Siemens A1A0100275, LDZ10501382, A5E03407403, A1A260986.00, A1A10000423.00M, A1A0100521 by SiemensRobicon

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Operating Manual

Medium-Voltage Drive SINAMICS PERFECT HARMONY GH180 NXGpro Control for version 6.8 software release AJ Edition

06/2019

A5E33474566

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ÿSHIELD CABLEÿA5E39047590003ÿ6SR5 KTP700 CABLE ASSEMBLY 96''ÿ6SR5900-0QM00-0AD0ÿ NXGII DCRÿNXGII DCR with FOHB kitÿA5E33065979ÿNXGII DCR with FOHB kitÿ6SR0960-0CB01-0AM0ÿ ÿNXGII DCR without FOHB KitÿA5E03931016ÿNXGII DCR without FOHB Kitÿ6SR0960-0CB21-0AD0ÿA1A10000313.00 ÿNXGII DCR with FOHB kit U55ÿA5E33561398ÿNXGII DCR with FOHB kit U55ÿ6SR0960-0CB02-0AM0ÿ ÿNXGII DCR without FOHB Kit U55ÿA5E33561420ÿNXGII DCR without FOHB Kit U55ÿ6SR0960-0CB04-0AM0ÿ NXGIIÿCPU KitÿA1A10000623.00MÿPCA, SBC, HARMONY NXGIIÿ6SR0900-0CB00-0AM0ÿLDZ10000623.00C / A1A10000623.00 ÿCPU BoardÿA1A0100521ÿCPU boardÿ6SR0960-0CD03-0AD0ÿ ÿKeypad adapter boardÿA1A10000283.01MÿKeypad adapter boardÿ6SR0960-0SM23-0AD0ÿ ÿCFÿA1A260986.00ÿCompact flash card inside CPUÿ6SR0960-0CB11-0AD0ÿ ÿSystem I/O BoardÿA1A10000423.00MÿPCA, W/FIRMARE,NXG SYSTEM I/Oÿ6SR0960-0CB02-0AD0ÿLDZ10000423.00C ÿBGA ModulatorÿA1A10000350.00MÿPCA, W/FIRMWARE, MODULATOR,ÿ6SR0960-0CB03-0AD0ÿLDZ10000225.00C ÿBackplaneÿA1A098194ÿPCA, COATED, ISA BACKPLANE, 8 SLOTÿ6SR0960-0CB01-0AA0ÿ ÿCommunications BoardÿA5E03407403ÿPCA, COMM BOARDÿ6SR3960-0CD02-0AD0ÿLDZ363818.00C /A1A363818.00M/461F11. ÿFOHB KitÿA1A252241.55SÿFOHB Kitÿ6SR0900-0CD00-0AM0ÿLDZ252241.55SC ÿFLAT CABLEÿA1A260901.00ÿFLAT LINK CABLE BETWEEN MB AND FOHBÿ6SR0960-0QM07-0AD0ÿ ÿFiber Optic Link boardÿA1A461D85.00MÿPCA, FIBER OPTIC, 12 CHANNELÿ6SR3900-0LM00-1AD0ÿLDZ461D85.00C/A1A461D8 ÿSignal Control BoardÿA5E01708486ÿPCA, SIGNAL CONDITIONING BOARDÿ6SR0960-0CB14-0AD0ÿLDZ01708486C/LDZ100004 ÿKEYPADÿA5E39206479ÿDEV_CONTROL_SIMATIC HMI, KTP700 BASIC Dÿ6SR4900-0SM00-0AM0ÿ ÿCABLE ASSY FOR 37BINÿA1A10000163.00ÿCABLE ASSY,ANALOG I/O,37 PIN ON I/O BOARDÿ6SR0960-0QM08-0AD0ÿ ÿCABLE ASSY FOR 50BINÿA1A10000162.00ÿCABLE ASSY, DIGITAL I/O,50 PIN ON I/O BOARDÿ6SR0960-0QM00-0AD0ÿ ÿCABLE ASSY FOR 10BINÿA1A10000540.00ÿRIBBON CABLE ASSY, 10 PINÿ6SR3900-0QA00-0AM0ÿ ÿI/O Breakout Board 120 V I/OÿA5E01649325ÿPCA, I/O BREAKOUT BOARD,120VACÿ6SR0960-0CB07-1AD0ÿLDZ01649325C ÿI/O Breakout Board 24 V I/OÿA5E01649374ÿPCA COATED 24VDC INPUTS SYS I/O BRKOUTÿ6SR0960-0CB07-2AD0ÿLDZ01649 ÿNXGII Power SupplyÿA1A0100275ÿPOWER SUPPLYÿ6SR0960-0CD01-1AD0ÿ ÿNXGII Power SupplyÿA1A14000461.00ÿPOWER SUPPLY KITÿÿ ÿNXGII Power Supply U55ÿA5E31055176ÿPOWER_SPLYÿ6SR0960-0EM02-0AD0ÿ ÿDB37 PIN cableÿA1A096535ÿDB37 PIN cable BETWEEN SCB IO BREAKOUT AND DCRÿ6SR0960-0QM01-0AD0ÿLDZ10504750 ÿDB50 PIN cableÿA5E00993969ÿDB 50 PIN cable BETWEEN DCR AND IO BREAKOUTÿ6SR0960-0QA02-0AA0ÿ ÿDCR FANÿA5E30653347ÿAXIALFANÿ6SR0960-0GM02-0AD0ÿA5E02381532/LDZ092828 NXG DCRÿNXG DCRÿA1A461R57.00ÿNXG DCRÿÿLDZ461R57.00C NXGÿCPU KitÿA1A10000623.00MÿPCA, SBC, HARMONY NXGIIÿ6SR0900-0CB00-0AM0ÿLDZ10000623.00C / A1A10000623.00 ÿCPU BoardÿA1A0100521ÿCPU boardÿ6SR0960-0CD03-0AD0ÿ ÿKeypad adapter boardÿA1A10000283.01MÿKeypad adapter boardÿ6SR0960-0SM23-0AD0ÿ ÿCFÿA1A260986.00ÿCompact flash card inside CPUÿ6SR0960-0CB11-0AD0ÿ ÿSystem I/O BoardÿA1A10000423.00MÿPCA, W/FIRMARE,NXG SYSTEM I/Oÿ6SR0960-0CB02-0AD0ÿ ÿBGA ModulatorÿA1A10000350.00MÿPCA, W/FIRMWARE, MODULATOR,ÿ6SR0960-0CB03-0AD0ÿ ÿBackplaneÿA1A363628.00MÿPCA, COATED, ISA BACKPLANE, 14SLOTÿ6SR3960-0CD01-0AD0ÿLDZ363628.00C ÿCommunications BoardÿA5E03407403ÿPCA, COMM BOARDÿ6SR3960-0CD02-0AD0ÿLDZ363818.00C /A1A363818.00M ÿCABLE ASSY FOR 10BINÿA1A10000540.00ÿRIBBON CABLE ASSY, 10 PIN CABLE BETWEEN MB AND I/Oÿ6SR3900-0QA00-0A ÿNXG Power SupplyÿLDZ10501382ÿPower Supplyÿ6SR3900-0KA00-0AM0ÿ

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NXGpro Control Operating Manual

A5E33474566_EN

Security information

Introduction

Security Information

Safety notes

NXGpro Control Description

Hardware Interface Description

Parameter Assignment / Addressing

Operating the Control

Advanced Operating Functions

Software User Interface

Operating the Software

Troubleshooting Faults and Alarms

NEMA Table

Abbreviations

Historical Logger

Legal information Warning notice system

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger. DANGER indicates that death or severe personal injury will result if proper precautions are not taken. WARNING indicates that death or severe personal injury may result if proper precautions are not taken. CAUTION indicates that minor personal injury can result if proper precautions are not taken. NOTICE indicates that property damage can result if proper precautions are not taken. If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

Qualified Personnel

The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.

Proper use of Siemens products Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks

All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AG Global Services Information Technology 80200 MÜNCHEN GERMANY

A5E33474566_EN Ⓟ 02/2019 Subject to change

Table of contents 1

Security information......................................................................................................................................9

Introduction.................................................................................................................................................11 2.1

Power Topology .....................................................................................................................12

2.2

Control Overview....................................................................................................................13

2.3

Protocol for Cell Communication............................................................................................14

Security Information....................................................................................................................................15

Safety notes................................................................................................................................................17

4.1

General Safety Information ....................................................................................................17

4.2

Safety Concept.......................................................................................................................18

4.3

Observing the Five Safety Rules............................................................................................19

4.4

Safety Information and Warnings...........................................................................................20

4.5

ESD-sensitive Components ...................................................................................................22

4.6

Electromagnetic Fields in Electrical Power Engineering Installations ...................................24

4.7

Security Information ...............................................................................................................25

NXGpro Control Description .......................................................................................................................27 5.1 5.1.1 5.1.2 5.1.3 5.1.4

Control System.......................................................................................................................28 Digital Control Rack (DCR) ....................................................................................................29 System Interface Board (SIB) ................................................................................................30 User I/O..................................................................................................................................31 Control System Power Supply ...............................................................................................31

5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 5.2.8

Control Modes........................................................................................................................33 Open Loop Vector Control (OLVC) ........................................................................................36 Open Loop Test Mode (OLTM) ..............................................................................................36 Synchronous Motor Control (SMC) ........................................................................................37 Volts/Hertz Control (V/Hz)......................................................................................................39 Closed Loop Control (CLVC or CSMC)..................................................................................39 Permanent Magnet Motor Control (PMM) ..............................................................................39 PMM with Conveyor ...............................................................................................................44 Synchronous Motor with DC Brushless Exciter (SMDC)........................................................50

5.3

Watchdog Protections ............................................................................................................51

5.4 5.4.1 5.4.2 5.4.3

Control Loops.........................................................................................................................52 Current Loop ..........................................................................................................................52 Speed Loop............................................................................................................................52 Flux Loop ...............................................................................................................................53

Hardware Interface Description ..................................................................................................................55 6.1

Non-user Accessible Interfaces .............................................................................................56

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6.1.1 6.1.2 6.1.3 6.1.4 6.1.5

System Inputs and Outputs for Motor Control........................................................................56 Test Point Port .......................................................................................................................57 Control Power ........................................................................................................................58 Modulator and Fiber Optics....................................................................................................58 Bypass Control.......................................................................................................................59

6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.4.1 6.2.4.2 6.2.4.3 6.2.5 6.2.6 6.2.6.1 6.2.6.2 6.2.6.3 6.2.7

User Accessible Interfaces.....................................................................................................60 Human Machine Interface ......................................................................................................60 Inhibit Input (Control Relay 3, CR3) .......................................................................................60 Encoder Interface...................................................................................................................61 User Inputs and Outputs ........................................................................................................62 User I/O Board .......................................................................................................................62 Discrete External I/O via WAGO System ...............................................................................66 Interface for External I/O ........................................................................................................66 I/O Configuration ....................................................................................................................68 Dedicated I/O .........................................................................................................................69 Dedicated I/O for Type 4 Pre-charge .....................................................................................69 Dedicated I/O for Type 5 and Type 6 Pre-charge ..................................................................70 Dedicated I/O for Input Protection (IP) ...................................................................................71 Network Connections .............................................................................................................73

Parameter Assignment / Addressing ..........................................................................................................77 7.1

Menu Descriptions .................................................................................................................77

7.2

Safety Notes for Parameter Changes ....................................................................................80

7.3

Options for Motor Menu (1) ....................................................................................................82

7.4

Options for Drive Menu (2).....................................................................................................92

7.5

Options for Stability Menu (3)...............................................................................................122

7.6

Options for Auto Menu (4)....................................................................................................134

7.7 7.7.1 7.7.2

Options for Main Menu (5) ...................................................................................................146 Options for Main Menu (5) ...................................................................................................146 Security Access Levels and Codes......................................................................................149

7.8

Options for Log Control Menu (6).........................................................................................150

7.9

Options for Drive Protect Menu (7) ......................................................................................153

7.10

Options for Meter Menu (8) ..................................................................................................156

7.11

Options for Communications Menu (9) ................................................................................161

7.12

Options for Multiple Configuration Files ...............................................................................164

Operating the Control ...............................................................................................................................169 8.1

Signal Frame of Reference for Motor...................................................................................170

8.2 8.2.1 8.2.2 8.2.3 8.2.4

Cell Bypass ..........................................................................................................................173 Fast Bypass (U11) ...............................................................................................................173 Forced Bypass - Non-faulted Cells ......................................................................................175 Mechanical Cell Bypass .......................................................................................................176 Neutral Point Shift during Bypass ........................................................................................177

8.3

Energy Saver .......................................................................................................................184

8.4

Power Monitoring .................................................................................................................185

NXGpro Control Operating Manual, AJ, A5E33474566_EN

Table of contents

8.5

Motor Thermal Overload Protection .....................................................................................186

8.6

Thermal Over Temperature Rollback...................................................................................193

8.7 8.7.1 8.7.2 8.7.3 8.7.4 8.7.5

Input Side Monitoring and Protection ...................................................................................195 One Cycle Protection ...........................................................................................................196 Transformer Protection for Cell Single-Phasing...................................................................198 Protecting Transformer by Limiting Secondary Currents .....................................................199 Excessive Drive Losses Protection ......................................................................................201 System Arc Detection...........................................................................................................204

8.8 8.8.1 8.8.2 8.8.3 8.8.4 8.8.5 8.8.6 8.8.7 8.8.8

Drive Output Torque Limiting ...............................................................................................205 Input Under-Voltage Rollback ..............................................................................................205 Extended Undervoltage Ride-through..................................................................................206 Input Single-Phase Rollback ................................................................................................207 Transformer Thermal Rollback.............................................................................................208 Torque Limit Setting .............................................................................................................209 Field-Weakening Limit..........................................................................................................210 Cell Current Overload ..........................................................................................................210 Timers for Drive Operation in Cell or Transformer Over-temperarure .................................210

8.9 8.9.1 8.9.2 8.9.3 8.9.4 8.9.5 8.9.6 8.9.7 8.9.8

Command Generator ...........................................................................................................212 Analog Input Sources...........................................................................................................212 Proportional-Integral-Derivative (PID) Controller .................................................................213 Set Point Sources ................................................................................................................214 Speed Profile........................................................................................................................214 Critical Speed Avoidance .....................................................................................................215 Polarity Control.....................................................................................................................215 Speed Ramp ........................................................................................................................216 Speed Limits ........................................................................................................................216

8.10

Process Tolerant Protection Strategy ..................................................................................217

8.11 8.11.1 8.11.2

Drive Tuning.........................................................................................................................219 Auto-tuning...........................................................................................................................219 Spinning Load ......................................................................................................................221

8.12 8.12.1 8.12.2 8.12.3

Data Loggers........................................................................................................................223 Event Log .............................................................................................................................223 Alarm/Fault Log....................................................................................................................223 Historic Log ..........................................................................................................................224

8.13

Faults and Alarms ................................................................................................................225

Advanced Operating Functions ................................................................................................................227 9.1

Frequency (Speed) Regulator..............................................................................................228

9.2

Overmodulation....................................................................................................................229

9.3

Slip Compensation ...............................................................................................................230

9.4

Speed Droop ........................................................................................................................232

9.5

Flux Regulator......................................................................................................................233

9.6

Flux Feed-Forward...............................................................................................................234

9.7

External Flux Reference.......................................................................................................236

NXGpro Control Operating Manual, AJ, A5E33474566_EN

Table of contents

9.8

Dual-Frequency Braking ......................................................................................................237

9.9

Regenerative Braking (six-step)...........................................................................................242

9.10

Dynamic Braking with External Resistors ...........................................................................244

9.11

Voltage Attenuator Resistors ...............................................................................................245

9.12

Torque Current Regulator ....................................................................................................246

9.13

Magnetizing Current Regulator ............................................................................................247

9.14

Phase Lock Loop .................................................................................................................248

9.15

Output Filters........................................................................................................................249

9.16 9.16.1 9.16.2 9.16.3 9.16.4 9.16.5 9.16.6

Synchronous Transfer..........................................................................................................250 Synchronous Transfer Operation Generator Options and Potential Fault Conditions .........251 Input/Output Signals for Synchronous Transfer (L29)..........................................................252 Synchronous Transfer without Output Reactor ....................................................................253 Synchronous Transfer Operation for Synchronous Motors..................................................257 Synchronous Transfer for Permanent Magnet Motors (PMM) .............................................259 Parameter Settings for Synchronous Transfer Operation ....................................................260

9.17 9.17.1 9.17.2 9.17.3 9.17.4 9.17.5 9.17.6

Pre-charge using SOP .........................................................................................................261 Electric Shock Hazard..........................................................................................................261 Limiting Function (applicable to all precharge types) ...........................................................261 Preconditions for Pre-charge Types 1 to 3...........................................................................261 Type 1 (Closed) Pre-charge ................................................................................................263 Type 2 (Open) Pre-charge ...................................................................................................265 Type 3 Pre-charge (Parallel Drives).....................................................................................267

9.18 9.18.1 9.18.2 9.18.3 9.18.4 9.18.5 9.18.6 9.18.7

Pre-charge using Dedicated I/O...........................................................................................270 Electric Shock Hazard..........................................................................................................270 Limiting Function (applicable to all precharge types) ...........................................................270 Pre-charge using Dedicated I/O...........................................................................................271 Type 4 Pre-charge (resonant-open transfer-capacitors only) ..............................................271 Preconditions for Pre-charge Types 5 and 6........................................................................275 Type 5 (Open) Pre-charge ...................................................................................................277 Type 6 (Closed) Pre-charge.................................................................................................282

9.19 9.19.1 9.19.2

Paralleling Multiple Drives....................................................................................................289 Parallel Drive Control ...........................................................................................................289 Master-Slave Drive Control ..................................................................................................291

9.20 9.20.1

Torque Mode........................................................................................................................292 Extended Torque During Ride-Through for ESP Applications .............................................293

9.21 9.21.1 9.21.2

High Performance Control....................................................................................................295 Low Speed Operation ..........................................................................................................295 High Starting Torque Mode ..................................................................................................295

9.22 9.22.1 9.22.2 9.22.3

Conveyor Application ...........................................................................................................297 Network Fast Access for Conveyor Applications .................................................................297 PLC Directed High Starting Torque Mode for Conveyor Applications..................................298 PLC-based Active Dampening for Conveyor Applications ...................................................303

9.23 9.23.1

Long Cable Applications ......................................................................................................306 Cable Inductance Compensation .........................................................................................306

NXGpro Control Operating Manual, AJ, A5E33474566_EN

Table of contents

9.23.2 9.23.3

Damping of Resonance due to Output Cable ......................................................................307 Operating Parallel Motors over Long Cables .......................................................................307

9.24

Drive with Output Transformers ...........................................................................................309

9.25

Motor Equivalent Circuit Parameters ...................................................................................311

Software User Interface............................................................................................................................313 10.1 10.1.1 10.1.2 10.1.3 10.1.4 10.1.5 10.1.6 10.1.7 10.1.8 10.1.9 10.1.10 10.1.11 10.1.12 10.1.13

SIMATIC Keypad .................................................................................................................314 SIMATIC Keypad User Interface .........................................................................................314 Fault Reset Key and Fault LED Indicator.............................................................................315 Automatic Key ......................................................................................................................318 Stop Key...............................................................................................................................318 Start Key ..............................................................................................................................319 Numeric Keys.......................................................................................................................319 Enter/Cancel Key .................................................................................................................321 Shift Function Keys ..............................................................................................................322 Arrow Keys...........................................................................................................................323 Diagnostic Indicators............................................................................................................327 Display .................................................................................................................................327 Summary of Common Shift Key and Arrow Key Sequences ...............................................334 Adjusting the SIMATIC KTP700 HMI Display Brightness ....................................................336

10.2 10.2.1 10.2.2 10.2.3 10.2.4 10.2.5 10.2.6 10.2.7 10.2.8 10.2.9 10.2.10 10.2.11

Multi-Language Keypad .......................................................................................................340 Fault Reset Key and LED Indicator......................................................................................341 Automatic Key ......................................................................................................................344 Manual Stop Key..................................................................................................................344 Manual Start Key..................................................................................................................345 Numeric Keys.......................................................................................................................345 Enter/Cancel Key .................................................................................................................348 Shift Function Keys ..............................................................................................................348 Arrow Keys...........................................................................................................................349 Diagnostic Indicators............................................................................................................353 Display .................................................................................................................................353 Summary of Common Shift Key and Arrow Key Sequences ...............................................360

10.3

NXGpro ToolSuite ................................................................................................................362

10.4 10.4.1 10.4.2

Communication Interface .....................................................................................................363 Available Networks...............................................................................................................363 Multiple Networks.................................................................................................................363

10.5 10.5.1 10.5.2 10.5.3 10.5.4 10.5.5 10.5.6 10.5.7 10.5.8 10.5.9

Security Measures ...............................................................................................................364 Overview ..............................................................................................................................364 Industrial Security.................................................................................................................364 Benefits ................................................................................................................................365 Parameter Security Levels ...................................................................................................365 Write Protection....................................................................................................................365 Network Protection...............................................................................................................365 Field Bus Protection .............................................................................................................366 USB Connection...................................................................................................................366 Virus Protection / Memory Card ...........................................................................................367

Operating the Software.............................................................................................................................369 11.1

SOP Development and Operation........................................................................................370

NXGpro Control Operating Manual, AJ, A5E33474566_EN

Table of contents

11.2

SOP Logic Functions ...........................................................................................................371

11.3

SOP Evaluation....................................................................................................................372

11.4

Input Flags ...........................................................................................................................373

11.5

Output Flags.........................................................................................................................374

11.6

Downloading the SOP..........................................................................................................375

11.7

Uploading the SOP ..............................................................................................................376

11.8

Multiple Configuration Files..................................................................................................377

11.9

Selecting the active SOP .....................................................................................................378

Troubleshooting Faults and Alarms .........................................................................................................379 12.1

Faults and Alarms ................................................................................................................380

12.2

Drive Faults and Alarms.......................................................................................................382

12.3 12.3.1 12.3.2 12.3.3 12.3.4 12.3.5

Cell Faults and Alarms .........................................................................................................415 Troubleshooting General Power Cell and Power Cell Circuitry Faults.................................425 Troubleshooting Cell Over Temperature Faults ...................................................................427 Troubleshooting Overvoltage Faults ....................................................................................427 Troubleshooting Cell Communications and Link Faults .......................................................428 Status Indicator Summaries for MV Mechanical Bypass Boards .........................................428

12.4

User Faults and Alarms........................................................................................................429

12.5 12.5.1

Unexpected Output Conditions ............................................................................................430 Speed Rollback ....................................................................................................................430

12.6

Drive Input Protection...........................................................................................................433

12.7

Flash Disk Corruption...........................................................................................................436

12.8

Loss of Communication to Keypad ......................................................................................437

NEMA Table .............................................................................................................................................439

Abbreviations............................................................................................................................................443

Historical Logger.......................................................................................................................................449 C.1

Historic Log ..........................................................................................................................449

C.2

Historical Logger ..................................................................................................................450

Glossary ...................................................................................................................................................455 Index.........................................................................................................................................................465

NXGpro Control Operating Manual, AJ, A5E33474566_EN

Security information

Siemens provides products and solutions with industrial security functions that support the secure operation of plants, systems, machines and networks. In order to protect plants, systems, machines and networks against cyber threats, it is necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial security concept. Siemens’ products and solutions constitute one element of such a concept. Customers are responsible for preventing unauthorized access to their plants, systems, machines and networks. Such systems, machines and components should only be connected to an enterprise network or the internet if and to the extent such a connection is necessary and only when appropriate security measures (e.g. firewalls and/or network segmentation) are in place. For additional information on industrial security measures that may be implemented, please visit https://www.siemens.com/industrialsecurity. Siemens’ products and solutions undergo continuous development to make them more secure. Siemens strongly recommends that product updates are applied as soon as they are available and that the latest product versions are used. Use of product versions that are no longer supported, and failure to apply the latest updates may increase customer’s exposure to cyber threats. To stay informed about product updates, subscribe to the Siemens Industrial Security RSS Feed under https://www.siemens.com/industrialsecurity.

NXGpro Control Operating Manual, AJ, A5E33474566_EN

Security information

NXGpro Control Operating Manual, AJ, A5E33474566_EN

Introduction

SINAMICS Perfect Harmony™ GH180 medium voltage drives maintain a common control system, the NXGpro control. This manual describes the NXGpro control system and the related hardware and user interfaces. This manual covers the parameter assignment necessary for operation and provides descriptions of specific functions and advanced features that may be required when operating the NXGpro control system. The NXGpro Control Operating Manual is intended for use with SINAMICS Perfect Harmony™ GH180 medium voltage drives. This manual is intended for use by persons with a working knowledge of the NXGpro control system. Specific configurations of the drive family are described in more detail in the specific Operating Instructions Manual pertaining to that hardware configuration. In addition, for information relating to maintenance and troubleshooting of the NXGpro control system, refer to the drive-specific Operating Instructions Manual.

NXGpro Software Version This manual applies to NXGpro software Version 6.1 and later.

NXGpro Control Operating Manual, AJ, A5E33474566_EN

Introduction 2.1 Power Topology

2.1

Power Topology SINAMICS Perfect Harmony™ drives contain individually controlled, interconnected power cells. Each cell consists of a three-phase input and a single phase output, which are configured in three individual, concatenated strings of cells making up three output phases. Control and diagnostic data is transmitted between the control and the cells on independent fiber optic channels.

NXGpro Control Operating Manual, AJ, A5E33474566_EN

Introduction 2.2 Control Overview

2.2

Control Overview SINAMICS Perfect Harmony™ GH180 drives maintain a simple "synchronous" control. It coordinates the complex, cell-based power topology to produce a simple, multi-level pulse width modulation (PWM) to the output connection of the drive. Basic operation is summarized as follows: 1. The control sends a message to each power cell control via dedicated fiber links. The return cell response, via a separate fiber, communicates cell status and diagnostics. 2. The cell executes the request by gating one switch pair, which results in one of the following outcomes: – Plus DC voltage – Minus DC voltage – Zero voltage 3. The cell control confirms that the switch pair gated. 4. The control confirms gating from: – Output voltage divider – Output Hall effect current transducer ● No two cells switch at the same time. ● The cell switching rate is low compared to the effective switching frequency of the VFD: – Typically 600 Hz carrier frequency per pole results in 1200 Hz switching frequency per cell. ● The VFD effective switching frequency is calculated simply as: – cell switching frequency * number of cells per phase ● The switching rate is constant over the entire output frequency range. ● The default control mode is open loop vector control (OLVC). Control modes Volts/Hertz (V/ Hz), closed loop vector control (CLVC) with encoder, and permanent magnet motor (PMM) control without encoder are also available.

NXGpro Control Operating Manual, AJ, A5E33474566_EN

Introduction 2.3 Protocol for Cell Communication

2.3

Protocol for Cell Communication SINAMICS Perfect Harmony™ GH180 power cells incorporate a dedicated, simple protocol to communicate with the cells. While the drive is running, information sent to each cell consists of: ● run enable ● gating information ● a synchronizing bit for the temperature feedback engine. Information sent from the cells consists of: ● the cell temperature ● the fault status ● a low cell voltage level warning. Fault information follows a "wire-OR'd" design in that all cells can be shut down within microseconds of a fault detection on any single cell. After a fault is detected, diagnostic routines run to identify the exact fault and cell location.

Advanced Protocol (AP) For certain GH180 power cells, an advanced protocol (AP) is available which provides additional information to and from the power cells. AP maintains backward compatibility with older cell types. AP requires specific cell control boards (CCBs) capable of communication using AP to be installed into a power cell. Not all power cells are capable of utilizing AP type CCBs. The control detects the presence of AP capable CCBs on an individual cell basis, and can dynamically fall back to original protocol for an older cell type. Although this capability is available in the control, it may not be feasible within the power electronics to mix cell types, unless running at the least common denominator of cell capability. AP provides additional feedback from cells equipped with this protocol capability for the control while the drive is running. AP maintains the fast legacy signals needed for control and fault handling.

NXGpro Control Operating Manual, AJ, A5E33474566_EN

Security Information

Security Information Siemens provides products and solutions with industrial security functions that support the secure operation of plants, systems, machines and networks. In order to protect plants, systems, machines and networks against cyber threats, it is necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial security concept. Siemens’ products and solutions only form one element of such a concept. Customer is responsible to prevent unauthorized access to its plants, systems, machines and networks. Systems, machines and components should only be connected to the enterprise network or the internet if and to the extent necessary and with appropriate security measures (e.g. use of firewalls and network segmentation) in place. Additionally, Siemens’ guidance on appropriate security measures should be taken into account. For more information about industrial security, please visit http://www.siemens.com/ industrialsecurity. Siemens’ products and solutions undergo continuous development to make them more secure. Siemens strongly recommends to apply product updates as soon as available and to always use the latest product versions. Use of product versions that are no longer supported, and failure to apply latest updates may increase customer’s exposure to cyber threats. To stay informed about product updates, subscribe to the Siemens Industrial Security RSS Feed under http://www.siemens.com/industrialsecurity.

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Security Information

NXGpro Control Operating Manual, AJ, A5E33474566_EN

Safety notes 4.1

General Safety Information

Proper Use SINAMICS Perfect Harmony™ GH180 medium voltage drives must always be installed in closed electrical operating areas. The drive is connected to the industrial network via a circuitbreaker. The specific transport conditions must be observed when the equipment is transported. The equipment shall be assembled/installed and the separate cabinet units connected properly by cable and/or busbar in accordance with the assembly/installation instructions. The relevant instructions regarding correct storage, EMC-compliant installation, cabling, shielding and grounding and an adequate auxiliary power supply must be strictly observed. Fault-free operation is also dependent on careful operation and maintenance. The power sections are designed for variable-speed drives use with synchronous and asynchronous motors. Operating modes, overload conditions, load cycles, and ambient conditions different to those described in this document are allowed only by special arrangement with the manufacturer. Commissioning should only be carried out by trained service personnel in accordance with the commissioning instructions. System components such as circuit-breaker, transformer, cables, cooling unit, motor, speed sensors, etc., must be matched to VFD operation. System configuration may only be carried out by an experienced system integrator.

NXGpro Control Operating Manual, AJ, A5E33474566_EN

Safety notes 4.2 Safety Concept

4.2

Safety Concept The medium-voltage variable frequency drive (VFD) and its components are subject to a comprehensive safety concept which, when properly implemented, ensures safe installation, operation, servicing, and maintenance. The safety concept encompasses safety components and functions to protect the device and operators. The VFD is also equipped with monitoring functions to protect external components. The VFD operates safely when the interlock and protection systems are functioning properly. Nevertheless, there are areas on the medium-voltage drive that are hazardous for personnel and that can cause material damage if the safety instructions described in this section and throughout the product documentation are not strictly observed.

NXGpro Control Operating Manual, AJ, A5E33474566_EN

Safety notes 4.3 Observing the Five Safety Rules

4.3

Observing the Five Safety Rules There are five safety rules that must always be observed to assure not only personal safety, but to prevent material damage as well. Always obey safety-related labels located on the product itself and always read and understand each safety precaution prior to operating or working on the drive. The five safety rules: 1. Disconnect the system. 2. Protect against reconnection. 3. Make sure that the equipment is de-energized. 4. Apply grounding means. 5. Cover or enclose adjacent components that are still live. DANGER Danger Due to High Voltages High voltages cause death or serious injury if the safety instructions are not observed or if the equipment is handled incorrectly. Potentially fatal voltages occur when this equipment is in operation which can remain present even after the VFD is switched off. Ensure that only qualified and trained personnel carry out work on the equipment. Follow the five safety rules during each stage of the work.

NXGpro Control Operating Manual, AJ, A5E33474566_EN

Safety notes 4.4 Safety Information and Warnings

4.4

Safety Information and Warnings DANGER Hazardous Voltage! ● Always follow the proper lock-out/tag-out procedures before beginning any maintenance or troubleshooting work on the VFD. ● Always follow standard safety precautions and local codes during installation of external wiring. The installation must follow wiring practices and insulation systems as specified in IEC 61800-5-1. ● Hazardous voltages may still exist within the VFD cabinets even when the disconnect switch is open (off) and the supply power is shut off. ● Only qualified individuals should install, operate, troubleshoot, and maintain this VFD. A qualified individual is "a person, who is familiar with the construction and operation of the equipment and the hazards involved." ● Always work with one hand, wear electrical safety gloves, wear insulated electrical hazard rated safety shoes, and safety goggles. Also, always work with another person present. ● Always use extreme caution when handling or measuring components that are inside the enclosure. Be careful to prevent meter leads from shorting together or from touching other terminals. ● Use only instrumentation (e.g., meters, oscilloscopes, etc.) intended for high voltage measurements (that is, isolation is provided inside the instrument, not provided by isolating the chassis ground of the instrument). ● Never assume that switching off the input disconnector will remove all voltage from internal components. Voltage is still present on the terminals of the input disconnector. Also, there may be voltages present that are applied from other external sources. ● Never touch anything within the VFD cabinets until verifying that it is neither thermally hot nor electrically alive. ● Never remove safety shields (marked with a HIGH VOLTAGE sign) or attempt to measure points beneath the shields. ● Never operate the VFD with cabinet doors open. The only exception is the control cabinet. ● Never connect any grounded (i.e., non-isolated) meters or oscilloscopes to the system. ● Never connect or disconnect any meters, wiring, or printed circuit boards while the VFD is energized. ● Never defeat the instrument’s grounding. ● When a system is configured with VFD bypass switchgear (e.g. contactors between line and motor, and VFD and motor), these switches should be interlocked so that the line voltage is never applied to the VFD output if the medium voltage input is removed from the VFD. ● When a system is configured with VFD pre-charge, medium voltage is present on the primary side of the input transformer and upstream device even though the MV contactor is not closed.

NXGpro Control Operating Manual, AJ, A5E33474566_EN

Safety notes 4.4 Safety Information and Warnings WARNING Potential Arc Hazard ● Arcing can result in damage to property, serious injury and even death. ● The equipment has not been tested and rated for arc flash protection. ● Avoiding arc hazard risks is dependent upon proper installation and maintenance. ● Incorrectly applied equipment, incorrectly selected, connected or unconnected cables, or the presence of foreign materials can cause arcing in the equipment. ● Follow all applicable precautionary rules and guidelines as used in working with medium voltage equipment. ● The equipment may be used only: – for the applications defined as suitable in the technical description. – in combination with equipment and components supplied by other manufacturers which have been approved and recommended by Siemens. ● Always follow the facility / installation site rules / guidelines for Personal Protectiive Equipment (PPE) based on the Arc Flash study of that facility. Additional safety precautions and warnings appear throughout this manual. These important messages should be followed to reduce the risk of personal injury or equipment damage. WARNING Obey Rules to Avoid Risk of Death ● Always comply with local codes and requirements if disposal of failed components is necessary. ● Always ensure the use of an even and flat truck bed to transport the VFD system. Before unloading, be sure that the concrete pad is level for storage and permanent positioning. ● Always confirm proper tonnage ratings of cranes, cables, and hooks when lifting the VFD system. Dropping the cabinet or lowering it too quickly could damage the unit. ● Never disconnect control power while medium voltage is energized. This could cause severe system overheating and/or damage. ● Never store flammable material in, on, or near the drive enclosure. This includes equipment drawings and manuals. ● Never use fork trucks to lift cabinets that are not equipped with lifting tubes. Be sure that the fork truck tines fit the lifting tubes properly and are the appropriate length.

NXGpro Control Operating Manual, AJ, A5E33474566_EN

Safety notes 4.5 ESD-sensitive Components

4.5

ESD-sensitive Components

Guidelines for Handling Electrostatic Sensitive Devices (ESD) NOTICE ESD Sensitive Equipment ● Always be aware of electrostatic discharge (ESD) when working near or touching components inside the VFD cabinet. The printed circuit boards contain components that are sensitive to electrostatic discharge. Handling and servicing of components that are sensitive to ESD should be done only by qualified personnel and only after reading and understanding proper ESD techniques. The following ESD guidelines should be observed. Following these rules can greatly reduce the possibility of ESD damage to printed circuit board (PCB) components. ● Always transport static sensitive equipment in antistatic bags. ● Always use a soldering iron that has a grounded tip. Also, use either a metallic vacuumstyle plunger or copper braid when desoldering. ● Ensure that anyone handling the printed circuit boards is wearing a properly grounded static strap. The wrist strap should be connected to ground through a 1 Megohm resistor. Grounding kits are available commercially through most electronic wholesalers. ● Static charge build-up can be removed from a conductive object by touching the object with a properly grounded piece of metal. ● When handling a PC board, always hold the card by its edges. ● Do not slide printed circuit boards (PCBs) across any surface (e.g., a table or work bench). If possible, perform PCB maintenance at a workstation that has a conductive covering that is grounded through a 1 Megohm resistor. If a conductive tabletop cover is unavailable, a clean steel or aluminum tabletop is an excellent substitute. ● Avoid plastic Styrofoam™, vinyl and other non-conductive materials. They are excellent static generators and do not give up their charge easily. ● When returning components to Siemens Industry, Inc. always use static-safe packing. This limits any further component damage due to ESD. Components that can be destroyed by electrostatic discharge (ESD) NOTICE Electrostatic discharge Electronic components can be destroyed in the event of improper handling, transporting, storage, and shipping. Pack the electronic components in appropriate ESD packaging; e.g. ESD foam, ESD packaging bags and ESD transport containers. To protect your equipment against damage, follow the instructions given below.

NXGpro Control Operating Manual, AJ, A5E33474566_EN

Safety notes 4.5 ESD-sensitive Components ● Avoid physical contact with electronic components. If you need to perform absolutely essential work on these components, then you must wear one of the following protective gear: – Grounded ESD wrist strap – ESD shoes or ESD shoe grounding strips if there is also an ESD floor. ● Do not place electronic components close to data terminals, monitors or televisions. Maintain a minimum clearance to the screen (> 10 cm). ● Electronic components should not be brought into contact with electrically insulating materials such as plastic foil, plastic parts, insulating table supports or clothing made of synthetic fibers. ● Place components in contact with ESD-suited materials e.g. ESD tables, ESD surfaces, ESD packaging. ● Measure on the components only if one of the following conditions is met: – The measuring device is grounded with a protective conductor. – The measuring head of a floating measuring device has been discharged directly before the measurement. The necessary ESD protective measures for the entire working range for electrostatically sensitive devices are illustrated once again in the following drawings. Precise instructions for ESD protective measures are specified in the standard DIN EN 61340-5-1.

H I F

I F

Sitting

Standing

Standing/sitting

Conductive floor surface, only effective in conjunction with ESD shoes or ESD shoe grounding strips

ESD furniture

ESD shoes or ESD shoe grounding strips are only effective in conjunction with conductive floor‐ ing

ESD clothing

ESD wristband

f Cabinet ground connection Figure 4-1 ESD Protective Measures

NXGpro Control Operating Manual, AJ, A5E33474566_EN

Safety notes 4.6 Electromagnetic Fields in Electrical Power Engineering Installations

4.6

Electromagnetic Fields in Electrical Power Engineering Installations WARNING Electromagnetic fields "electro smog" when operating electrical power engineering installations Electromagnetic fields are generated during operation of electrical power engineering installations. Electromagnetic fields can interfere with electronic devices, which could cause them to malfunction. For example, the operation of heart pacemakers can be impaired, potentially leading to damage to a person's health or even death. It is therefore forbidden for persons with heart pacemakers to enter these areas. The plant operator is responsible for taking appropriate measures (labels and hazard warnings) to adequately protect operating personnel and others against any possible risk. ● Observe the relevant nationally applicable health and safety regulations. For example, in Germany, "electromagnetic fields" are subject to regulations BGV B11 and BGR B11 stipulated by the German statutory industrial accident insurance institution. ● Display adequate hazard warning notices on the installation. ● Place barriers around hazardous areas. ● Take measures, e.g. using shields, to reduce electromagnetic fields at their source. ● Ensure personnel are wearing the appropriate protective gear.

NXGpro Control Operating Manual, AJ, A5E33474566_EN

Safety notes 4.7 Security Information

4.7

Security Information Siemens provides products and solutions with industrial security functions that support the secure operation of plants, solutions, machines, equipment and/or networks. They are important components in a holistic industrial security concept. With this in mind, Siemens’ products and solutions undergo continuous development. Siemens recommends strongly that you regularly check for product updates. For the secure operation of Siemens products and solutions, it is necessary to take suitable preventive action and integrate each component into a holistic, state-of-the-art industrial security concept. Third-party products that may be in use should also be considered. For more information about industrial security, visit http://www.siemens.com/industrialsecurity. To stay informed about product updates as they occur, sign up for a product-specific newsletter. For more information, visit http://support.automation.siemens.com.

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Safety notes 4.7 Security Information

NXGpro Control Operating Manual, AJ, A5E33474566_EN

NXGpro Control Description

The NXGpro control monitors input power conditions and status, coordinates all power components, controls output power to the motor, and performs special functions such as integration into a process and transferring motors synchronously to and from power lines. At the same time, the control protects the drive, the connected system process and the motor. With specially equipped cells, the control also allows the cells to cleanly regenerate power back into the input power feed.

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Operational Structure of NXGpro Control

Note The terms velocity and speed are used interchangeably throughout this manual.

NXGpro Control Operating Manual, AJ, A5E33474566_EN

NXGpro Control Description 5.1 Control System

5.1

Control System The NXGpro control system consists of four main functional sections: 1. Digital control rack (DCR) 2. System interface 3. Fiber optic connected user I/O 4. Power supply. 2SWLRQDO :$*2 H[SDQVLRQ DYDLODEOH &DQ EH UHPRWHO\ ORFDWHG )LEHU RSWLF XVHU , 2 ERDUG )LEHU RSWLF XVHU , 2 ERDUG )LEHU RSWLF XVHU , 2 ERDUG )LEHU RSWLF XVHU , 2 ERDUG

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The following sections describe each of the functional sections.

NXGpro Control Operating Manual, AJ, A5E33474566_EN

NXGpro Control Description 5.1 Control System

5.1.1

Digital Control Rack (DCR) The NXGpro DCR consists of a three part combined system: 1. Main control board 2. Fiber optic board 3. Single board computer utilizing the ETX form factor attached to the main control board.

Cover with expansion knock-outs

Fiber optic expansion

Main control board

Fiber optic board

Network 1 (optional)

Network 2 (optional)

Bypass, FO user I/O, critical I/O and additional fiber optic communication

System interface

USB (2) ports

Compact flash drive

Modem/debug

Keypad

External user I/O (serial)

VGA

NXGpro Control Operating Manual, AJ, A5E33474566_EN

NXGpro Control Description 5.1 Control System Figure 5-3

NXGpro Digital Control Rack (DCR)

Main Control Board There are three main functions that are contained on the main control board: ●

Digital: The digital sub-system section of the main control board, has a two part function: – provide various data communication interfaces for the control. – process the digitized motor feedback data from the analog section into pole firing commands for the power cells.

● Analog: The analog sub-system section of the main control board has a three part function: – receive analog motor feedback inputs. – perform analog signal conditioning on the feedback input signals. – convert the conditioned feedback signals into digital data. ● Power supply: The power supply section for the main control board is divided into three parts: – DC power input with redundancy – DC to DC conversion with regulated outputs – Power supply failure detection.

Fiber Optic Main Board/Fiber Optic Expansion Boards Each fiber optic main board has a three part function: ● Connection point and signal driver for all of the fiber optic connections for the control system. ● Connection point for the Anybus network communication modules. ● Mechanical function utilizing different physical board dimensions which allow for the appropriate fiber optic bend radius to be applied during the mechanical assembly of the control cabinet. The fiber optic expansion boards are a single rank (A,B,C phase) add on board to the fiber optic main board and are used to expand the DCR from 12 power cell operation up to 24 power cell operation. The power for the fiber optic expansion boards is sourced from the fiber optic main board.

5.1.2

System Interface Board (SIB) The system interface board (SIB) has a two part function: 1. interface between the drive system feedback and the DCR. 2. platform for a dedicated circuit for the drive input breaker control (M1 permissive).

NXGpro Control Operating Manual, AJ, A5E33474566_EN

NXGpro Control Description 5.1 Control System

5.1.3

User I/O The fiber optic user I/O board (user I/O is also referred to as internal I/O for backwards compatibility with NXG systems) is designed to be the external customer interface connection into the drive control system. Each user I/O has: ● 16 digital inputs ● 20 digital outputs ● 3 analog inputs ● 2 analog outputs The user I/O are all contained within one board. Up to four user I/O can be connected together to increase the number of I/O that are available for use. A single fiber optic user I/O board requires a power supply capable of +24 VDC (+/-5%), 1 A at 50 C at a minimum. The external WAGO I/O system may be included in certain applications but is not included in all systems. Refer to Section Discrete External I/O via WAGO System for further information.

See also Discrete External I/O via WAGO System (Page 66)

5.1.4

Control System Power Supply The control uses an external AC/DC power supply. The external power supply design accepts AC voltage input and produces a three part DC voltage output: 1.

+12 VDC digital

2. +/-15 VDC analog 3. +/- Hall Effect (+/-15 VDC or +/-24 VDC option) A single fiber optic user I/O board requires a power supply capable of +24 VDC (+/-5%), 1 A at 50 C at a minimum.

NXGpro Control Operating Manual, AJ, A5E33474566_EN

NXGpro Control Description 5.1 Control System

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NXGpro Control Operating Manual, AJ, A5E33474566_EN

NXGpro Control Description 5.2 Control Modes

5.2

Control Modes

Vector Control SINAMICS PERFECT HARMONY GH180 drives use vector control to control induction motors and synchronous motors. Vector control provides a framework that is simple to implement, and performs nearly as well as a DC motor. Figure Vector Control Algorithms shows a simplified representation of the vector control algorithms implemented in the drives. The basic components of vector control are: 1. Motor model: determines motor flux, angle and speed. 2. Current regulators: these regulators are referred to as the inner loops. 3. Flux and speed regulators: these regulators are referred to as the outer loops. 4. Feed-forward (FF) compensation: improves the transient response of torque loop and flux loop.

Components of Vector Control Motor Model The motor model uses measured motor voltage and estimated stator resistance voltage drop to determine stator flux amplitude, motor speed and flux angle. This allows stator resistance compensation to be automatic. A simplification of motor equations is obtained by transforming the three-phase AC quantities, which are referred to being in a stationary reference frame, to DC quantities that are in a synchronously rotating or DQ reference frame. A phase-locked loop (PLL) within the motor model tracks the stator frequency and angle of the flux vector. Flux and Speed Regulators Motor flux amplitude is controlled by the flux regulator; its output forms the command for the magnetizing or flux-producing component. Motor speed is determined from stator frequency, and is controlled by the speed regulator. Its output is the command for the torque-producing current regulator. Motor speed is compensated for slip in induction machines. Current Regulators The flux angle is used to decompose the measured motor currents into magnetizing and torque producing components. It is this decomposition that allows independent control of flux and torque, similar to DC motor control. These current components are regulated to their commanded values by the current regulators. Outputs of the current regulators are combined and converted to produce three-phase voltage commands that get modified with signals from various other control routines, before being passed on to the modulator. These control routines include: ● Dead-time compensation to compensate for dead-time in the switching of the upper and lower IGBTS of each pole in a power cell. ● Peak reduction for third-harmonic injection to maximize drive output voltage, and for drive neutral-shift during transparent cell-bypass. ● Voltage commands to produce losses for dual-frequency braking.

NXGpro Control Operating Manual, AJ, A5E33474566_EN

NXGpro Control Description 5.2 Control Modes Feed-forward Compensation Transient response of the flux and torque regulators is improved with the use of feed-forward (FF) compensation as shown in Figure Vector Control Algorithms. )OX['6

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Numbers within square brackets show the parameter ID for the corresponding function. Figure 5-5 Vector Control Algorithms Table 5-1

Symbols used in Figure Vector Control Algorithms

Symbol

Description

FluxDS

D-component of motor flux as referenced to the stator; also equal to the motor flux, since Qcomponent is zero. Motor Flux is defined as: Motor_Voltage / Stator_Frequency (rad/s). Flux (which has units of Volt-seconds) is also proportional (but not equal) to Volts-per-Hertz ratio.

For an induction motor: Motor_Speed = Stator_Frequency / Pole_Pairs – Slip_Speed This is the rotor (mechanical) frequency, which is equivalent to the motor speed. For a synchronous motor: Motor _Speed = Stator_Frequency / Pole_Pairs

Ids

Magnetizing component of motor current.

Iqs

Torque producing component of motor current.

NXGpro Control Operating Manual, AJ, A5E33474566_EN

NXGpro Control Description 5.2 Control Modes Symbol

Description

Vds,ref

Output of magnetizing current regulator used in the inverse D-Q transformation to produce 3-phase voltages.

Vqs,ref

Output of torque current regulator used in the inverse D-Q transformation to produce 3phase voltages.

ωs

Stator frequency or output frequency of the drive. This is motorspeed (r) + Slip.

θs

Flux angle. This is the instantaneous position of the rotating flux vector.

Ia, Ib, Ic

Motor phase currents.

Motor torque in newton-meters and shaft power can be calculated as: Torque (Nm)

= 3 * Pole_Pairs * Flux (V-secs) * Iqs (A) ≈ 3 * Pole_Pairs * Motor_Voltage (V) * Iqs (A) / (2 π * Frequency (Hz)) Shaft Power (W) = Torque (Nm) * Speed (rad/s) = Torque (Nm) * Speed (rpm) / 9.55 Rated Speed = 120 * rated frequency / number of pole pairs

Vector Control Modes The control provides several control modes. The modes are described in the sections that follow.

Summary of the Control Modes Control Mode

Vector Control

Type of Motor

Encoder

Features

Open loop vector con‐ trol mode (OLVC)

Vector control

Induction

Without encoder

● Fast bypass option

Open loop test mode (OLTM)

N/a

Not for motor control

N/a

Fast bypass and spin‐ ning load are disabled.

Synchronous motor control mode (SMC)

Vector control

Synchronous

Without encoder

● Fast bypass option

Volts / Hertz control mode (V/Hz)

No vector control

● Spinning load option

● Spinning load option Induction - usually mu‐ Without encoder liple connected in par‐ allel

● No fast bypass

Closed loop vector con‐ Vector control trol mode (CLVC)

Induction

● Fast bypass option

Closed synchronous motor control mode (CSMC)

Synchronous

Vector control

NXGpro Control Operating Manual, AJ, A5E33474566_EN

With encoder

● No spinning load

● Spinning load option With encoder

● Fast bypass option ● Spinning load option

NXGpro Control Description 5.2 Control Modes Control Mode

Vector Control

Type of Motor

Encoder

Features

Permanent magnet motor control mode (PMM)

Vector control

Permanent magnet motor

Without encoder

● Fast bypass option ● Spinning load option ● High starting torque enabled automatically

Synchronous motor brushless DC exciter mode (SMDC)

5.2.1

Vector control

Synchronous with DC exciter

Without encoder

● No fast bypass ● No spinning load

Open Loop Vector Control (OLVC) Open loop vector control (OLVC) is used for most applications with single induction motors. In this mode, the control estimates motor slip as a function of load torque, and provides a performance that matches a vector controlled drive with speed sensor/transducer above a certain minimum speed. With the correct motor parameters, the control can provide good performance even at 1% of rated speed. With this mode, speed feedback is synthesized from the stator frequency and the estimated motor slip, and slip compensation is automatic. In this control mode, if spinning load is selected, the drive begins by scanning the frequency range to detect the speed of the rotating motor. Once the drive has completed the scan or if the feature is disabled, the drive goes into magnetizing state. During this state, the drive ramps the motor flux to its commanded value at the specified flux ramp rate. Only when the flux feedback is within 90% of the commanded flux, the drive changes to the run state. Once in run state, the drive increases the speed to the desired value. All motor and drive parameters are required for this mode of operation. Default values for the control loop gains are sufficient for most applications.

5.2.2

Open Loop Test Mode (OLTM) CAUTION Open loop test mode (OLTM) is used for test purposes during commissioning only. Do not use this mode to control a motor. This mode is intended for commissioning only, for the purpose of establishing correct current feedback polarity. The speed should not exceed 20 % rated speed when in use. In OLTM the motor current feedback signals are ignored. This control mode is used during drive setup, when the modulation on the cells is to be verified, or when testing the drive without a load. It can also be used when the motor is first connected to the drive to make sure that the Hall effect transducers are working correctly and are providing the correct polarity on the feedback signals. Do not use this mode to adjust scale factors for input and output, voltage and currents.

NXGpro Control Operating Manual, AJ, A5E33474566_EN

NXGpro Control Description 5.2 Control Modes In this mode, the drive goes through the magnetizing state to the run state without considering the motor flux. Only motor nameplate values and some drive related parameters are required for this mode. Ensure the following parameter settings are configured for this control mode: ● Spinning load and fast bypass are disabled internally for this mode. ● Increase acceleration and deceleration times in the Speed Ramp Menu. ● Reduce flux demand. Flux and voltage instability may occur with an attached motor. ● Uncouple any connected motor from a load. Do not run higher than 20 to 25 % of drive rating, this allows for verification of the current feedback polarity.

5.2.3

Synchronous Motor Control (SMC) For synchronous motor control (SMC), the drive is equipped with a field exciter that usually consists of a SCR based current regulator. The field exciter operates to maintain a field current level that is commanded by the flux regulator. An example application for a brushless synchronous motor is shown in the figure below. 'ULYH

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Drive Arrangement for Synchronous Motor with AC Brushless Exciter

The figure shows a brushless synchronous motor with the static exciter wound for 3-phase AC in the range of 350 to 400 volts. If this is not the case, then a transformer is needed between the auxiliary power and the field exciter. The circuit wheel needs only a rectifier. Motor Protection The control provides for minimal motor protection when the motor is connected to the drive. For a system that employs drive, not cell, bypass, external protection of the motor is required. The

NXGpro Control Operating Manual, AJ, A5E33474566_EN

NXGpro Control Description 5.2 Control Modes control will trip the drive on a loss of field fault if the motor draws excessive reactive current, which will occur when the exciter fails full on or off. An external means to disconnect the exciter power from the field is required to fully protect the motor. Flux regulator implementation The overall control strategy is similar to OLVC, except for the flux regulator implementation. Refer to Figure Vector Control Algorithms. For synchronous motors, the flux regulator provides two current commands, one for the field exciter current, and another for the magnetizing component of stator current. Determining motor speed SMC avoids the need to scan the motor frequency to determine motor speed. The control uses information from the rotor-induced speed voltages on the stator to determine rotor speed. The drive begins, in the magnetizing state, by giving a field current command that is equal to the noload field current setting to the exciter. This lasts for a time equal to the programmable flux ramp time that is entered through the menu system. After this period of time, the drive goes into the run state. In most cases, the regulator in the field exciter is slow, and the drive applies magnetizing current, through the stator windings to assist the exciter in establishing rated flux on the motor. At the same time, the speed regulator commands a torque-producing current to accelerate the motor to the demanded speed. Once the field exciter establishes the required field current to maintain flux in the motor, the magnetizing component of stator current reduces to zero. From this point onward, the drive provides torque-producing current, for acceleration or deceleration that is in-phase with the drive output voltage. That is, under steady state conditions, unity power factor condition is automatically maintained at the drive output. The field current command is provided to the field exciter with the use of an analog output signal.

Summary of differences between SMC and OLVC ● The motor no-load current parameter represents the field no-load current value in SMC. ● With SMC, the flux loop gains are slightly lower than with OLVC. ● Spinning load is always enabled with SMC. ● The drive magnetizing current regulator uses only the proportional gain for the flux exciter. ● Only Stage 1 auto-tuning can be used with synchronous motors. ● When you are performing Stage 1 auto-tuning, you must short the field winding to get a proper setup of the stator resistance. CAUTION Incorrect use of Stage 2 auto-tuning will lead to drive instability. Never use Stage 2 auto-tuning with synchronous motors. Only use Stage 1 auto-tuning with synchronous motors.