . . . . . . . . . . . . .

integral action time, p1462 = . . . . . . . . . . . . . .

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Optimization via Simulated Step of Load

Profibus

Integrated

i.Sq.set

simulated

load

i.Sq.act

-

-

currentcontroller

negative torque limiting symmetrical

DR-SM150

page 98

4.20 Optimization of the Speed Controller via Step of Load

In actual operation steps of setpoint as used in the previous approach of optimization will rarely occur because any

request to change the speed will pass a ramp function generator (either the one within the drives setpoint channel or

some other implemented in the higher level control like Automation.

In practical operation the motor will have to handle steps of load. Since real steps of load can hardly be generated on

demand, simulated steps of load are used to test the response of the drive to a step of disturbance variable.

Set the commissioning torque limit in LCOMRG, block SETPOINTS_010, input TQ_LIM to 75% and verify via Starter

that this value is active.

This setting limits the maximum torque the drive will accept on request from the speed controller to 75%. In

consequence a simulated load of more than 75% cannot be counteracted by the speed controller; the drive would

accelerate up to the voltage limit!

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Optimization of the Speed Controller via Step of Load

cycle time c

step value - inevitable requirement: c > a

- the settings of a and b

define the symmetry ofthe generated signal

c

a, ba

b

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

load =20% 40% 60%

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

18 / 200ms 18 / 40ms

ISD =

0.55 %s

ISD =

0.15 %s

8 / 200ms

ISD =

1.25 %s

t

n

load = 50%

DR-SM150

page 100

Go to chart LCOMRG, sheet D5, block OPTI_101, input X2 and set the disturbance variable to simulate a 10% load

for 1s with a 1s zero load interval (remember that a setting of 1 acts as 100% ! ).

Switch on the drive via LCOMRG, have it run up to a speed of 60% and activate the simulated disturbance variable

(ENABLE_TOPT).

Trace the same signals as before for a step of load of 20%, 40% and 50%: you will notice that the maximum loss of

speed is proportional to the step of load.

If your drive should trip with overcurrent, fault 30001 while simulating steps of load, check your current controller

settings; at the TC-stand they should read p1715 = 0.15, p1717 = 6ms (in particular your gain might be set too

large). If necessary, adapt your settings.

If you compare the step response for a constant step of load but for different controller settings you will notice that the

area made up by the loss of actual speed versus the constant speed setpoint decreases the more dynamically the

speed controller is set.

This area defines the quality of the speed controller setup. It is known by the name Impact Speed Drop and should

be less than 0.25%s for a step of load of 50% according to following equation

(you might want to substitute your signal by an approximated triangle):

ISD = 0.5 * t * n [t in s, n in % (nmax = 100%), ISD in %s]

Take one of your traces for the optimized speed controller and calculate the ISD:

ISD = . . . . . . . . . . . . %s

Once you terminate this test, set the value of the disturbance variable to 0% and disable the additional step of

torque.

To continue, be sure that the speed controller data are set to your optimized values.

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DC-Link Voltage Pre-Control

i.Sq pre-control

of up to four

Motor Modules

with pre-control

ideally zero

U.DC

distribution of

the overall i.Sq

request to the

overall number

of ALMs

Pre-Control

0 off

100 on

CU-Link

active power

setpoint

r82[3]

MoMo 1

r82[3]

MoMo 4

...

DR-SM150

page 102

4.21 Setting the Infeed Pre-Control

As you can see in the function diagram, the control of the DC-link voltage combines the outputs of the DC-link voltage

controller and of the pre-control channel. As common in such an arrangement, the pre-control has to be set to fully

provide the voltage request; the PI-controller will act as a correction controller only (it will become active to handle

any step of disturbance variable which might occur in the DC-link itself).

The active power requested by the Motor Module is transferred to the Infeed via CU-link and has to be scaled with the

aim of minimizing the contribution of the PI-voltage controller (r77 should ideally read zero with a setting of p3521

close to 100 %).

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Influence of the DC-Link Voltage Pre-Control

p3521 = 100%

p3521 = 150%p3521 = 50%p3521 = 0%

UDC, actual

isq (precontrol)

isq (UDCcontrol)

DR-SM150

page 104

At present the pre-control is already active (generally enabled by p3400.11 = ON / scaled with 100 % via p3521[0]).

Prepare the tracer to record following Infeed values (endless trace with 5s recording time / sampling rate = 4ms):

- Iactive-setpoint, r77 - Ppre-control , r3522[0] - UDC-actual, r70[0]

To tune the Infeed Pre-Control, a reversing run with about 50 % torque generating current component will be

required. Operate the drive using the commissioning mode HIN und HER and adjust the acceleration and

deceleration ramps to get ISq-actual = 50 %).

Use the parameter for the scaling (p3521) to analyze its influence on the recorded signals:

- without pre-control the PI-controller provides all active current for the change of load

- with 100% pre-control the PI-controller operates in idle state

- if the pre-control is too large, the PI-controller counteracts

- the quality of the DC-link voltage is roughly the same for any setting(UNLESS the limits of the PI-controller should be reached)

Finally find the optimized setting (such that the PI-controller output, r77 shows the least deflection):

p3521 = . . . . . . . . . . . %

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Adjusting Instrumentation Meters

functiond

iagram

c

ircuitdiagram

PSA-meters can be tested by

assigning 0%, 100% directly or

by parameters r6888[0 3].

These parameters additionally

offer a -100% value and a

sawtooth signal (-100% to 100%).

-1.0 +1.0

+10V

-10VOffset = 0

Scaling = 1

-1.0

+10V

-10VOffset = 0

Scaling = 2

+5V

-5V

+1.0

-1.0 +1.0

+10V

-10VOffset = -1

Scaling = 2

in

out

DR-SM150

page 106

4.22 Adjusting the Instrumentation Meters

When you run the TC-drive you will notice that the instrumentation meters indicate unexpected values.

The meters of the training rack are wired as per standard (refer to the excerpt of the circuit diagram above). Find out

first which meter is connected to which PSA terminal:

Signal PSA terminal Signal in-par. out-par. scaling offset

standard required p6860 cd. p6870 cd.

Voltage . . . . . . . . . . . Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current . . . . . . . . . . . Current . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed . . . . . . . . . . . Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power . . . . . . . . . . . DC-link . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Next find out which input-parameters you have to use to feed a signal to the assigned meters as required and which

output-parameters you have to wire to get the physical quantity indicated (select the smoothed values).

Use the Calibration signals for PSA analog outputs to test the assignment and function of the meter for the speed:

constant value 0 0% / constant value -1.0 (1.0) -100% (100%).

Program the parameters for scaling and offset to tune the meter as required.

Now assign the smoothed actual speed to this meter and verify that the speed is indicated as requested:

- Speed 0rpm 0% / value as scaled in p2000 100% (same at positive and negative speed)

(run the drive via OP177 at various positive and negative speed values).

Follow the same approach for the other signals and have the meters indicate as suggested:- Voltage 0V 0% / value as scaled in p2001 100% (same at positive and negative speed)

- Current 0A 0% / value as scaled in p2002 100% (same at positive and negative speed)

- DC-link 0V 0% / 600V 100%

. . .

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Important Values for the Motor Module

for commissioning purposes / protection DEF = 100%Current limit softwarep6920

0.8 to 1.2 => 160 to 240 Hz -> WE = 1.0Switch frequency factor for RZAp6961

U/F Table guidep6974 [0-37]

U/F Table typep6972 [0-7]

Parameters

Raw actual value to X75 -> U_wu9971PSA raw value loaded to X75r6765[0n]

Raw actual value to X74 -> U_vu9971PSA raw value loaded to X74r6764[0n]

Raw actual value to X73 -> I_W9971PSA raw value loaded to X73r6763[0n]

Raw actual value to X72 -> I_U9971PSA raw value loaded to X72r6762[0n]

PSA Raw Values

Double smoothed speed actual value4715Nist_smoothed (p1441 & p0045 = smoothing)r0063[1]

Actual value can also be calculated (sensorless)4715Nist_smoothed (p1441 = smoothing)r0063[0]

Speed actual value unsmoothed (raw value)4715Nist_unsmoothed from SMC30r0061

Speed

Active power setpoint6714P_nomr0082[2]

Active power actual value smoothed6714P_act_smoothedr0082[1]

Active power actual value unsmoothed6714P_actr0082[0]

Power

Motor- current actual value reactive component6714Id_actr0076

Motor- current actual value active component6714Iq_actr0078

Motor voltage actual value6732Motor_PhaseVoltagesr0089[0-4]

Filtered current actual value (r6910) as sine wave6732I_Ist_Motor_corrected (without pulsing)r0069[0-4]

Calculated motor voltage actual values (R,S,T, , )6732U_act_Motor with harmonic oscillations (raw values)r6911 [0-4]Calculated motor current actual values-I_act_Motor_with harmonic oscillations (raw values)r6910 [0-4]

U & I

CommentSheetMeaningActual Value

DR-SM150

ITR

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