mm4 hoisting gear

Application for Drive Technology

MICROMASTER 4 Application Description

Conveyor Systems

Hoisting Gear Engineering and Commissioning

Warranty, Liability and Support

Conveyor Systems Hoisting Gear Engineering and Commissioning

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1 Warranty, Liability and Support

We do not accept any liability for the information contained in this docu-ment.

Any claims against us based on whatever legal reason resulting form the use of the examples, information, programs, engineering and perform-ance data etc., described in this document shall be excluded. Such an ex-clusion shall not apply in the case of mandatory liability, e.g. under the German Product Liability Act (Produkthaftungsgesetz), in case of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of a condi-tion which goes to the root of the contract (wesentliche Vertragspflichten). However, claims arising from a breach of a condition which goes to the root of the contract shall be limited to the foreseeable damage which is intrinsic to the contract, unless caused by intent or gross negligence or based on mandatory liability for injury of life, body or health. The above provisions does not imply a change in the burden of proof to your detriment.

The Application Examples are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. They do not represent customer-specific solutions. They are only intended to provide support for typical applications. You are responsible in ensuring that the described products are correctly used.

These Application Examples do not relieve you of the responsibility in safely and professionally using, installing, operating and servicing equip-ment. When using these Application Examples, you recognize that Sie-mens cannot be made liable for any damage/claims beyond the liability clause described above. We reserve the right to make changes to these Application Examples at any time without prior notice. If there are any de-viations between the recommendations provided in these Application Ex-amples and other Siemens publications e.g. Catalogs then the contents of the other documents have priority.

Copyright 2005 Siemens A&D. It is not permissible to transfer or copy these Application Examples or excerpts of them without first having prior authorization from Siemens A&D in writing.

For questions about this document please use the following e-mail-address:

mailto:[email protected]

Definitions and Warnings


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2 Definitions and Warnings

2.1 Qualified Personnel

In the sense of this documentation qualified personnel are those who are knowledgeable and qualified to install, mount, commission, operate and service/maintain the products to be used

e.g.:

o Trained and authorized to energize and de-energize, ground and tag circuits and equipment according to applicable safety standards.

o Trained or instructed according to the latest safety standards in the care and use of the appropriate safety equipment.

o Trained in rendering first aid. There is no explicit warning information in this documentation. However, reference is made to warning information and instructions in the Operating Instructions for the particular product.

2.2 User group

The application software and the application example were developed to support Siemens personnel in the generation of user programs for machines or systems.

This is not intended to be directly passed-on or sold to persons/companies outside Siemens AG.

Application software may only be passed-on as part of a complete machine or plant software.

If application software, which is not integrated in a complete project, is passed-on to persons/companies outside Siemens AG, then the person or persons who transferred this information carry full responsibility for any liability or damage claims.

Only qualified personnel may apply the application software and the application example.

If this is incorrectly used, this can result in the plant or system being destroyed and/or injury to personnel.

Definitions and Warnings


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2.3 Applicable conditions

The valid Edition for the General Conditions of Sale and Delivery for Products and Services for internal Siemens business applies.

2.4 Information regarding trademarks

SIMOVERT is a Siemens registered trademark MICROMASTER is a Siemens registered trademark

2.5 Revision/Author

Version Date/change Author 01/05 First edition M. Schmittele

A. Bader

Hoisting gear


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3 Hoisting gear

3.1 Introduction

These instructions are used to commission hoisting gear equipment. Please refer to the appropriate Operating Instructions and/or parameter lists if certain issues are not clear or the functionality is to be expanded. The frequency converter must be ready to operate. This means that the frequency converter must have been installed, mounted and connected-up according to the data in the Operating Instructions.

In practice, difficulties are often encountered when using MM440 frequency converters for hoisting gear applications. Frequently, incorrect commissioning and engineering mistakes as well as unsuitable operating modes are the reasons. Generally, a hoisting gear doesnt tolerate any faults/errors.

These Instructions are a guide for engineering and commissioning the MM440 for hoisting gear applications to allow you to quickly and reliably engineer conventional hoisting gear.

3.2 Hoisting gear applications

MM440 frequency converters can be especially recommended for cranes with low and average performance requirements both as hoisting gear as well as traversing gear drive. Not only this, it can be used for hoisting applications in conveyor systems. Application examples include:

o Cranes in halls e.g. in workshops and storage facilities/warehouses: Hoisting and traversing gear equipment

o Hoisting gear in conveyor systems with and without counter-weight o Outdoor storage locations/warehouses cranes: Hoisting and traversing

gear

3.3 Validity/ restrictions

o This application document describes the closed-loop control types V/f control and closed-loop vector control with encoder and KTY 84. Closed-loop vector control with encoder and KTY 84 is the preferred operating mode.

o It should be clearly pointed-out that at the present time, the MM440 does not reliably detect pulse encoder faults and when the motor stalls.

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o Presently, we do not recommend additional operating modes as mentioned in this Section for example SLVC or VC with speed encoder without KTY.

o When using the parameter assignments recommended in Section 10.1.4 Pre-control to prevent the load dropping/sagging when entering a uni-polar speed setpoint, CDS command data sets cannot be used.

o In this document, reference is made in the literature references to documents that are only available in the SD Intranet.

3.4 Information and instructions when selecting/dimensioning motors and frequency converters, definitions

3.4.1 Selecting/dimensioning motors and frequency converters using SIZER

Here, reference should be made to the SIZER program, that also provides engineering support when selecting and dimensioning hoisting gear.

3.4.2 Rough selection/dimensioning of motors and converters for VC with pulse encoder

The rough selection/dimensioning described here has proven itself in practice and for most hoisting gear applications, provides good results. It assumes the following:

The rated hoisting power Pnh at the rated velocity of the hoisting gear is calculated.

A maximum power that has been empirically determined of Pmax = 2 Pnh is required for accelerating or a maximum torque, refer below.

The motor is dimensioned for the rated hoisting torque Mnh, if, starting from Mnh, 200% overload is possible. Otherwise, the motor must be dimensioned corresponding to the overload or the ramp-up and ramp-down times of the hoisting velocity should be extended.

For frequency converters up to 75 kW, 150% overload can be utilized and for frequency converters from 90 to 200 kW, 136% overload.

We do not recommend that 200% overload is used. When the 200% overload is used, this results in a load duty cycle, that does not match the usual operating mode of cranes and hoisting gear.

The formulas for the calculation example are shown below. The essential quantities of a hoisting gear are shown in Fig. 3.4.2.

Hoisting gear


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3~M

nM; MMi

nT

d/2

S

F'

m

FvLoad

GearMotorEncoder Rope drum

Distance s

Load

S = 2

Load

S = 1

m m

Fig. 3.4.2: Diagram showing the essential quantities of a hoisting gear

Calculation example:

- Total load (load + load suspension equipment): m = 3.141 kg

- Rated hoisting velocity: v = 21.75 m/min = 0.36 m/s

- mechanical = 0.9 (without motor (!))

- Cable drum diameter d = 0.4 m

- Gear ratio: i = 1 : 37

- Suspension/ reeving S = 2

a) Calculating the rated hoisting power Pnh = (m g v) / mechanical = (3141kg 9.81kg/ m 0.36 m/s) / 0.9 = 12.325 W = 12.3 kW

With

Pnh = rated hoisting power in [kW]

g = 9.81 m/s2, acceleration due to gravity

v = rated hoisting velocity in [m/s]

m = nominal mass of the load to be hoisted in [kg]

Hoisting gear


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Note:

The hoisting power can be quickly calculated with just few data and provides a rough basis for the hoisting gear power. Generally, it is not suitable for selecting/dimensioning the motor and frequency converter. To do this, the following formulas should be used.

b) Calculating the shaft speed nM of the motor from: nM = i nT = (i S v) / ( d) = (37 2 0.36 m/s) / ( 0.4 m) = 21.2 1/ s = 1.271 RPM

With

i = gear ratio

nM = motor speed in [RPM]

nT = cable drum speed in [RPM]

S = reeving

d = cable drum diameter in [m]

c) Calculating the required rated hoisting torque Mnh for v = constant: Mnh = (m g d) / (2 i S ) = (3141 kg 9,81 m/ s^2 0,4) / (2 37 2 ,09) = 93 Nm

With

Mnh = rated hoisting torque in [Nm]

d) Selecting a motor: Starting from a rated torque of 93 Nm and a speed of 1.271 RPM, a 1LA7 166-4AA.. motor is selected.

Check whether the motor can output the maximum required torque:

Mhmax = 2 Mnh, as required:

The motor supplies the following maximum torque:

Mmaxm = 0,77 Mk Mnm = 0,77 3,0 98 = 226 Nm

Hoisting gear


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From c):

Mhmax = 2 Mnh

= 2 93 Nm = 186 Nm

The motor can output the max. hoisting torque.

With

Mmaxm = max. motor torque in [Nm]

Mhmax = max. hoisting torque in [Nm]

Mk = stall torque/ rated torque = 3.0 from Catalog M11

Mnm = rated torque = 98 Nm from Catalog M11

e) Calculating the max. motor current Imaxm:

e1) Torque overload factor m:

m = Mhmax / Mnm = 186 Nm / 98 Nm = 1,9

e2) Calculating the max. motor current Imaxm:

cos = 0.84, from the Catalog

Inm = 28.5 A (rated motor current), from the Catalog

from e1): m = 1,9

Io = Inm (1 cos ) = 28,5 A (1 0,84) = 11,4 A

With Io = magnetizing current in [A]

Iw = (In Io) = (28,5 A - 11,4 A) = 26, 1 A

With Iw = active current in [A]

Imaxm = (Io + (m Iw)) = (11,4 A + (1,9 26,1 A)) = 51 A

Hoisting gear


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f) Selecting and dimensioning the frequency converter: From e):

Imaxm = 51 A

When using the frequency converter overload, the rated frequency converter current Infu is given by:

Infu = Imaxm / 1,5 = 51 A / 1,5 = 34 A

A 6SE6440-2UD31-8AD1 frequency converter with 18.5 kW power and a rated output current of 38 A is selected.

For information and instructions to set parameters P0640, P1520 and P1521, refer to function chart 7710:

o Prerequisite: P0305 = 28.5 A (rated motor current, from the rating plate already calculated, refer to e): Imax = 54 A

o Overload factor P0640 = 54 A / 28.5 A 100 % = 189 % or the maximum value from P0640

o Upper torque limit P 1520 = 194 Nm or maximum value from P1520 (Mmax = 0.77 Mk)

o Lower torque limit P 1521 = -194 Nm or minimum value from P1521 (Mmin = - 0.77 Mk)

3.4.3 Roughly selecting and dimensioning motors and frequency converters for V/f

The motor and frequency converter are selected/dimensioned the same as described above with the following restrictions: The rated motor torque may not be exceeded!

Hoisting gear


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3.4.4 Others

When using field weakening it should be carefully ensured that the torque taken from the motor is reduced corresponding to the square of the field-weakening speed.

For hoisting gear equipment with heavy duty cycles and the appropriate overload when accelerating and decelerating, the load duty cycle should be used to check whether the motor and frequency converter selection/dimensioning is sufficient from the perspective of the RMS value of the current.

The braking resistor should be dimensioned for the duration of the lowering and the load duty cycle. For more detailed information, refer to Document /5/. Further, the MM440 Operating Instructions should be taken into account.

This information only includes special issues that have to be noted when engineering hoisting gear applications. The other rules that apply must also be carefully observed.

3.5 Closed-loop control technique

The following closed-loop control techniques are available a) V/f characteristic (P1300 = 0)

an encoder is not required either no overload or just a low motor overload is possible restricted dynamic performance of the hoisting gear as there

is no torque reserve b) Closed-loop vector control (P1300 = 21) and KTY 84

an encoder and KTY 84 are required when appropriately selecting and dimensioning the

frequency converter

the overload capability of the motor can be fully used. dynamic crane operation is possible

Hoisting gear


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3.6 Commissioning

If a harmonized and coordinated parameter set is still not available for the frequency converter / hoisting gear, then before optimizing the closed-loop vector control or the V/f control, carry-out and observe the following steps:

1. Loads that are potentially hazardous a) Lower the load to the floor (secure the load), or

b) Ensure that the frequency converter cannot control the motor holding brake (MHB)

c) When commissioning the load, e.g. optimizing the controller etc., it must be possible to immediately stop the hoisting gear. This should be able to be done, for example, using an Emergency Stop button located close by that also directly acts on the hoisting gear brake. Before starting any work, the effectiveness of this function must be carefully checked to ensure that it is working perfectly.

2. Quick commissioning (refer to Chapter 4) Quick commissioning should always be carried-out..

3. Motor holding brake (MHB) (refer to Chapter 5) For drives that must be secured in the powered-down condition against undesirable motion, the brake sequence control of the MM4 (this function is enabled using P1215) can be used to control the motor holding brake. Notes

a. When controlling the MHB, the interaction between opening/closing the mechanical brake and the motor torque being established is decisive. This interaction in the frequency converter is instantaneous without any delay. This is the reason that the control implemented in the frequency converter itself is preferred over an external control (e.g. Simatic.

b. If the motor holding brake is controlled from a higher-level control system (e.g. Simatic, crane control, etc.), then the brake control should be realized there!

c. The term MHB of course includes for example, an external brake mounted on the brake drum, that, for example, is controlled from the frequency converter.

d. If P1215 = 0 (P1215: enable MHB), then r52.12 = 1 a brake controlled by the frequency converter opens. Therefore: The binary output, that controls the hoisting gear brake, may only be connected with r52.12 if P1215 = 1.

Hoisting gear


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4. Regenerative energy (refer to Chapter 6) If the frequency converter brakes a motor in a short time or a hoisting gear lowers a heavy load, the motor operates in the regenerative mode and feeds energy back into the frequency converter. The frequency converter DC link voltage increases. If this voltage becomes too high (overvoltage F0002), the frequency converter inhibits the inverter and the motor coasts-down. By using the resistor brake, the regenerative energy is fed through the braking chopper to the external braking resistor where it is converted into heat. This means that the frequency converter can control the motor corresponding to the setpoint even in regenerative operation.

5. Motor data identification (refer to Chapter 7) a. P1910 = 1 + ON command

Motor data identification

b. P1910 = 3 + ON command Comment.: It is not absolutely necessary to determine the saturation characteristic, if the frequency converter is only used in the voltage control range. However, the saturation characteristic must be determined when operating in the field-weakening range

6. Magnetizing current (refer to Chapter 8) The value of the magnetizing current r0331/P0320 has aspecial influence on the accuracy of the motor model parameters. This value is estimated from the rating plate on SIEMENS standard motors. Especially for third-party motors, the determined magnetizing current should be again checked and if required corrected. The following criteria can be used for the magnetizing current:

o Flux setpoint (r1598=100%) matches the flux actual value (r0084=96..104%) of the motor model.

o The Xm adaptation (r1787) of the motor model should, if possible, not intervene. Good values lie between 1-5%.

o Please refer to /6/ and Section 0 when setting the magnetizing current.

Hoisting gear


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7. Optimizing the closed-loop control Depending on the closed-loop control technique, the individual parameters for the hoisting gear application must be appropriately optimized. The important parameters can be taken from the following sequence diagrams:

o V/f characteristic refer to Chapter 10.1 o Closed-loop vector control with encoder refer to Chapter 10.2

8. Motor temperature (refer to Chapter 9) A KTY84 sensor is used to measure the motor temperature. Among other things, the motor temperature depends on the load level, load duration, speed and type of motor cooling. The motor temperature influences the stator and rotor temperature and must, as far as possible, be precisely emulated in the motor model of the drive converter.

3.7 Series commissioning

If a harmonized, coordinated parameter set is available for the drive converter / hoisting gear, then please observe the following:

1. Potentially hazardous loads

a) Secure the load, or

b) Inhibit the MHB control (e.g. disconnect the connection between the drive converter and the motor holding brake)

c) Under all circumstances, ensure that the hoisting gear motor does not unintentionally rotate (cable drum) in order to avoid mechanical damage.

Then start the fast commissioning / parameter download using the PC tool (e.g. STARTER, AOP)

Quick commissioning


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4 Quick commissioning

Note:

Before starting any of the commissioning steps in Section 4, the hoisting gear motor must be secured so that it cannot unintentionally start and the holding brake of the hoisting gear must be locked-out so that it cannot be unintentionally opened (e.g. so that the holding brake cannot be intentionally released).

o The steps shown in Section 4 should be carried-out for both closed-

loop control types (VC with pulse encoder and KTY 84 and V/f. o With the fast commissioning, the drive converter is adapted to the

motor and important technology parameters are set. o The parameters designated with a * offer more setting possibilities

than are listed here. Please refer to the parameter list for these additional setting possibilities.

Note: Factory setting We recommend that before starting any commissioning work, all of

the parameters are set to the factory setting. If required, settings should be made at Starter/ DriveMonitor and at

the drive unit (P2010, P2012).

Access stage * 1 Standard (basic/simple application) 2 Expanded (standard application) 3 Expert (complex application)

Commissioning parameters * 0 Ready 1 Fast commissioning 30 Factory setting NOTE P0010 should be set to 1 in order to enter the motor rating plate data.

P0100 =...

P

0100

= 1

, 2

P01

00 =

0

Europe/ North America Select the power entry (kW / hp) and the rated motor frequency 0 Europe [kW], rated motor frequency 50 Hz

and DIP2(2) OFF (factory setting) 1 North America [hp], rated motor frequency

60 Hz and DIP2(2) ON

2 North America [kW], rated motor frequency 60 Hz

NOTE For P0100 = 0 or 1, the setting of switch DIP50/60 defines the value of P0100.

Remove the I/O module access to DIP 2(2)

DIP50/60

START

P0003 = 2 1

P0010 = 1 0

0

Quick commissioning


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Rated motor voltage (the rating plate in V is entered) Check the rated motor voltage on the rating plate regarding the star/ delta circuit with the connections on the motor terminal board.

Rated motor current Input acc. to the rating plate in Amps

Rated motor power (the rating plate in kW/hp is entered).If P0100 = 0 or 2, then the input is in kW, for P0100 = 1, in hp.

P0304

P0305P0307P0308 P0311

P0310

Rated motor power factor (the cos data on the rating plate is entered) For the setting 0, the value is automatically calculated. P0100 = 1,2: P0308 has no significance, an entry is not required

Rated motor efficiency (input acc. to the % data on the rating plate) For the setting 0, the value is automatically calculated. P0100 = 0: P0309 has no significance an entry is not required

Rated motor frequency (the Hz specified on the rating plate is entered) The number of pole pairs is automatically taken into account.

Rated motor speed The input is acc. to the rating plate in RPM

Motor cooling * (the motor cooling system is entered) 0 Self-ventilated using the fan mounted on the motor shaft 1 Force-ventilated (separately-driven fan)

Motor overload factor (entered as a % referred to P0305) This defines the limit value of the maximum output current as a % of the rated motor current (P0305). Note: Generally, the overload factor here is selected so that the motor can provide the maximum demanded torque when hoisting and lowering the load refer to Section 3.4

Selects the command source Defines the command source withwhich the drive converter is controlled. 0 Factory pre-setting 1 BOP (converter keyboard) 2 Terminal strip 4 USS at the BOP link 5 USS at the COM link 6 CB at the COM link

BOP

USSBOP link

USSCOM link

P0700 = 2

Terminals

CBCOM link

Sequence control

Setpointchannel

Closed-loopmotor ctrl.

P0304 =... P0304 =...

P0305 =... P0305 =...

P0307 =... P0307 =...

FC spec.

FC spec.

FC spec.

P0308 =... P0308 =...

P0309 =... P0309 =...

P0310 =...

P0311 =...

P0335 =...

P0640 =...

FC spec.

FC spec.

50.00 Hz60.00 Hz

FC spec.

0

150 %

P0700 =... 2

Quick commissioning


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Selects the setpoint source * Defines the frequency setpoint source that is defined by the setpoint that has been entered. 1 Motorized potentiometer setpoint 2 Analog input 3 Fixed frequency 4 USS at the BOP link 5 USS at the COM link 6 CB at the COM link 7 Analog input 2

MOP

ADC

FF

USSBOP link

USSCOM link

CBCOM link

ADC2

P1000 = 12

P1000 = 12

Sequence control

Mainsetpoint

Setpointchannel

Motorcontrol

Additonalsetpoint

Minimum frequency (the lowest motor frequency in Hz is entered) The lowest motor frequency with which the motor can operate independent of the frequency setpoint is entered. The value set here applies for both directions of rotation. Note: P1080 = 0

Maximum frequency (the highest motor frequency in Hz is entered) The maximum frequency to which, e.g. the motor is limited independent of the frequency setpoint, is entered. The value set here applies for both directions of rotation.

Ramp-up time (accelerating time) (the accelerating time in s is entered) The time in which, e.g. the motor should accelerate from standstill up to the maximum frequency P1082 is entered.

Ramp-down time (deceleration time) (input the deceleration time in s) The time in which e.g. the motor should brake from the maximum frequency P1082 down to standstill is entered. Note: This time should not be set too long in order to avoid actuating a limit switch. Recommended setting: P1121 = P1120

P1000 =... 2

P1080 =...

P1082 =...

P1120 =...

P1121 =...

0.00 Hz

50.00 Hz60.00 Hz

10.00 s

10.00 s

Quick commissioning


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OFF 3 ramp-down time (the fast stop ramp-down time in s is entered) The time in which e.g. the motor should brake from the maximum frequency P1082 down to standstill for an OFF3 command (fast stop) is entered. Note: Generally, the value of P1135 is < the value of P1121

Closed-loop control type * (the required closed-loop control type is entered) 0 V/f with linear characteristic 21 Closed-loop vector control with sensor

End of fast commissioning (start of the motor calculation) 3 Only motor calculation. The remaining parameters are not reset. NOTE For P3900 = 3 internally, P0340 is set to 1 and the appropriate data calculated (refer to the parameter list P0340).

ENDE End of the fast commissioning/drive setting.

P1135 =...

P1300 =...

P3900 = 1

5.00 s

0

0

Motor holding brake (MHB) and hoisting gear brake


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5 Motor holding brake (MHB) and hoisting gear brake

This Section applies both for V/f control as well as for closed-loop vector control with encoder.

Series / commissioning for potentially hazardous loads proceed as follows

Lower the load to the floor The hoisting gear motor must be inhibited so that it cannot

unintentionally start.

When replacing the drive converter, prevent the drive converter from controlling the MHB until the new drive converter has been completely commissioned.

Secure the load, and ensure that the MHB cannot be controlled and then, and only then commission / download parameters using the PC tool (e.g. STARTER, AOP)

Only connect the binary output (P0731 P0733) for the brake control to r52.12 if P1215 = 1.

Generally, every hoisting gear has a brake. This brake is either the

motor holding brake or is an external brake e.g. that is mounted on the cable drum. It makes sense if this brake is controlled by the drive converter itself.

Generally, the hoisting gear brake is only designed as holding brake and not as operational brake.

Pre-control to prevent the load sagging/dropping when the holding brake is opened (weight equalization) and delayed setpoint enable, refer to Section 10.

Notes:

The pre-control to prevent the load sagging depends on the weight of the suspended load that must be raised. In most cases, one setting is suitable for all load situations.

The modified brake control can result in improved drive behavior when starting.



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The application / release times (brake closing / brake opening times) can be taken from the appropriate documentation. The following typical values have been taken from the M11 Motor Catalog 2003/2004, Page 2/51

Motor frame size

Brake type Release time [ms]

Application time [ms]

63 2LM8 005-1NAxx 25 56

71 2LM8 005-2NAxx 25 56

80 2LM8 010-3NAxx 26 70

90 2LM8 020-4NAxx 37 90

100 2LM8 040-5NAxx 43 140

112 2LM8 060-6NAxx 60 210

132 2LM8 100-7NAxx 50 270

160 2LM8 260-8NAxx 165 340

180 2LM8 315-0NAxx 152 410

200 225 2LM8 400-0NAxx 230 390

Table 3: Application/release times (M11 Motor Catalog)



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Enables the motor holding brake Activates/de-actives the motor holding brake (MHB). 0 Motor holding brake inhibited 1 Motor holding brake released Note The following applies when controlling the brake relay via, e.g. digital output 1: P0731 = 52.C (or 52.12) 0 t

fmin(P1080)

P1217P1216

1r0052Bit12

t

f

Point 2Point 1

BI: Fct., digital output 1 Defines the source for digital output 1. Note The brake relay can be controlled via one of the two other digital outputs.

52.0 Ready to power-up 0 closed 52.1 Ready 0 closed 52.2 Drive running 0 closed 52.3 Fault present 0 closed 52.4 OFF2 active 1 closed 52.5 OFF3 active 1 closed 52.6 Power-on inhibit active 0 closed 52.7 Alarm active 0 closed 52.8 Setpoint/actual value deviation 1 closed 52.9 PLC control (PZD control) 0 closed 52.A Maximum frequency reached 0 closed 52.B Alarm: Motor current limiting 1 closed 52.C Motor holding brake (MHB) active 0 closed 52.D Motor overload 1 closed : :

MM440

(52:3)

BI: Fct. of DOUT 1P0731.C

-1

0

1

Invert DOUTs0 ... 7

P0748 (0) CO/BO: State DOUTs

r0747r0747

T.20

T.18

.0Functio

nxxxx.y

rxxxx.y

P0731 = xxxx.y

DOUTchannel

Relay:

30 V DC / 5 A250 V AC / 2 A T.28

T.9

int. 24 Vmax. 100mA

NO

COM

NC

T.19or

- max. load capability

- max. opening / closing time5 / 10 ms

Enable delay, holding brake This defines the time interval in which the drive converter runs with the min. frequency P1080 after being magnetized before ramp-up. Recommendation: P1216 = 0

P1215 =... 0

P0731=52.C 52.3

P1216 =... 1.0 s



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P1217 =... Ramp-down holding time, holding brake This defines the time during which the drive converter operates with the minimum frequency (P1080) after ramp down to the minimum frequency. Recommendation: P1217 brake application (closing) time + relay closing time P1217 10 ms + application (closing) time of the brake + the switching time of a braking contactor if a braking contactor is being used.

1.0 s

Regenerative energy


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6 Regenerative energy

This Section applies both for V/ f open-loop control as well as for closed-loop vector control with encoder.

The following settings should always be made:

The Vdc_max controller de-activated P1240 = 0 - (def.: P1240 = 1) The compound brake de-activated P1236 = 0 - (def.: P1236 = 0) Resistor brake activated P1237 > 0 - (def.: P1237 = 0)

Resistor braking Resistor braking is activated using parameter P1237 and the nominal load duty cycle / power-on duration of the braking resistor defined. 0 Inhibited 1 Load duty cycle 5 % 2 Load duty cycle 10 % 3 Load duty cycle 20 % 4 Load duty cycle 50 % 5 Load duty cycle 100 % Using the resistor brake, the regenerative energy is transferred through the chopper control (braking chopper) to the external braking resistor where it is converted into heat. This means that the drive can be braked in a controlled fashion. To select and dimension the braking resistor and set the load duty cycle, please refer to

3.15.3 Resistor brake of the MM440 Operating Instructions and /5/ and /7/.

The regenerative power when lowering Pns is obtained as follows (compare Section 3.4): Pns = (m g v)

with m = max. weight when lowering v = max. velocity when lowering = total efficiency of the system and motor

Braking resistor

Choppercontrol

B-

=~

~

B+

=

~

MM4

P1237 = ... 0



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7 Motor data identification

The motor data identification routine must be carried-out for all closed-loop control types

When carrying-out the motor identification routine, the motor temperature must approximately correspond to the value in P0625

During the motor data identification routine, the motor can remain locked (the rotor locked).



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Motor ambient temperature (entered in C) Enter the ambient temperature of the motor at the time that motor data is determined (factory setting: 20 C).

Yes No

Value in P0625 ~ motor temperature Note: If the motor is equipped with an KTY 84 temperature sensor, then we recommend that the KTY 84 is parameterized using P601 = 2 and the value from r0035 is entered into P625.

Selects the motor data identification routine with P1910 = 1 P1910 = 1: Identifies the motor parameters with parameter change. When p1910 = 1 is selected, alarm A0451 (motor data identification active) is output, and data calculation can be started after the measurement has been completed (P0340 = 3). Note: The existing hoisting gear brake can remain closed.

Starts the motor data identification routine with p1910 = 1 The measuring operation must be started with a permanent ON command. The motor aligns itself and conducts current. Diagnostics is possible via r0069 (CO: Phase currents).

p1910 is reset after the motor data identification routine has been completed (p1910 = 0, motor data identification routine inhibited) and alarm A0541 is withdrawn.

In order to bring the drive converter into a defined state, an OFF1 command must be issued before the next step.

Selects the motor data identification routine with p1910 = 3 p1910 = 3: Identifies the saturation curve with parameter change When p1910 = 3 is selected, alarm A0451 (motor data identification routine active) is output, and after the measurement has been completed, data calculation is started (P0340 = 2).

Starts the motor data identification routine with p1910 = 3 The measuring operation must be started with a permanent ON command.

After the motor data identification routine has been completed, p1910 is reset (p1910 = 0, motor data identification routine inhibited) and alarm A0541 is withdrawn.

In order to bring the drive converter into a defined state, an OFF1 command must be issued before the next step.

START

P0625 = ? 20 C

|Motor temp. - P0625 | 5 K ?

Allow the motor to cool down

P1910 = 1 0

A0541

ON

OFF1

P1910 = 3 0

A0541

ON

OFF1

End

Magnetizing current


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8 Magnetizing current

For V/f control, it is not necessary to determine the magnetizing current. The value of the magnetizing current - r0331/P0320 has a special

effect on the closed-loop control. However, this value cannot be measured at standstill and for 4-pole standard 1LA7 SIEMENS motors, this is estimated using the automatic parameterization P0340=1 (P0320=0; result in r0331).

If the deviation between the actual magnetizing current and the magnetizing current saved in the drive converter, then also the values for the magnetizing reactance and the rotor resistance cannot be precisely determined.

The magnetizing current that is determined should, especially for third-party motors, be if necessary corrected.

The following description describes how to proceed when manually determining the magnetizing current and re-calculating the equivalent circuit diagram when operating the drive in closed-loop vector control (P1300=20/21).

Note: For this measurement, the motor must be running under no-load conditions i.e. it must be de-coupled from the load.

Also refer to /6/

Magnetizing current


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Quick commissioning The drive converter is adapted to the motor using the fast commissioning procedure.

Motor data identification routine Using the motor data identification routine, measuring techniques are used to determine the equivalent motor circuit diagram data.

Determines the magnetizing current When determining the magnetizing current (P0320/r0331), the motor should be accelerated up to approx. 80% of its rated speed under no-load conditions. In so doing the following conditions must be carefully maintained: The closed-loop vector control must be activated, P1300 = 21 No field weakening (r0056.8=0) Flux setpoint r1598=100% The efficiency is not optimized, P1580=0%

No-load means that the motor is operated with the load de-coupled (not coupled).

A current r0027 is obtained under steady-state conditions. This approximately corresponds to the rated magnetizing current r0331 (the current is always lower than the no-load current for a pure V/f control).

No Yes

Measuring and entering the magnetizing current and the associated re-calculation of the equivalent circuit diagram data of the motor are iterative procedures. It should be repeated at least 2-3 times until the following criteria have been fulfilled:

The more accurate that the magnetizing current is entered, the better the flux setpoint (r1598=100%) matches the flux actual value (r0084=96..104%) of the monitor model.

The output Xm adaptation (r1787) of the monitor model should be as low as possible. Good values lie between 1-5%. The less that the Xh adaptation of the monitor must work, then the motor parameters are that much less sensitive after power failures.

Note: To display r0084 on the BOP/AOP, LEVEL 4 parameters must be enabled using the service parameter P3950=46.

Calculating P0320 From the flux-generating current component r0029 that was determined, using the following equation the new value can be entered into P0320.

P0320 = r0029 * 100 / P0305 Calculating the motor parameters

The values of the motor equivalent circuit diagram data are calculated from the rating plate data that was entered. In addition, the parameters of the controls are pre-set (P0340 = 3).

START

Quick commissioning

(refer to Chapter 4


(refer to Chapter 1

Operation under no-load

Criterion fulfilled?

P0320 = ... 0

0 P0340 = 1

End

Drive converter and motor overload


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9 Drive converter and motor overload

This Section must be carefully observed both for V/f closed-loop control as well as with closed-loop vector control with encoder and KTY 84.

In addition to the thermal motor protection, the motor temperature is also incorporated in the adaptation of the motor equivalent circuit diagram data. Especially for high thermal motor loads, this adaptation has a significant influence on the stability of the closed-loop vector control.

For hoisting gear applications with closed-loop control mode VC with encoder (P1300 = 21), presently, the motor temperature must be measured using a KTY 84 temperature sensor.

The KTY 84 temperature sensor is not required when using a V/f closed-loop control; however, the motor must then be protected against overload in another way, e.g. using a thermo switch that is integrated in the winding overhangs of the motor.

Parameter settings: P0290 = 1 shutdown with F0004/ F0005 P0601 = 2 KTY 84 is evaluated; mandatory for VC with encoder, practical for V/ f P0601 = 0, 1 additional settings for V/ f r0035 motor temperature

Drive converter overload response

This defines the drive converter response to an internal overtemperature condition. 0 The output frequency is reduced 1 Shutdown (F0004 / F0005) 2 The pulse frequency and output frequency are reduced 3 The pulse frequency is reduced, then shutdown (F0004)

A0504

A0505

A0506

F0004

F0005

Overload response, driveconverter

P0290

Pulse frequencycontroller

i_max controller(V/f)

current controller(SLVC, VC)

r0036

r0037 Heatsinktemperature

P0292

IGBTtemperature

P0292

i2tP0294

Monitoring, driveconverter

P0290 = ... 0

Drive converter and motor overload


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Motor temperature sensor Selects the motor temperature sensor. 0 No sensor, only for V/ f 1 PTC thermistor, only for V/ f 2 KTY84 this is mandatory for VC with encoder When "no sensor" or PTC thermistor is selected, the motor temperature is determined using as basis the value estimated in the thermal motor model.

r0631

ADC

5 V

Monitorsignalloss

T1 = 4 s

2

1

No encoderPTCKTY

0

P0604

FaultF0015

&P0601 = 2

Thermalmotormodel

r0633

r0632

r0035

1 Motortemp.response

P0610P0601

Equivalentcircuit

PV,motPower loss

V

0

1

0

1

r0052Bit13

PTCKTY

P0601 = ... 0

Closed-loop control techniques


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10 Closed-loop control techniques

Information regarding commissioning:

All of the previously mentioned safety information and instructions must be carefully complied with.

It is especially important to ensure that the hoisting gear cannot unintentionally start (the load may not sag when the brake opens, controlled by the drive converter).

An Emergency Stop, that must act directly on the holding brake, must be located in the immediate vicinity and its function must have been checked to ensure that it operates correctly.

Note the information and instructions in Section 10.2

10.1 V/ f open-loop control

Closed-loop control mode * The closed-loop control mode is selected using this parameter. The ratio between the drive converter output voltage and the drive converter output frequency is defined for the "V/f characteristic" control mode 0 V/f with linear characteristic Note: Only operating mode P1300 = 0 is permitted for sensorless operation

Constant voltage boost (entered as a %) Voltage boost as a % relative to P0305 (rated motor current) and P0350 (stator resistance). At low output voltages, the ohmic active resistances of the winding can no longer be neglected. The reason for this is that the voltage drop results in a lower motor flux if it is not compensated. Note: We recommend P1310 = 100 %

f

V/f linear

OFFON

t

t

f

P1310 active

t01

Validity rangeVmax

Vn(P0304)

VConBoost,100

0 fn(P0310)

f max(P1082)

V

fBoost,end(P1316)

boost

Outpu

t voltag

e

V act

Norm

al V/

f

(P13

00 =

0)

VConBoost,50

Boost voltage

Voltage boost when accelerating P1311 = 0

Voltage boost when starting P1312 = 0

0 P1300 = ...

P1310 = ... 50.0 %

P1311 = ... 0.0 %

P1312 = ... 0.0 %



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Slip compensation P1335 = 0, Refer to Sections 10.1.33, 10.1.4 (V/ f)

Resonance damping, gain V/f Defines the controller gain to dampen resonance for operation with V/f characteristic.

10.1.1 Supplements to the brake control and slip compensation:

The following parameterization is only valid for the V/ f open-loop control mode.

The subsequently discussed parameterization is additionally used to that already described if satisfactory results are not obtained with the previously described standard setting at starting, and when

The brake is controlled The load sags which is unacceptable behavior.

10.1.2 Extended brake control

Overview, refer to Section 10.1.4

Setpoint delay: P1142 = 2852 delayed enable for the ramp-function generator P1215 = 1 motor holding brake released P1216 = 0,0 s release delay holding brake P1217 = 0,1 s set the brake closing time (brake delay time) as short as

possible.

P0732 = 52:12 control, e.g. DO 2 (terminals 21, 22), brake P2800 = 1 enable free FBs P2802.0 = 3 execution level 3 P2849 = 52:12 control the timer to open brake P2851 = 0 switch-in delay mode P2850 = 0,1 s delay n* enable

0.0 % P1335 = ...

P1338 = ... 0.00



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Information regarding the setting of P2850:

Lowest effective value: 180 ms, effective stages: 180 ms Recommended setting for P2850:

P2850 = -180 ms + brake release time + switching time of a braking contactor if one is used

Usual release time of brakes, refer to Section 1 and Table 3 in the same Section.

10.1.3 Pre-control to prevent the load sagging when entering a bipolar speed setpoint

Notes:

It is assumed, as was declared at the start of this document, that hoisting requires a positive speed setpoint and lowering a negative speed setpoint and this is fed-in at parameter P1070, main setpoint, function chart Page -5000-..

Monitoring parameters: r1078 total setpoint, refer to the function chart Sheet -5000- r1170 setpoint after the ramp-function generator, refer to the

function chart, Sheet -5300-

Parameterization without extended brake control:

P1142 = 1 enable ramp-function generator (factory setting) P1075 = 2889 pre-control, load sagging P2000 = 50 50 Hz reference frequency P2889 = z. B. + 6 + (!) 6 % of 50 Hz corresponds to 3 Hz

Parameterization with extended brake control: P1070 = 2889 pre-control, load sagging P2000 = 50 50 Hz reference frequency P2889 = z. B. 6 + (!) 6 % of 50 Hz corresponds to 3 Hz P1142 = 1 enable ramp-function generator (factory setting) P1075 = 755 main setpoint is connected to the supplementary

setpoint

P1074 = 2853 switch-in speed setpoint after brake is open.



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The slip frequency that prevents load sag, is fed-in via P1070, main speed setpoint, function chart Page 5000-. This slip frequency can either be calculated from the size of the load or should be empirically determined.

A bipolar speed setpoint can, for example, come from PROFIBUS, the fixed frequencies or analog input 1 (r0755.0) and is fed-in via P1075, supplementary speed setpoint, function chart Page 5000-..

10.1.4 Pre-control to prevent load sag when entering a unipolar speed setpoint

Notes:

The parameterization discussed in this Section is required if a unipolar setpoint is used and the reversing command (P1113) is used to changeover between hoisting (positive speed setpoint) and lowering (negative speed setpoint).

The prerequisite to prevent load sag is, as described in this Section, the parameterization of Section 10.1.2 Extended brake control.

Monitoring parameters: r1078 total setpoint, refer to the function chart, Sheet -5000- r1170 setpoint after the ramp-function generator, refer to the

function chart, Sheet -5300-

The parameterization used in this Section is shown in the following diagram in the form of a function chart. This is then followed by the parameterization itself.



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- 500

1 -

Func

tion

diag

ram

87

65

43

21

Appl

icat

ions

MIC

RO

MAS

TER

440

13.0

4.20

04

V2.

0Ex

tend

ed B

rake

Con

trol a

nd P

reve

ntin

g Lo

ad S

ag

T0

0T

TT

1

0 1 2 3

P28

51=0

P285

0 =0

.1P

2800

=1P

2802

.0=3

Sw

itch-

in d

elay

Sw

itch-

out d

elay

Sw

itch-

on/s

witc

h-ou

t del

ay

Pul

se g

ener

ator

Inde

x0

T

r285

2

r285

3

P28

49

P28

16[0

] = 2

853

P28

16[1

] = 0

:0M

HB

act

ive

r005

2.C

P28

00=1

P280

1[3]

=2

Inde

x0P2

816

Inde

x1r2

817

1

P28

00=1

P280

1[0]

=2

&In

dex0

P281

0

Inde

x1r2

811

Rev

ersi

ngr7

22.1

0:0

P081

0

P081

1

P08

11 =

281

1

P08

10 =

281

7P

2849

= 5

2.C

P10

70[0

] = 7

55

P10

70[1

] = 0

P10

70[2

] = 7

55

00

10

x1Hoi

st

Hol

d

Low

er

P10

75[0

] = 2

889

P10

75[1

] = 2

889

P10

75[2

] = 2

890

00

10

x1Hoi

st

Hol

d

Low

er

+ +

f set,

MS

f set,

SS

f set

MH

B v

ia D

O2

P07

32 =

52.

C

P07

32

P28

10[0

] = 2

852

P28

10[1

] = 5

4.B

Mai

n se

tpoi

ntP

1070

Sup

plem

enta

ry se

tpoi

ntP

1075

MH

B a

ctiv

er0

052.

C

r281

1

Rev

ersi

ngP

1113

P111

3

P11

13 =

281

1



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Parameterization

Data set changeover: P0810 = 2817 CDS changeover P2801.3 = 2 enable OR 1, execution level 2 P2816.0 = 2853 OR 1 BI P2816.1 = 0 OR 1 BI P0811 = 2811 CDS changeover

Information regarding the drive data set changeover:

P811 P810 DDS0 0 1 0 1 2 1 X 3

r0050 = display, actual BDS

Assigning slip values when hoisting and lowering P1075.0 = 2889 slip, hoisting P1075.1 = 2889 slip at setpoint = 0 (brake release time) P1075.2 = 2890 slip, lowering P2000 = 50 Hz reference frequency P1335 = 0 slip compensation P2889 = ? [%] slip, hoisting, e.g. 4 % P2890 = -? [%] slip, lowering, e.g. 4 %

Interlocking reversing (P1113) during setpoint = 0 (brake release time) P2801.0 = 2 enable AND 1, Level 2 P2810.0 = 2852 AND 1 BI P0702.0 = 99 (enable BiCo wiring) P2810.1 = 722.1 AND 1 BI P1113.0 = 0 reversing

Ramp-function generator P1142 = 1



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Copy CDS - CDS1 must be copied into CDS2 and CDS3. 0: CDS1; 1: CDS2; 2: CDS3 Procedure: P0809.0 = 0 this data set CDS is copied, in this case CDS1 P0809.1 = 1 copied into this data set, here CDS2 P0809.2 = 1 start copying

Note: CDS1: Data set that is used in crane operation when hoisting CDS2: Data set that is effective at setpoint = 0 (brake release time) CDS3: Data set that is used in crane operation when lowering

Main setpoint P1070.0 = 755 here, e.g. analog input 1 P1070.1 = 0 P1070.2 = 755 P1075.2 = 2890 slip, lowering

Inhibiting reversing (P1113) at setpoint = 0 (brake release time) P1113.0 = 2811 P1113.2 = 2811

10.2 Closed-loop vector control (VC) with pulse encoder

The operating mode described in this Section 10.2 is the preferred mode for hoisting gear.

When commissioning the closed-loop vector control with encoder (VC), the drive converter should first be operated with V/f control (P1300 = 0). When the motor is rotating and the speed encoder is connected (activated using P0400), then parameters r0061 and r0021 must correspond regarding the following quantities:

sign absolute value (a deviation of a few percent is permissible)

The closed-loop vector control with encoder (P1300 = 21) may only be activated if both of these conditions are fulfilled (refer to Chapter 10.2.3).



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10.2.1 Limits

The limit values for the torque (P1520, P1521) and the power (P1530, P1531) can be set to the maximum value. This therefore avoids a possible limit that could result in instability in the closed-loop control.

Calculating the values, refer to Section 3.4. Motor overload factor [%]

Determines the motor overload factor as a [%] relative to P0305 (rated motor current). Limited to the maximum drive converter current or to 400 % of the rated motor torque (P0305), whereby the lower value is applied.

100 P0305

P0305) 4 (r0209, min P0640max =

CO: Upper torque limit Specifies the upper torque limit. Pre-setting (default): P1520 = - 1,5 r0333 Max. Value: P1520 = - 4 r0333 Refer to section 3.4.2

CO: Lower Torque Limit Specifies the lower torque limit.Pre-setting (default): P1521 = - 1,5 r0333 Max. Value: P1521 = - 4 r0333 Refer to section 3.4.2

f 1 ~

Torque limit

Resultingtorque limit

Powerlimit

|fact

r1526r1527

Stalllimit

P1530P1531

f 1 ~ 2

Constanttorque

fstallConstant

power

|

|M|

Stallpower

Limit value, power when motoring Specifies the maximum permissible power when motoring.

P1530 defP1530 max 0307P3 =

0307P5.2 =

Recommended: P1530 = max

Limit value, power when regenerating Specifies the maximum permissible power when regenerating.

P1531max P0307 3- =P1531def P0307 2.5- =

Recommended: P1531 = - P1530

M

f

f 2 P M =

Power limit (motoring, regenerating)

P1530

P1531P1530

P1531

P0640 = ...

P1520 = ...

P1521 = ...

P1530 = ...

P1531 = ...

150.0 %

FC spec.

FC spec.

FC spec.

FC spec.



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10.2.2 Pulse Encoder

Selects the encoder type 2 Two-track pulse encoder The following table indicates the values of P0400 as a function of the number of tracks:

Note: For hoisting gear applications (4-quadrant operation (!)), a 2-track encoder must be used! P0400 = 2

Parameter Terminal Track Pulse encoder output

Referred to ground(single ended)P0400 = 1 A

DifferentialA

AN

A

B

A

AN

B

BN

Differential

P0400 = 2 Referred to ground(single ended)

The DIP switch on the encoder module must be set as follows depending on the encoder type (TTL, HTL) and the encoder output:

TypeDifferential

TTL

HTL

111111 010101

101010 000000

Referred to ground(single ended)

Output

(e.g.

(e.g.1XP8001-1)

1XP8001-2)

Number of encoder pulses Specifies the number of encoder pulses per revolution. For pulse encoder 1XP8001: 1024 pulses/ revolution

Response, speed signal loss Defines the calculation method. 0 No transition 1 Transition into SLVC

Permissible frequency difference Parameter P0492 defines the frequency threshold for encoder signal loss (fault F0090).

P0492 = 0 (no monitoring): With P0492 = 0, the loss of the encoder signal both at a high frequency and also at a low frequency is de-activated. This means that the system does not monitor for loss of encoder signal..

Delayed response to speed signal loss P0492 is used to detect the loss of the encoder signal at low frequencies. If the motor speed is lower than the value of P0492, then the encoder signal loss is determined using the appropriate algorithm. P0494 defines the delay time after detecting the speed signal loss until the appropriate response is initiated.

P0494 =...

P0494 = 0 (no monitoring): With P0494 = 0, the loss of the encoder signal is de-activated at a low frequency. This means that when the encoder signal is lost at these frequencies then it is not detected (the loss of the encoder signal at a higher frequency remains active as long as parameter P0492 > 0).

P0400 =...

P0408 =...

P0491 =...

P0492 =...

0

1024

0

10.00 Hz

10 ms



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10.2.3 Closed-loop speed control with encoder

Closed-loop control mode *

21 closed-loop vector control with sensor

Filter time for the actual speed Sets the time constant of the PT1 filter in order to smooth the control system error (deviation) of the speed controller. When this value is reduced, it results in a higher dynamic response of the closed-loop speed control however, there is a potential danger of instability at low values. P1442 is set to 2 ms for most applications.

Gain factor, speed control. Specifies the speed controller gain. Recommended optimization: Set P1460 to 5 to 10 to 15.

Integration time, speed controller Specifies the integration time constant of the speed controller.

Pre-control

Freq. setpoint

r1438r1084

Kp Tn

P1460 P1462

r0064

Speedsetpoint

P1496 P0341 P0342

P1442

Act. frequencyfrom the pulse encoder

r0063

r1170

P1492

P1489P1488

Droopinput

r1490150 ms

r1518

0

1 0

r0079r1508

*) only active if the pre-control has been activated (P1496 > 0)

*)

P1300=21

P1442 = ...

P1460 = ...

P1462 = ...

4 ms

3.0

400 ms



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10.2.4 Supplements to the brake control and load sag

The following parameterization only applies for the closed-loop vector control mode with pulse encoder.

The subsequently discussed parameterization is additionally used to that already described, if satisfactory results are not obtained with the previously described standard setting at starting and when

The brake is controlled The load sags which is unacceptable behavior.

10.2.4.1 Extended brake control

Setpoint delay: P2800 = 1 enable free FBs P2802.0 = 3 execution level P2849 = 52:12 control timer to open brake P0732 = 52:12 control e.g. DO 2 (terminals 21, 22), brake P2851 = 0 switch-in delay mode P1216 = 0,0 s enable delay, holding brake P2850 = 0,1 s delay n* enable P1142 = 2852 delayed enable, ramp-function generator

Note regarding the setting of P2850:

Lowest effective value: 180 ms, effective steps: 180 ms Recommended setting P2850:

P2850 = -180 ms + release time of the brake + switching time of a braking contactor if one is being used

normal release times for brakes, refer to Section 1 and Table 3 in the same Section.



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10.2.4.2 Pre-control to prevent load sag

The pre-control to avoid load sag can be compared with the brake control of Section 10.2.4.1. However 10.2.4.1 is not a prerequisite.

It is assumed that, as was already declared at the start of this document, hoisting requires a positive speed setpoint and lowering a negative speed setpoint and this is fed-in at parameter P1070, main setpoint, function chart, Page -5000-.

The torque to prevent the load sagging is fed-in via P1511, supplementary torque setpoint (function chart [7210]). The positive (!) M-ZSW can either be calculated from the size of the load or must be empirically determined.

M-ZSW can either be fixed which is sufficient for many applications where the ratio between the minimum and maximum load is low; or it can be entered, e.g. via PROFIBUS or analog input 2.

Procedure:

Normalization of P2003: P2003 = 93 corresponding to a rated hoisting torque of 93

Fixed torque setpoint to prevent load sag:

P1511 = 2889 A hoisting torque of 40 Nm is to be pre-controlled:

(40 Nm/ 93 Nm) 100 % = 43 %

P2889 = 43 this corresponds to a hoisting torque of 40 Nm Torque setpoint that can be continually entered to prevent load sag:

P1511 = 2050.3 word 4 PROFIBUS A torque stroke of 53 Nm should be pre-controlled:

(53 Nm/ 97 Nm) 4000 H = 2186 H should be entered at PROFIBUS



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CI: Supplementary torque setpoint Selects the source of the supplementary torque setpoint..

Frequent settings: 2889 Fixed setpoint 1 in % 2890 Fixed setpoint 2 in % 755.0 Analog input 1 755.1 Analog input 2 2015. 2 USS (BOP link) 2018. 2 USS (COM link) 2050. 2 CB (e.g. Profibus)

CO: Supplementary torque setpoint Indicates the supplementary torque setpoint.

Reference torque The reference torque P2003 corresponds to a normalized value of 100% or 4000H.

Torquesetpoint

"Droopinput"

Actual frequency

r1538 r1538

r1539 r1539

CI: Add. trq. setp

(0:0)P1511.C

Pre-control

Freq. setpoint

PIspeed

controller

SLVC:VC:

P1452P1442

P1470P1460

P1472P1462

Ti

Kp Tn

Ti Kp Tn

*)

*) only active, if the pre-control has been activated (P1496 > 0)

r0079r1508r0063

r1170

r1515

r1518

P2003=...

r1515=...

P1511=... 0:0

FC spec.

Appendix


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11 Appendix

11.1 Function charts

Appendix


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PID

trim

from

AFM

Freq

uenc

y ou

tput

tom

odul

ator

n/f(m

ax) +

cont

rol r

eser

ve

active

- 610

0 -

Func

tion

diag

ram

87

65

43

21

V/f

Con

trol

MIC

RO

MAS

TER

440

05.0

8.20

02

V2.

0O

verv

iew

of V

/f C

ontro

l

Imax

con

trolle

r set

poin

t

+

r134

3C

O:Im

ax c

trl F

outp

r134

4C

O:Im

ax c

trl V

outp

P120

0Fl

ying

sta

rt

++P

1240

Vdm

axco

ntro

ller

r117

0C

O:S

etp.

afte

r RFG

+P13

35Sl

ipco

mpe

nsat

ion

r006

3C

O: A

ct. f

requ

ency

P133

8R

eson

ance

dam

ping

r002

4C

O: A

ct o

utp.

freq

+

P135

0Vo

ltage

build

-up

Volta

ge o

utpu

t to

mod

ulat

or

RFG

Imax

freq

uenc

y ct

rl.P1

340

P134

1

Cur

rent

feed

back

r002

5C

O: A

ct.o

utp.

vol

t

active

+

P13

00V/

f cha

ract

eris

tic+

FCC +

Volta

ge b

oost

P131

0 ...

P13

12

19

Con

trol m

ode

0 ...

23

P130

0.D

(0)

r111

9C

O:S

etp

befo

re R

FG

r006

7C

O: O

utp

cur l

imit

[A]

r006

8C

O: O

utpu

t cur

rent

[A]

CI:

Volta

ge s

etp.

(0:0

)P1

330.

C

+

Mot

or o

vl fa

ct [%

]10

.0 ..

. 400

.0 [

%]

P064

0.D

(150

.0) R

ated

mot

. cur

rent

0.01

... 1

0000

.00

[A]

P030

5.D

(3.2

5)

Mot

or te

mpe

ratu

rIn

verte

r tem

pera

tur

i2 tin

verte

r

Imax

vol

tage

ctrl

.P1

345

P134

6

f(V

DC

)

FP 4600

CO

/BO

:Sta

t Mot

Ctrl

r005

6r0

056 .

13

Appendix


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From

Enc

oder

from

setp

oint

chan

nel

Asy

c.M

ot. 3

~

++

14

2

Max

. freq

uenc

y0.

00 ..

. 650

.00

[Hz]

P108

2.D

(50.

00)

Max

. freq

uenc

y0.

00 ..

. 650

.00

[Hz]

P108

2.D

(50.

00)

r117

0C

O:S

etp.

afte

r RFG

[Hz]

Sca

l acc

. pre

ctrl.

0.0

... 4

00.0

[%

]P1

496.

D (0

.0)

Iner

tia [k

g*m

^2]

0.00

010

... 1

000.

0P0

341.

D (0

.001

80)

Tot/m

ot in

ert.r

at.

1.00

0 ...

400

.000

P034

2.D

(1.0

00)

Gai

n of

n-c

trl.

0.0

... 2

000.

0P1

460.

D (3

.0)

Tn o

f n-c

trl.

25 ..

. 320

01 [

ms]

P146

2.D

(400

)

Filte

r tim

e n_

act.

0 ...

320

00 [

ms]

P144

2.D

(4)

r006

3C

O: A

ct. f

requ

ency

[Hz]

Not

eTh

e cu

rren

t inj

ectio

n of

P16

10 is

only

calc

ulat

ed w

hen

the

obse

rver

mod

el is

off.

CO

: Upp

er tr

q. lim

-999

99.0

... 9

9999

.0 [

Nm

]P1

520.

D (5

.13)

CO

: Low

er tr

q. lim

-999

99.0

... 9

9999

.0 [

Nm

]P1

521.

D (-

5.13

)

CI:

Upp

er tr

q. lim

(152

0:0)

P15

22.C

CI:

Low

er tr

q. lim

(152

1:0)

P15

23.C

Torq

uelim

itatio

n

x y

Effi

cien

cy op

timiz

0 ...

100

[%

]P1

580.

D (0

)

CO

: Fva

l flux

set

p50

.0 ..

. 200

.0 [

%]

P157

0.D

(100

.0)

Mot

or o

vl fa

ct [%

]10

.0 ..

. 400

.0 [

%]

P064

0.D

(150

.0)

Mot

orin

g po

wer

lim0.

0 ...

800

0.0

P153

0.D

(0.7

5)R

egen

er. p

ower

lim-8

000.

0 ...

0.0

P153

1.D

(-0.

75)

r003

0C

O: T

orqu

e ge

n.cu

r [A

]

Gai

n cu

rren

t ctrl

.0.

0 ...

5.0

P171

5.D

(0.2

5)

Int.t

ime

cur.

ctrl

1.0

... 5

0.0

[ms]

P171

7.D

(4.1

)

KpTn

r00

29C

O: F

lux

gen.

cur

. [A

]

Vol

tage

r006

5C

O: S

lip fr

eque

ncy

[%]

r006

6C

O: A

ct. o

utp

freq

[Hz]

Kp

n-ad

apt. (

SLV

C)

0.0

... 2

.5P1

764.

D (0

.2)

Tn n

-ada

pt. (

SLV

C)

1.0

... 2

00.0

[m

s]P1

767.

D (4

.0)

Obs

erve

rm

odel

Cur

rent

mod

el

6

Pul

se fre

quen

cy2

... 1

6 [k

Hz]

P180

0 (4

)

r006

8C

O: O

utpu

t cur

rent

[A]

5 3

r005

0 =

act.

com

man

d da

ta s

et(C

DS

)r0

051.

1 =

act.

driv

e da

ta s

et(D

DS

)

*)

*)

*)

*)

She

et75

00

Spee

d co

ntro

l

She

et77

00

Torq

ue/c

urre

nt li

mit

Flux

set

poin

tS

heet

7900

r007

1C

O: M

ax. o

utp.

volt [

V]

She

et78

00

r007

0C

O: A

ct. V

dc [V

]

r007

2C

O: A

ct. o

utp.

volt [

V]

Cur

rent

con

trol,

Obs

erve

r mod

el

**) s

etta

ble

via

P10

00*)

onl

y ac

cess

leve

l 4

- 701

0 -

Func

tion

diag

ram

87

65

43

21

Vec

tor C

ontro

lM

ICR

OM

ASTE

R 4

4015

.04.

2002

V

2.0

Ove

rvie

w o

f Spe

ed C

ontro

l with

Enc

oder

(VC

):P1

300

= 21

and

P15

01 =

0

Mod

ulat

or

Sca

l. lo

w tr

q. lim

-400

.0 ..

. 400

.0 [

%]

P152

5.D

(100

.0)

Appendix


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Forw

ard s

peed

Spee

d pre

cont

rol

Spee

d con

trolle

r out

put

from

torq

ue lim

itatio

n

from

torq

ue lim

itatio

n

**) c

hang

eabl

e in

run

via

DD

S

to ob

serv

er m

odel

to to

rque

limita

tion

to to

rque

limita

tion

from

spee

d mea

sure

men

t

from

ram

p gen

erat

or

- 751

0 -

Func

tion

diag

ram

87

65

43

21

Vect

or C

ontro

lM

ICR

OM

ASTE

R 4

4015

.04.

2002

V

2.0

Spee

d C

ontro

ller w

ith E

ncod

er (V

C):

r0

062

CO

: Fre

q. s

etpo

int [

Hz]

0 > 0

Filte

r tim

e n_

act.

0 ...

320

00 [

ms]

P144

2.D

(4)

Iner

tia [k

g*m

^2]

0.00

010

... 1

000.

0P0

341.

D (0

.001

80)

Tot/m

ot in

ert.r

at.

1.00

0 ...

400

.000

P034

2.D

(1.0

00)

Sca

l acc

. pre

ctrl.

0.0

... 4

00.0

[%

]P1

496.

D (0

.0)

r151

8C

O: A

ccel

. tor

que

[Nm

]

r143

8C

O: F

req.

set

p ct

l [Hz]

r006

4C

O: D

ev. f

req

ctrl

[Hz]

KpTn

Con

fig. o

f n-c

trl.

0 ...

3P1

400.

D (1

)

Gai

n of

n-c

trl.

0.0

... 2

000.

0P1

460.

D (3

.0)

Tn o

f n-c

trl.

25 ..

. 320

01 [

ms]

P146

2.D

(400

)

**)

**)

(0:0

)

BI: S

et in

tegr

ator

P147

7.C

CI:

Set i

nt. v

alue

(0:0

)P1

478.

C

r153

8

r153

9

r148

2C

O:In

t.out

p n-

ctrl

[Nm

]

r006

3C

O: A

ct. f

requ

ency

[Hz]

r144

5C

O: A

ct. f

ilt fr

eq [H

z]

Dro

op in

put s

ourc

e0

... 3

P148

8.D

(0)

Dro

op sc

alin

g0.

0 ...

0.5

0P1

489.

D (0

.05)

0 21 3

0

0

r149

0C

O: D

roop

freq

. [H

z]En

able

droo

p0

... 1

P149

2.D

(0)

*)

*) o

nly

acce

ss le

vel 4

P130

0 =

21 a

nd P

1501

= 0

1 0

aFP

7710

bFP

7710

r007

9

r150

8

FP77

10

FP77

10

Max

. fre

q set

poin

t [H

z]r1

084

r006

1C

O:A

ct ro

tor s

peed

[Hz]

FP79

00

References


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11.2 References

/1/ Micromaster 440 0.12 250 kW

Operating Instructions

Order No.: 6SE6400-5AW00-0AP0

/2/ Micromaster 440

Parameterliste

Order No.: 6SE6400-5BB00-0AP0

/3/ Micromaster

Micromaster 410/420/430/440 Drive Converters 0.12 250 kW

Catalog DA51.2

Order No.: E86060-K5151-A121-A4

/4/ Low-Voltage

Squirrel-Cage Induction Motors Frame sizes 56 - 450 0.06 450 kW

Catalog M11

Order No.: E86060-K1711-A101-A3

/5/ MICROMASTER 440 engineering braking chopper operation http://support.automation.siemens.com/WW/view/en/22101908

/6/ MICROMASTER 440 Measuring the magnetizing current http://support.automation.siemens.com/WW/view/en/22078991

/7/ MICROMASTER 440, FX and GX with a MASTERDRIVES braking unit http://support.automation.siemens.com/WW/view/en/22093967

mm4 hoisting gear

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