ECO Technology SIMOCRANE. ECO Technology. Preface. Safety instructions. Description. Application engineering/configuring/plan.

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1 Preface Safety instructions 1 SIMOCRANE Operating Instructions Description 2 Application engineering/configuring/plan 3 ning Parameter assignment/addressing 4 (DCC library) Alarm, error and system messages 5 ECO RTG standard application 6 A Appendix valid for SIMOCRANE V1.0 hardware: SIMOTION D435-2 DP/PN as of version V4.3 SP1 SINAMICS as of version V4.5 12/2012

2 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: Trademarks 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. 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 Industry Sector Postfach NÜRNBERG GERMANY P 02/2013 Technical data subject to change Copyright Siemens AG All rights reserved

3 Preface This document is part of the SIMOCRANE package. SIMOCRANE is a power management system for fuel-electrical-operated cranes. It is designed for use on cranes which are operated with a combustion engine and a generator and use these to generate their electrical energy for operating the drives and supplying the auxiliary power. SIMOCRANE controls the speed of the combustion engine to optimize consumption depending on the load which is based on the actual electrical energy requirement of the crane. This leads to a reduction in fuel consumption in all operating modes compared to similar cranes which operate with the combustion engine at a fixed speed or which only work with fixed speed levels, e.g. no-load speed and operating speed. SIMOCRANE is designed as an extension of the SIMOCRANE Basic Technology package. can also be used by other SIMOCRANE technologies, such as the SIMOCRANE Sway Control pendulum control system. A SIMOTION DCC library forms the core of. A free standard application with Basic Technology and for easy use has been prepared and described to offer you support. It is suitable for both "ready-to-run" (parameterization only) and "ready-toapply" (adapted by users) applications. The applications are not part of the product. The applications must be adapted by the crane operator and tested systematically before regular operation. Additional information Siemens product support The latest information about SIMOTION products, product support, and FAQs can be found on the Internet here ( The latest information about SINAMICS products, product support, and FAQs can be found on the Internet here ( The latest information about SIMOCRANE products, product support, and FAQs can be found on the Internet here ( Crane application notes can be found on the Internet: here ( Operating Instructions, 12/2012 3

4 Preface Product support for SIMOCRANE The following addresses provide support for your SIMOCRANE products: Support request on the Internet: Europe hotline Tel.: +49 (0) Fax: +49 (0) support.automation@siemens.com America hotline Tel.: Fax: support.america.automation@siemens.com Asia/Pacific hotline Tel.: Fax: support.asia.automation@siemens.com Application support for SIMOCRANE For additional customer-specific requirements and applications, please contact the following address: applications.cranes.aud@siemens.com Further assistance We are currently only able to offer individual support for. Please contact your local Siemens sales office. We also offer introductory courses to help you familiarize yourself with SIMOCRANE Basic Technology. You can find more information here ( General liability information The combustion engine must be selected by the user with a valid emission standard according to the laws in the country of use. The user must ensure adherence to legal regulations for handling a combustion engine. The product does not undertake any exhaust-related functions or safety-related monitoring functions during operation of the combustion engine. These must be ensured by the user. 4 Operating Instructions, 12/2012

5 Preface Guarantee and liability application example Unless guaranteed in writing, the application examples in this document are not binding and do not claim to be complete regarding configuration, equipment, and any eventuality. These application examples do not represent specific customer solutions, but are only intended to provide support when it comes to typical tasks. You are responsible for the proper operation of the described products. These application examples do not relieve you of your responsibility regarding the safe handling when using, installing, operating, and maintaining the equipment. By using these application examples, you agree that Siemens cannot be made liable for possible damage beyond the mentioned liability clause. We reserve the right to make changes and revisions to these application examples at any time without prior notice. We do not provide a guarantee for any of the information contained in this application example. We accept no liability for any damage or loss caused by the examples, information, programs, configuration or performance data, etc. described in this application example, irrespective of the legal basis for claims arising from such damage or loss, unless liability is mandatory (for example, in accordance with the German Product Liability Act for intent, acts of gross negligence, harm to the life, body or health of human beings, the assumption of a guarantee for a product's characteristics of state, malicious concealment of a defect, or violation of basic contractual obligations). Copyright information MATLAB The MathWorks, Inc. Siemens is confirmed as having a valid license agreement with Mathworks. Operating Instructions, 12/2012 5

6 Preface 6 Operating Instructions, 12/2012

7 Table of contents Preface Safety instructions General safety instructions Safety instructions for electromagnetic fields (EMF) Handling electrostatic sensitive devices (ESD) Residual risks of power drive systems Description Application engineering/configuring/planning Information about planning an ECO configuration ECO principle Parameter assignment/addressing (DCC library) Nomenclature General information Concept DCC_Setpoint Brief description Objective Detailed description Inputs boinenable activation of the power management functions boinreset error acknowledge rinengineactspeed combustion-engine actual speed rinextspeedrequest combustion-engine external specified speed boinmchoenable positive deflection, hoisting-gear master switch, lifting direction boinmcgaenable master switch deflection, crane travelling gear left or right travel rinhospeedsetpoint hoisting-gear speed setpoint rinhoactspeed current hoisting-gear actual speed rinactualcranepower current total power of all application electrical consumers rinenginespeed combustion-engine speed specification from the power requirement rinmaxoperatingspeed combustion-engine maximum operating speed rinenginemaxspeed combustion engine maximum speed rinmaxtowingspeed combustion engine maximum towing speed rinmaxtowingpower combustion engine maximum towing power rinenginetowingspeed speed for combustion engine towing operation rinreleasespeedtowing release speed of towing operation for combustion engine rinmaxdifferencespeed maximum deviation of the actual speed value from the speed setpoint of the combustion engine rinprectrlspeedlvl hoisting-gear speed for the precontrol-speed supplementarysetpoint threshold...50 Operating Instructions, 12/2012 7

8 Table of contents rinhomaxdiff difference between the hoisting-gear speed and the threshold value rinhoaddprectrlvalue additional speed precontrol setpoint for hoisting-gear actions rinhoprectrlspeed precontrol speed for hoisting-gear actions rinhooffdelaytime combustion-engine delay time after hoisting-gear actions (hoisting) rinhoramptimevalue hoisting-gear ramp time (hoist) rinhoinhibittowingspeed inhibit combustion-engine towing operation for hoisting gear ringaprectrlspeed precontrol speed for crane travelling-gear actions ringaoffdelaytime combustion-engine delay time after crane travelling-gear actions (gantry) ringaramptimevalue crane travelling-gear ramp time (gantry) rinmaxposrfgcap value of the maximum positive increase for the preventative intervention of the open-loop control rinmaxposrfgstd default value for the maximum positive increase rinmaxnegrfgcap value of the maximum negative increase for the preventative intervention of the open-loop control rinmaxnegrfgstd default value for the maximum negative increase Outputs routenginespeedsetpoint speed-setpoint specification for the combustion engine routmaxtowingspeed combustion-engine speed limitation in towing operation routmaxtowingpower combustion-engine power limitation in towing operation routhoramptime hoisting-gear ramp time (hoist) routgaramptime crane travelling-gear ramp time (gantry) boutstatusword1 SIMOCRANE status word boutinputerrors1 SIMOCRANE status word boutinputerrors2 SIMOCRANE status word DCC_Speeds Brief description Objective Detailed description Inputs rinmaxpower ECO application maximum power rinactualcranepower current total power of all application electrical consumers rinminpower ECO application minimum power rinefficiency efficiency of complete application rinpowervalue1 power value 1 (X coordinate 1) rinspeedvalue1 speed value 1 (Y coordinate 1) rinpowervalue2 power value 2 (X coordinate 2) rinspeedvalue2 speed value 2 (Y coordinate 2) rinpowervalue3 power value 3 (X coordinate 3) rinspeedvalue3 speed value 3 (Y coordinate 3) rinpowervalue4 power value 4 (X coordinate 4) rinspeedvalue4 speed value 4 (Y coordinate 4) rinpowervalue5 power value 5 (X coordinate 5) rinspeedvalue5 speed value 5 (Y coordinate 5) rinpowervalue6 power value 6 (X coordinate 6) rinspeedvalue6 speed value 6 (Y coordinate 6) rinpowervalue7 power value 7 (X coordinate 7) rinspeedvalue7 speed value 7 (Y coordinate 7) rinpowervalue8 power value 8 (X coordinate 8) rinspeedvalue8 speed value 8 (Y coordinate 8) rinpowervalue9 power value 9 (X coordinate 9) rinspeedvalue9 speed value 9 (Y coordinate 9) Operating Instructions, 12/2012

9 Table of contents rinpowervalue10 power value 10 (X coordinate 10) rinspeedvalue10 speed value 10 (Y coordinate 10) Outputs routactualcranepower current total power of all application electrical consumers routenginespeed optimum speed setpoint specification for further calculations Interconnection of the DCC blocks Setup and uninstallation of the ECO DCC Library Alarm, error and system messages Error messages boutstatusword1 SIMOCRANE status word boutinputerrors1 SIMOCRANE status word boutinputerrors2 SIMOCRANE status word ECO RTG standard application Precondition Hardware configuration Interface (communication) Description of the standard application Commissioning Overview Setting instructions for the Motor Module and generator Commissioning the infeed Commissioning the auxiliary power supply frequency converter Commissioning the ECO software Operation and optimization A Appendix A.1 Abbreviations Operating Instructions, 12/2012 9

10 Table of contents 10 Operating Instructions, 12/2012

11 Safety instructions General safety instructions DANGER Danger to life as a result of touching live parts Touching live parts can result in death or severe injury. Only work on electrical equipment if you are appropriately qualified. Always observe the country-specific safety rules for all work. Generally, six steps apply when establishing safety: 1. Prepare for shutdown, and notify team members who will be affected by the procedure. 2. Bring the machine into no-voltage condition. Switch off the machine. Wait until the discharge time specified on the warning labels has elapsed. Check that it really is in a no-voltage condition, from phase conductor to phase conductor and phase conductor to protective conductor. Check that every auxiliary circuit is in a no-voltage condition. Ensure that the motors cannot move. 3. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or water. 4. Isolate or neutralize all hazardous energy sources by closing switches, grounding or short-circuiting or closing valves, for example. 5. Lock out the energy sources so that they cannot be switched on again. 6. Make sure that the machine is completely locked out... and that you have the right machine. After you have completed the work, restore the operational readiness in the inverse sequence. WARNING Danger to life as a result of a dangerous voltage when connecting a power supply that is not suitable In the case of a fault, touching live parts can result in death or severe injury. For all connections and terminals of the electronic boards, only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV (Protective Extra Low Voltage) output voltages. Operating Instructions, 12/

12 Safety instructions 1.1 General safety instructions WARNING Danger to life as a result of touching live parts on damaged equipment Incorrectly handling equipment can damage it. With damaged equipment, dangerous voltages can be present at the housing or at exposed components. When transporting, storing and operating, maintain the limit value specified in the technical data. Do not use any damaged equipment. Protect the components against conductive pollution, e.g. by installing them in a cabinet with IP54 degree of protection according to EN Provided conductive pollution can be prevented at the installation site, the degree of protection for the cabinet can be decreased accordingly. WARNING Danger of fire spreading as a result of an in adequate enclosure Fire and smoke can cause severe personal injury or material damage. For devices without a protective enclosure, install them in a metal control cabinet (or protect the device using another appropriate measure), so that contact with fire is prevented inside and outside the enclosure. WARNING Danger to life as a result of unexpected movement of machines when using mobile wireless devices or mobile phones Using mobile radios or mobile phones with a transmit power > 1 W closer than approx. 2 m to the components may cause the devices to malfunction, influence the functional safety of machines therefore putting people at risk or causing material damage. When close to components, switch off all mobile radios and mobile phones. WARNING Risk of the motor catching fire when the insulation is overloaded For a ground fault in an IT system, the motor insulation is subject to a higher stress. A possible consequence is that the insulation fails, which can endanger persons as a result of smoke and fire. Use monitoring equipment that signals an insulation fault. Resolve the fault as quickly as possible so that the motor insulation is not overloaded. 12 Operating Instructions, 12/2012

13 Safety instructions 1.2 Safety instructions for electromagnetic fields (EMF) WARNING Risk of fire through overheating if there are insufficient ventilation clearances Insufficient ventilation clearances can result in overheating with associated risk to persons as a result of smoke and fire. Further, this can result in increased failures and a shorter service life of devices/systems. Always maintain the minimum ventilation clearances specified for the components. You can find these in the dimension drawings or in the "Product-specific safety instructions" at the beginning of the particular chapter. WARNING Danger to life as a result of electric shock if cable shields are not connected Hazardous touch voltages can occur as a result of capacitive coupling effects if cable shields are not connected. As a minimum, connect cable shields and the cores of power cables that are not used (e.g. brake cores) at one end at the grounded housing potential. 1.2 Safety instructions for electromagnetic fields (EMF) WARNING Danger to life from electromagnetic fields Electromagnetic fields (EMF) are generated by the operation of electrical power equipment such as transformers, converters or motors. People with pacemakers or implants are at a special risk in the immediate vicinity of these devices/systems. Keep a distance of at least 2 m. Operating Instructions, 12/

14 Safety instructions 1.3 Handling electrostatic sensitive devices (ESD) 1.3 Handling electrostatic sensitive devices (ESD) Electrostatic sensitive devices (ESDs) are individual components, integrated circuits, modules or devices that may be damaged by either electrostatic fields or electrostatic discharge. NOTICE Damage caused by electric fields or electrostatic discharge Electric fields or electrostatic discharge can result in malfunctions as a result of damaged individual parts, integrated circuits, modules or devices. Only pack, store, transport and send electronic components, modules or devices in their original packaging or in other suitable materials, e.g conductive foam rubber of aluminum foil. Only touch components, modules and devices if you are first grounded by applying one of the following measures: Wearing an ESD wrist strap Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring Only place electronic components, modules or devices on conductive surfaces (table with ESD surface, conductive ESD foam, ESD packaging, ESD transport container). 1.4 Residual risks of power drive systems Residual risks of power drive systems The control and drive components of a drive system are approved for industrial and commercial use in industrial line supplies. Its use in public line supplies requires a different configuration and/or additional measures. These components may only be operated in closed housings or in higher-level control cabinets with protective covers that are closed, and when all of the protective devices are used. These components may only be handled by qualified and trained technical personnel who are knowledgeable and observe all of the safety information and instructions on the components and in the associated technical user documentation. When assessing the machine's risk in accordance with the EC Machinery Directive, the machine manufacturer must take into account the following residual risks emanating from the control and drive components of a drive system: 14 Operating Instructions, 12/2012

15 Safety instructions 1.4 Residual risks of power drive systems 1. Unintentional movements of driven machine components during commissioning, operation, maintenance, and repairs caused by, for example: Hardware defects and/or software errors in the sensors, controllers, actuators, and connection technology Response times of the controller and drive Operating and/or ambient conditions not within the scope of the specification Condensation/conductive contamination Parameterization, programming, cabling, and installation errors Use of radio devices/cellular phones in the immediate vicinity of the controller External influences/damage 2. In the event of a fault, exceptionally high temperatures, including an open fire, as well as emissions of light, noise, particles, gases, etc. can occur inside and outside the inverter, e.g.: Component malfunctions Software errors Operating and/or ambient conditions not within the scope of the specification External influences/damage Inverters of the Open Type/IP20 degree of protection must be installed in a metal control cabinet (or protected by another equivalent measure) such that the contact with fire inside and outside the inverter is not possible. 3. Hazardous shock voltages caused by, for example: Component malfunctions Influence of electrostatic charging Induction of voltages in moving motors Operating and/or ambient conditions not within the scope of the specification Condensation/conductive contamination External influences/damage 4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a risk to people with a pacemaker, implants or metal replacement joints, etc. if they are too close. 5. Release of environmental pollutants or emissions as a result of improper operation of the system and/or failure to dispose of components safely and correctly. Note The components must be protected against conductive contamination (e.g. by installing them in a control cabinet with degree of protection IP54 according to EN 60529). Assuming that conductive contamination at the installation site can definitely be excluded, a lower degree of cabinet protection may be permitted. Operating Instructions, 12/

16 Safety instructions 1.4 Residual risks of power drive systems For more information about residual risks of the components in a drive system, see the relevant sections in the technical user documentation. 16 Operating Instructions, 12/2012

17 Description 2 Introduction The new SIMOCRANE software provides extension functions to be used on the already proven SIMOCRANE crane platform. All tasks are clearly segregated so that as well as handling all crane technologies (Basic Technology, pendulum control), SIMOTION also takes care of the ECO functions. A self-contained functional unit is provided thanks to the seamless interaction between Basic Technology and. First, we will present a system overview, in which we will briefly discuss boundary conditions, adaptations, and requirements. More information about configuring an ECO application can be found in Chapter Application engineering/configuring/planning (Page 21). System overview The hardware configuration example for a rubber-tired gantry crane (RTG crane; not trackbound portal crane) with a new platform is shown in the figure below. Figure 2-1 Configuration with the new platform using ECO RTG as an example Operating Instructions, 12/

18 Description The product consists of SIMOTION DCC blocks which can be used in a SIMOCRANE environment (SIMOTION and SINAMICS). For, different boundary conditions must be adhered to in comparison to a conventional SINAMICS S120 system; these are: Permanent-magnet synchronous motor as generator Infeed for the DC link with Motor Modules in SINAMICS S120 chassis frame size (mains voltage range V). Infeed for auxiliary power supply with SINAMICS S120 Motor Modules (in booksize or chassis frame size) with suitable sine-wave filter SIMOTION D435-2 controller V1.0 software including license There are also certain adaptations to and requirements for the rest of the crane configuration, which must be observed. For clarification, we will next discuss the other components from the figure above. Combustion engine (not shown in figure) In principle, any combustion engine can be used as long as it is compatible with the selected crane system in terms of power and dynamic properties. Only combustion engines with CAN bus interface have been tested for so far. Movement converter SINAMICS S120 power units must be provided for movements by the hoisting gear, trolley, or crane travelling gear. Braking module with resistors (not shown in the figure) Energy is discharged when lowering a load or slowing down travel. This energy must be dissipated exactly as it is for cranes without. Crane controller The programmable logic controller (PLC) and the distributed I/O from the SIMATIC series are available for crane control. Which PLC and which I/O you decide to use does not make any difference to. is executed in a suitable SIMOTION controller. Certain interface signals are required and must be made available at the appropriate time. We recommend carrying out the specific movement control for the hoisting gear, trolley, or crane travelling gear with SIMOCRANE Basic Technology because Basic Technology works seamlessly with. HMI/CMS WinCC and SIMOCRANE CMS/RCMS are available for the crane visualization. Which one you decide on has no influence on because runs in its own SIMOTION controller. The visualization of data and error messages is discussed in this document. The developer and commissioner of the entire crane must ensure that the data and error messages are processed and/or displayed. For further information on design, refer to Chapter Application engineering/configuring/planning (Page 21). 18 Operating Instructions, 12/2012

19 Description Scope of delivery The SIMOCRANE package (order number: 6GK7230-0AA00-0AA0) offers an ECO control system for various crane applications with combustion engines and generator-supplied auxiliary power supplies. It includes: Software DVD with Setup for installing the Crane ECO DCC library and online help Standard application Documentation V1.0 license (displayed license code: 6AU1662-0AE10-0AX0) Note If SIMOTION SCOUT is reinstalled, the crane package (setupecotechnology) must also be reinstalled. The software package contains the ECO DCC library and a complete ECO standard application for an RTG crane (ECO RTG). The cranes DCC library comprises a collection of blocks that are implemented as "Drive Control Charts" (DCC) blocks. DCC is a representation which supports graphic configuring and interconnecting. For detailed information about the scope of functions of the ECO crane library, refer to the table below. The standard application contains the ready-to-use application software for a RTG crane (ECO RTG). This solution is "ready-to-run" for users who only need to set the necessary parameters. This solution can be considered a "ready-to-apply" basis for large-scale adaptations and expansions, offering a high degree of expansibility and flexibility. Figure 2-2 Structure of, product, and application Operating Instructions, 12/

20 Description Scope of functions For an overview of the ECO-specific DCC blocks and their function, refer to the following table: Table 2-1 Overview, ECO-specific technology functions No. Function/block Brief description 1 DCC_Speeds Speed calculation 2 DCC_Setpoint Power management functions 20 Operating Instructions, 12/2012

21 Application engineering/configuring/planning Information about planning an ECO configuration In this chapter, information is presented about ECO configuration for the crane-specific components. The savings of an ECO configuration depends on a range of crane-specific factors and only some of these can be influenced by. Siemens is therefore not in a position to make any concrete statement about the possible savings. It is to be expected that you will make savings using in comparison to operation with fixed speeds. For maximum savings, the following factors should be taken into consideration: Selection of combustion engine; every combustion engine has typical dynamic behavior and typical consumption. Design of the crane (total weight, gears, wheels, spreaders, etc.) Speed, acceleration times, and design of, for example, the hoisting gear, trolley, or crane travelling gear Design of the auxiliary power supply (lighting, heating, cooling, etc.); the basic load of the auxiliary power supply should be as low as possible. Utilization of the crane The following parts of crane configuration are discussed here in detail: Combustion engine Combustion-engine communications interface Generator Baseframe, damping, coupling of the combustion engine Infeed Auxiliary power supply Movement converter Braking module software Operating Instructions, 12/

22 Application engineering/configuring/planning 3.1 Information about planning an ECO configuration Combustion engine In principle, any all-speed combustion engine can be used as long as it is compatible with the selected crane system in terms of power and dynamic properties. The combustion engine should not be selected solely on the basis of power and dynamic properties. Each manufacturer of combustion engines has their own combustion and exhaust procedure based on the applicable emission regulations. The most inexpensive or most popular combustion engine doesn't necessarily have the lowest consumption. Because with ECO Technology the entire range of speeds is used and there is always an attempt to operate at the lowest possible speed, the combustion engine should be set optimally for its power, and driven in an optimum manner. The fuel consumption is given in g/kwh. In modern combustion engines, optimum consumption generally produces between 1,100 and 1,400 revolutions per minute. When selecting the combustion engine, the following general requirements must be observed: The speed of is between 0 and 3,000 revolutions per minute. The lowest speed value depends on the combustion engine itself and on the minimum voltage of the generator which supplies the infeed. The maximum speed depends on the selected combustion engine and on its maximum power in combination with the generator. The minimum voltage (input voltage of the infeed) is 140 V. Typical load applications, duty cycles, maximum and average power, and maximum auxiliary power supply loads must all be taken into consideration when selecting the combustion engine. The maximum and average power and the dynamic requirements on the shaft of the combustion engine must be specified. The acceleration power of the hoisting gear, trolley, and crane travelling gear (the latter usually only 10%), and the maximum auxiliary power supply output in night mode should be added together to determine the maximum power of the combustion engine, e.g. for an RTG crane. The system losses and the deterioration of the combustion engine must also be considered (usually 20-25%). Combustion-engine communications interface requires direct communication between SIMOTION and the combustionengine closed-loop control. continuously specifies the appropriate speed for each power requirement. The actual speed of the combustion engine is required for a closed control loop. It is used to check whether the combustion engine (actual speed) obeys the setpoint specification. Closed-loop controls of modern combustion engines can be addressed via CAN bus. Short cycle times are required for transmitting telegrams between the combustion engine and the ECO controller. SIMOTION can communicate via both PROFIBUS and PROFINET. A suitable gateway should be used for direct CAN bus communication via PROFIBUS or PROFINET. Typical setpoint and actual speed values should then be processed in a CAN bus cycle of 10 milliseconds. Additional nodes within the communication line, such as a SIMATIC controller, increase the total time for data transfer and must be separated. 22 Operating Instructions, 12/2012

23 Application engineering/configuring/planning 3.1 Information about planning an ECO configuration The preparation of CAN telegrams is different for every combustion engine and for every supplier and is therefore not part of. Note Older combustion engines are generally analog controlled and are therefore not as quick in terms of communication and their dynamic behavior. The use of combustion engines with analog communications interfaces is possible in principle. It is however to be expected that the ECO closed-loop control will need to be set as more progressive (controlled over and understeer) to compensate for the slow reaction of these engines. SIMOCRANE ECO Technology has not been tested with combustion engines with analog communications interfaces. Generator is based on a permanent-magnet synchronous motor as the generator. The performance of this type of motor is well matched to the performance profile of a combustion engine, as long as the synchronous motor is designed correctly. The speedpower limiting curves of the combustion engine and the generator must match and ideally be able to be superimposed. This combination can deliver considerable power even at low speeds, which has a positive impact on fuel efficiency. also makes it possible to tow the combustion engine. During towing, regenerative energy is used to drive the combustion engine with the generator in motor operation, thereby saving fuel. Demand on the braking resistors is also reduced thanks to the power absorbed by the engine. It is also theoretically possible to use a field-regulated synchronous generator with an external permanent magnet exciter. However, this variant has not yet been tested by Siemens and is therefore not supported at this time. It is also not possible to use the towing function with this generator, reducing the energy-saving effect. Baseframe, damping, coupling A conventional combustion engine/generator set for cranes is optimized for vibrations, shocks, and resonances at one speed. Because uses the entire available speed range of the combustion engine and generator, there are therefore higher requirements for the supporting structure, baseframe, damping, and coupling. An improvised assembly without calculations and verification measurements can lead to mechanical damage. Infeed A SINAMICS S120 Motor Module in chassis frame size with a mains voltage range of V must be selected as the infeed. Basic Line Modules (BLM) and Smart Line Modules (SLM) from the SINAMICS range cannot increase an alternating input voltage to a stable DC link voltage, and therefore cannot be used. Active Line Modules (ALM) cannot be used because they do not offer the specific ECO functionalities and are also not able to carry out the towing function. Operating Instructions, 12/

24 Application engineering/configuring/planning 3.1 Information about planning an ECO configuration The Motor Module generates the necessary stable DC link voltage which supplies the drives and the auxiliary power supply from the alternating voltage supplied by the generator. Design the infeed according to the instructions in the Configuration Manuals and using the information provided in the catalog. The input voltage, maximum power of the simultaneous movements, and the maximum power consumption of the auxiliary power supply are essential factors. The continuous and maximum currents of the generator must also be taken into consideration. The input voltage range for is 140 to 500 VAC. The frequency is not crucial, but should be within the SINAMICS specifications. If the Motor Module on the input side is directly connected to the generator when the combustion engine is started up (no isolator with protection), a precharging device is not required. The generator voltage generates a small voltage when the combustion engine is at low speed, which precharges the DC link. A precharging device is required if you want to connect a contactor between the generator and infeed at the rated speed when the DC link is inactive. Auxiliary power supply (auxiliary drives supply) Because always calculates the optimum speed for the required power, the generator voltage which is produced is constantly changing. It is therefore essential to supply the auxiliary power supply using the DC link voltage. To compensate for their variations, you can use a converter with a suitable sine-wave filter and transformer to generate the star point on the secondary side for single-phase consumers. The design and configuration of the auxiliary power supply must be geared to: Average utilization Peak load Continuous current Peak current (switching on high power) In principle, the user is solely responsible for the design and selection of their electrical components. Incorrect pulse frequencies or incorrect selection of the filter can cause damage to or failure of components. The greatest care must be taken during design and configuration, particularly regarding all components used for the auxiliary power supply system. The circuit with a sine-wave filter (L- C combination) and if necessary a transformer (L) constitutes a circuit with static (C) and dynamic (L) energy storage and is essentially oscillatory. The selected circuit must not cause resonance to occur when operated with the set pulse frequency. Careful configuration is required! The specifications and requirements with respect to electrical engineering must be observed. To avoid resonant circuit problems, the hardware selection and the hardware setting (for example, the pulse frequency of the auxiliary converter) must match each other. The selection and calculation of the selected filters and reactors must be made according to the manufacturer's specifications. 24 Operating Instructions, 12/2012

25 Application engineering/configuring/planning 3.1 Information about planning an ECO configuration To reduce voltage peaks when using a SINAMICS S120 Motor Module as an auxiliary converter, the converter should be driven at higher elementary frequencies, e.g. 4 or 8 khz. Voltage distributions at an elementary frequency of 4 khz, for example, on the auxiliary converter downstream of the sine-wave filter lead to considerable voltage peaks. Reduction factors must be taken into consideration when selecting a converter, as described in the SINAMICS Configuration Manual for using filters. Note You can find more information in the relevant configuration instructions and manuals from Siemens. Installation wiring and EMC standards for converter-protected auxiliary power supplies should be followed in their entirety to avoid damage to or failures of components due to voltage peaks. Note The "Cabling and wiring guidelines" (CablingWiringGuidelinesCranes_1.2.pdf) from Siemens Cranes provide information on cable selection, laying of cables, and wiring in a crane. Movement converter SINAMICS S120 power units must be provided for movements by the hoisting gear, trolley, or crane travelling gear. The Motor Modules are connected to the DC link. The design and selection of the infeed (voltage, current, power) also correspond to a conventional crane design. Because the requirements vary from crane to crane and also depending on the OEM and system integrator, we cannot specify a fixed configuration. You can devise your own specification using standard products from the catalog. Braking module with resistors (not shown in the figure) Energy is discharged when lowering a load or slowing down travel. This energy should be dissipated. SINAMICS offers the following possibilities: Braking modules installed in large converters Separate braking modules connected via DC link Motor Module as a braking module can work with all known variants. Operating Instructions, 12/

26 Application engineering/configuring/planning 3.1 Information about planning an ECO configuration software runs on the SIMOTION platform, specifically on SIMOTION D SIMOTION is not included in the scope of delivery of and should be bought separately along with the memory card. We recommend executing the specific movement control for the hoisting gear, trolley, or crane travelling gear with SIMOCRANE Basic Technology because Basic Technology works seamlessly with. See also Chapter ECO RTG standard application (Page 91). When using SIMOCRANE Basic Technology, the CF card is already included when you purchase SIMOTION. This means that the memory card just needs to be updated with an License. SIMOCRANE V1.0 requires a software license. The software is executed as a DCC library on SIMOTION. If this license is not available, all power management functions are automatically deactivated. The combustion engine is then controlled at the rated speed, meaning that the crane remains functional but fuel is not saved. The automatic shutdown of power management reactions due to a missing license has the same effect as manual deactivation of the ECO software via the enable input. The internal license query cannot be circumvented. In the next few chapters, we will discuss further details of the design and information about the software. 26 Operating Instructions, 12/2012

27 Application engineering/configuring/planning 3.2 ECO principle 3.2 ECO principle The aim of ECO software is to ensure that the electrical power requirement of the application is met at all times. This is limited by the maximum available power which can be delivered by the combustion engine, minus losses. Therefore, the maximum required power (the sum of simultaneous axis movements of the crane and auxiliary power supply) must also match the maximum power which the combustion engine can deliver. The closed-loop control ensures a speed setpoint which varies constantly between the minimum and maximum speeds of the combustion engine, depending on the required power of, for example, the hoisting gear or other electrical drives and consumers. The aim of the ECO software is to counteract an overspeed of the combustion engine. If the combustion engine is overloaded or stalls, this should be recognized and if possible prevented by making interventions to decrease the power of the crane. The ECO principle of fuel efficiency is accompanied by a high turnover rate. Higher turnover rates require shorter cycle times. These in turn are achieved through higher drive speeds and shorter startup times. The aim of ECO software is to achieve an optimum compromise between saving fuel and short cycle times. The total power of all consumers for an ECO application (e.g. hoisting gear, trolley, auxiliary drives) can be negative or positive. Positive means that energy is taken by the consumers, i.e. it must be created by the combustion engine/generator combination. In concrete terms, this means that the hoisting gear lifts a container in motorized operation, the trolley travels, or the air-conditioner on the crane switches on. There is also a negative total power if, for example, the hoisting gear makes the transition to generator operation. When loads are lowered with the hoisting-gear motor, it becomes a generator again. It feeds energy into the DC link of the application. The generated energy exceeds the energy need of the other consumers several times over. In version V1.0 of, there is no provision for storing this energy. Hybrid mode is not explicitly implemented or supported. A function extension is planned in version V2.0 of. To prevent the DC link voltage from increasing, this excessive energy must be dissipated. Two basic options are available for this. The use of braking resistors is conceivable. Braking resistors can either be integrated as standard brake chopper in the converter or a three-phase braking resistor is regulated by a SINAMICS Motor Module. Whereas the standard brake chopper initiates for a set voltage limit above the selected DC-link voltage and below the overvoltage limit of the system, a braking resistor connected to a Motor Module can be controlled explicitly. The standard brake chopper is less expensive than the Motor Module solution. Furthermore, the limited internal space available in the electrical room must be considered for the design of a SIMOCRANE solution. Furthermore, the combustion engine can be used in towing operation as a brake or an energy absorber. The generator connected to it becomes a motor again. The energy flow reverses to the combustion engine direction. The combustion engine stops the injection of fuel into its cylinders. Only the air in the cylinders is compressed. The generator driving the engine accelerates it to the maximum towing speed. This function can be used in combination with additional braking resistors to consume the energy produced when lowering the hoisting gear. Operating Instructions, 12/

28 Application engineering/configuring/planning 3.2 ECO principle Readjustment time Hoisting-gear and crane travelling-gear motors are the largest consumers of electricity on a crane. For example, a hoisting-gear motor can use 250 kw or more power while auxiliary drives or trolley motors consume much less, around 30 kw. Consequently, hoisting-gear and crane travelling-gear movements place the highest dynamics requirements on the combustion engine used. It must generate the required electrical power for the hoisting-gear and crane travelling-gear movements with the generator coupled to it. There are basically two different processes. The start of a hoisting-gear or crane travelling-gear movement from a standstill, i.e. at zero speed. This happens, for example, when the crane lifts a container from the ground or generally needs to change its position in the container terminal. The crane driver initiates this process by deflecting the corresponding master switch. software recognizes these precontrol conditions and accelerates the combustion engine to the set precontrol speeds in preparation for a high electrical power requirement from the hoisting gear or crane travelling gear. The first situation is less critical. The other procedure is explained using a hoisting-gear action as an example. Once the crane driver has deflected his master switch in the lifting direction, the precontrol of the combustion engine speed begins. The hoisting-gear motor is premagnetized. Experience shows that the power required for magnetization can be covered at low combustion-engine speeds, such as no-load speed. No separate deceleration is required for magnetization. The hoisting-gear brakes are opened and a start pulse is sent to the hoisting-gear motor. The start pulse to the hoisting-gear motor prevents unwanted sagging of the load as soon as the load stops being held by the hoisting-gear brakes. Experience also shows here that deceleration is not necessary for opening the brakes. The hoisting-gear action starts now, initiated by the deflection of the master switch. The hoisting-gear motor accelerates and increases its speed. As the speed increases, so too does the power. The power consumed reaches its maximum during the acceleration phase. Once the acceleration phase is completed and the hoisting-gear motor has reached its load-dependent maximum velocity, the power consumption declines. The critical maximum power during acceleration must be generated by the combustion engine including losses of converters and generator. The generator absorbs this power, driven by its closed-loop DC-link control and generates a torque at the shaft for the combustion engine. A torque which is too high causes the combustion engine to overload or stall. For this reason, the combustion engine is precontrolled as quickly as possible during corresponding hoisting-gear or crane travelling-gear movements. There is enough time for acceleration. The torque and power increase at higher speeds. The combustion engine is now able to deliver the power required for the hoisting-gear motor to accelerate. Unlike the first one, the second conceivable process does not take place from a standstill. Here, the example given will concern crane travelling-gear positioning actions. The crane is not always precisely at the target position when in manual operation. The crane driver may have to position the crane several times to the left and right to achieve the desired position above the container or above the truck. Unlike in the first process, the electric power is available within just a few milliseconds. Deceleration through magnetizing, brakes open, motor acceleration not applicable. The combustion engine does not therefore spend any time at no-load speed or low speeds to accelerate to the required operating speed. This would cause it to stall immediately. A delay time is consequently necessary for increased combustion-engine speeds. The speed corresponds to the set precontrol speed. 28 Operating Instructions, 12/2012

29 Application engineering/configuring/planning 3.2 ECO principle Successive positioning or other hoisting-gear actions can be handled by the combustion engine immediately. Experience from planning studies indicates the duration for delay times to be about 10 seconds. The exact values can be adapted to the requirements of the system. Figure 3-1 Theoretical generator power (green) and crane electrical consumers (blue) The processes mentioned above primarily relate to manual operations involving a crane driver. In the future, the degree of automation of cranes will increase. Semi or fullyautomatic processes are also conceivable. Computer-controlled processes result in fewer repositioning actions, as the targets are approached precisely. SIMOCRANE V1.0 does not have algorithms for automatic processes. When using V1.0 in automatic mode, it is however conceivable and sensible to reduce a corresponding delay time to zero or close to zero. The actual values must be tested and checked during the testing phase. Hoisting gear Lowering the hoisting gear causes energy to be generated by the hoisting-gear motor. This energy is fed into the system's intermediate DC circuit via the hoisting-gear converter. The voltage in the DC link increases. The energy must be dissipated. It is possible to convert the energy into thermal energy using the braking resistors. There is also a braking function via the combustion engine. This can make the transition to what is known as towing operation and absorb the energy. For this process, the generator goes into motorized operation and drives the combustion engine. This stops fuels being injected. Interior friction and air compression in the cylinders ensure that what is known as towing power is absorbed by the combustion engine. Operating Instructions, 12/

30 Application engineering/configuring/planning 3.2 ECO principle For reasons relating to dynamics, the combustion engine should not make the transition to towing operation if there is slight negative power. The time delay before making the transition from towing operation back to travel operation is unfavorable in terms of dynamics. A short lowering action followed by a lifting action would cause the combustion engine to stall, as it is unable to make the transition from towing operation to combustion operation quickly enough. The energy which accumulates during lowering must therefore first be dissipated by the braking resistors. The combustion engine can also make the transition to towing operation from a selected reduced speed of the hoisting-gear motor and dissipate energy from the DC link accordingly. Towing operation Towing operation happens if the combustion engine is turned by the motorized generator and uses little or no fuel itself. The combustion engine can be used in towing operation as a brake or an energy absorber. The generator connected to it becomes a motor again. The energy flow reverses to the combustion engine direction. The combustion engine stops the injection of fuel into its cylinders. Only the air in the cylinders is compressed. The generator driving the engine accelerates it to the maximum towing speed. This function can be used in combination with additional braking resistors to consume the energy produced when lowering the hoisting gear. A speed below the operating speed must be selected as the speed setpoint in towing operation. If the operating range is between 600 and 2,200 rpm, for example, 500 rpm would be a suitable setpoint specification for the combustion engine to switch to towing operation. Note It is important to bear in mind that some older motors with analog speed control do not allow fixed speed setpoint specifications below the operating range. A large difference between the actual speed of the combustion engine and the lower speed setpoint specification leads to an error. These engines require an updated speed setpoint specification for towing operation which is, for example, 100 rpm below the current actual speed of the engine. This type of engine is not supported by version V1.0 of the ECO software. 30 Operating Instructions, 12/2012

31 Application engineering/configuring/planning 3.2 ECO principle Overspeed protection The electrical consumers on a crane take energy from the DC link without restrictions under normal conditions. The SINAMICS Motor Module closed-loop DC-link control with connected generator ensures that compensation or a stabile DC-link voltage are present. The generator (e.g. Siemens 1PH8) has a maximum permitted current, which in this case is 900 A. Higher currents lead to loss of the magnetic field of the permanent magnet used. The current causes a torque on the shaft between the generator and engine. If the torque generated by the combustion engine for a specified speed or load situation is smaller than the generator torque, the speed of the combustion engine decreases. As the speed decreases, so too does the torque of the combustion engine. This self-perpetuating effect causes the combustion engine to stall or overload. It cuts out. This situation must be avoided. The deviation between the setpoint and actual value is a criterion for possible overloads. In the relevant situation, the speed setpoint is lowered and updated according to the actual speed value. The overload functions become active and limit the power of, for example, the hoisting-gear converter and extend the ramp time of the hoisting gear. Operating Instructions, 12/

32 Application engineering/configuring/planning 3.2 ECO principle 32 Operating Instructions, 12/2012

33 Parameter assignment/addressing (DCC library) Nomenclature A block is shown as follows as an example in the ECO DCC library: Figure 4-1 Symbol for a DCC block Operating Instructions, 12/

34 Parameter assignment/addressing (DCC library) 4.1 Nomenclature Connections and data types The connection name must often be abbreviated due to the restricted number of characters. The abbreviated designators of the data types and prefixes are listed in the following table. Prefix DCC Prefix FB Elementary data types (designator) Value range bo bo BOOL Bit (1) TRUE, FALSE b b8 BYTE Byte (8) 16# #FF b b16 or w WORD Word (16) -2**15...2**15-1 b b32 or dw DWORD Double word (32) -2**31...2**31-1 i i16 INT Integer number (16) -2**15...2**15-1 i i32 DINT Double integer number (32) -2**31...2** i16 UINT Integer number (16) without sign r r32 REAL Floating-point number (32) Refer to IEC 559 r r64 LREAL Long floating-point number (64) Refer to IEC 559 r r32 SDTIME Time Real time data (as floating-point number) 0 ms E38 ms - - Anyobject Connection of TO ENUM System data types for enumeration, e.g. ACTIVE, INACTIVE Connection type Abbreviation IN OUT Connection type Input Output 34 Operating Instructions, 12/2012

35 Parameter assignment/addressing (DCC library) 4.2 General information 4.2 General information A differentiation between inputs and outputs is always made for DCC blocks. The inputs and outputs are shown on the left- and right-hand side of a block, respectively. Inputs can either be interconnected with project variables or the outputs of other blocks or act as parameters. Whereas the selected interconnect automatically assigns to the inputs those values that change at runtime, parameters retain their static value. NOTICE Changing parameter values Parameter values may only be changed if the application is disabled. A parameter, for example, can be the specified maximum speed defined by the application. An input can be an actual speed and an output can be a speed setpoint, for example. The DCC block works with the inputs / parameter values and issues its results via the outputs. The error check of the inputs and parameters ensures that their value ranges are monitored actively. If the range limits are violated, the values are internally automatically limited to the set limits. The block status word "boutstatusword1" informs the user about the error automatically. Note A detailed description of the handling and operation of Drive Control Chart is contained in the SCOUT/DCC documentation. This document assumes adequate knowledge of this documentation. SIMOTION license required SIMOCRANE requires a software license. The power management functions can be used fully only when this license is available. If the internal license query does not report a valid software license, all power management functions deactivate themselves automatically. Instead, a fixed speed setpoint is issued. The higher-level overall function of the crane application is guaranteed, all fuel-saving ECO functions, however, are disabled. Operating Instructions, 12/

36 Parameter assignment/addressing (DCC library) 4.3 Concept 4.3 Concept The implementation of the functions required for the fuel-efficient regulating of the combustion engine-speed results from the interaction of the two DCC_Speeds and DCC_Setpoint blocks. Whereas the DCC_Speeds block is primarily responsible for the assignment of the electrical power and the required combustion-engine speed, the DCC_Setpoint block processes the closed- and open-loop control algorithms. This means the DCC_Speeds block prepares the data and supplies the required specifications to the DCC_Setpoint control-loop block. A correct parameterization and interconnection of both blocks is the basic prerequisite for the implementation of the SIMOCRANE functions. The user is responsible for the parameterization and interconnection; for details, refer to the representations in the following sections. The necessary interconnection of the DCC blocks is shown in Chapter Interconnection of the DCC blocks (Page 80) as an example. 4.4 DCC_Setpoint Brief description The DCC_Setpoint block contains the closed- and open-loop control algorithms for the fuelefficient speed control of a combustion engine Objective supports the user for the resource-saving use of the user's ECO application. The primary focus is the fuel-efficient deployment of a combustion engine depending on the requirements placed on the cycle times and the application operation. Faster startup times, faster drive velocities and shorter cycle times for reversal are balanced with the fuel saving. 36 Operating Instructions, 12/2012

37 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint Detailed description The DCC_Setpoint block contains all closed- and open-loop control algorithms that ensure the optimum speed of the combustion engine. Optimum means that the fuel consumption over the complete application cycle is reduced compared to normal applications with the fixed-speed combustion engines. Overview Figure 4-2 DCC_Setpoint, connections The DCC_Setpoint block calculates the speed setpoint (routenginespeedsetpoint) for the combustion engine. The user is given information about the operating and error status via the "boutstatusword1", "boutinputerrors1", and "boutinputerrors2" status outputs. The DCC_Setpoint block contains functions to counteract overloads and stalling of the combustion engine. It also contains overspeed protection functions for the combustion engine. Operating Instructions, 12/

38 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint NOTICE Overspeed protection The ECO software overspeed protection does not replace the mechanical overspeed protection of the combustion engine. It simply provides assistance Inputs boinenable activation of the power management functions The input serves to activate the power management functions for SIMOCRANE ECO Technology V1.0. A logical one activates all power management functions, whereas a logical zero deactivates the functions. The signal can, for example, come from a higher-level controller. The signal must be present permanently; no edge evaluation is performed. The deactivation of the power management functions can be useful in a service situation. Type Input Value range 0 and 1 Sign Unit Resolution Boolean expression Target Project-specific variable ECO-functionality control interconnection Notes The interconnection of the "boinenable" input to a higher-level controller is not essential. A permanent connection as parameter with a logical one is also conceivable. In the deactivated state, the value entered in the "rinmaxoperatingspeed" parameter is issued to the combustion engine as speed setpoint at the "routenginespeedsetpoint" output. 38 Operating Instructions, 12/2012

39 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint boinreset error acknowledge The input resets active error messages in "boutinputerrors1" and "boutinputerrors2". The cause for the error message, such as an incorrect parameterization, must be corrected. Only then can a reset be performed and the error message cleared. If several errors are pending, only the resolved errors are cleared. Unresolved problems continue to be indicated as errors. For safety reasons, a pending error deactivates the power management functions. Instead, the value from the "rinmaxoperatingspeed" parameter is issued as the constant speed setpoint at the "routenginespeedsetpoint" output. Type Input Value range 0 and 1 Sign Unit Resolution Boolean expression Target Project-specific variable reset ECO error messages interconnection rinengineactspeed combustion-engine actual speed The "rinengineactspeed" input expects the actual speed of the combustion engine (in rpm). The actual speed of the combustion engine must be connected to the "rinengineactspeed" input. The speed may have only positive values within the specified value range. The actual speed is evaluated by the DCC_Setpoint block. The speed setpoint is passed to the combustion engine via the "routenginespeedsetpoint" output. Type Input Value range 0 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number Target interconnection Project-specific variable combustion-engine actual speed Notes The actual operating range for ECO cranes generally lies between 700 and 1800 rpm. Operating Instructions, 12/

40 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint rinextspeedrequest combustion-engine external specified speed The "rinextspeedrequest" input permits an external speed setpoint specification for the combustion engine. A maximum selection is made internally between the "rinextspeedrequest" values and the calculated ECO speed so that the higher value is always forwarded to the combustion engine. This ensures that the combustion engine always makes enough power available. Users can define any number of speed wishes in their software and forward them at the "rinextspeedrequest" input. Type Input Value range 0 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number Target Project-specific variable external combustion-engine speed specification interconnection Notes Service, commissioning or special project requirements can make it necessary to disable temporarily the internal speed setpoint calculation for fuel-efficient operation or for special operation. Rather than needing to select the predefined speeds, the user can use the "rinextspeedrequest" input to specify the required speed boinmchoenable positive deflection, hoisting-gear master switch, lifting direction The "boinmchoenable" input evaluates the hoisting-gear master switch for lifting action deflections. The crane driver initiates a hoisting-gear action. The combustion-engine speed is precontrolled corresponding to the set precontrol speed in the "rinhoprectrlspeed" input. This precontrol is made to achieve the best-possible dynamic response. Type Input Value range 0 and 1 Sign Unit Resolution Boolean expression Target interconnection Project-specific variable positive deflection signal, hoisting-gear master switch, lifting direction (hoisting) 40 Operating Instructions, 12/2012

41 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint boinmcgaenable master switch deflection, crane travelling gear left or right travel The "boinmcgaenable" input evaluates the crane travelling-gear master switch. The crane driver initiates crane travel. The combustion-engine speed is precontrolled corresponding to the set precontrol speed in the "ringaprectrlspeed" input. This precontrol is made to achieve the best-possible dynamic response. Type Input Value range 0 and 1 Sign Unit Resolution Boolean expression Target interconnection Project-specific variable master switch deflection signal, crane travelling gear left or right travel (gantry) rinhospeedsetpoint hoisting-gear speed setpoint The "rinhospeedsetpoint" input expects the speed setpoint of the hoisting-gear motor (in rpm). Connect the speed setpoint of your hoisting gear to the "rinhospeedsetpoint" input. Type Input Value range -3,000 to 3,000 Sign Positive, negative Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number Target interconnection Project-specific variable hoisting-gear speed setpoint Notes The "rinhospeedsetpoint" input is connected to the hoisting-gear speed setpoint which is also transmitted to the SINAMICS drive. The corresponding SINAMICS variable must be applied as SIMOTION variable via the internal communication and connected to this input. Operating Instructions, 12/

42 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint rinhoactspeed current hoisting-gear actual speed The "rinhoactspeed" input expects the actual speed of the hoisting-gear motor (in rpm). This is evaluated by the internal logic. Lifting is in the positive direction, lowering is in the negative direction. Type Input Value range -3,000 to 3,000 Sign Unit Resolution Target interconnection Positive, negative Revolutions per minute [rpm] 32-bit floating-point number Project-specific variable hoisting-gear actual speed Notes The "rinhoactspeed" input is connected to the hoisting-gear actual speed, which comes from the SINAMICS drive. The corresponding SINAMICS variable must be applied as SIMOTION variable via the internal communication and connected to this input rinactualcranepower current total power of all application electrical consumers The "rinactualcranepower" input expects the current total power of all electrical consumers for the ECO application. The target interconnection is entered in the table below. A positive value implies energy creation by the combustion engine/generator combination. A negative value causes switching to so-called towing operation. To achieve this, the combustion engine is provided with a speed setpoint below its operating range, for example 700 rpm, while the operating range lies between 750 and 1,800 rpm. The open-loop control evaluates the power and then decides on combustion operation or towing operation for the combustion engine. Type Input Value range -1,500 to 1,500 Sign Positive, negative Unit Power in kilowatt [kw] Resolution 32-bit floating-point number Target interconnection SIMOCRANE V1.0 DCC_Speeds block "routactualcranepower" output 42 Operating Instructions, 12/2012

43 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint rinenginespeed combustion-engine speed specification from the power requirement The ideal speed setpoint determined from the polyline in the DCC_Speeds DCC block must be passed to the DCC_Setpoint DCC block via the "rinenginespeed" input. Refer to the table below for the target interconnection. This setpoint is further processed in the DCC_Setpoint block. Type Input Value range 0 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number Target interconnection DCC_Speeds, "routenginespeed" output; see Chapter routenginespeed optimum speed setpoint specification for further calculations (Page 79) rinmaxoperatingspeed combustion-engine maximum operating speed This parameter defines the maximum usable operating speed of the combustion engine. This speed is normally the combustion-engine speed at its rated power. This ensures the reliable generation of the required power for every operating and load state of the crane application when the overall system has been designed correctly. The careful selection and matching of the combustion engine and the generator are basic prerequisites. This speed is output as constant speed setpoint at the "routenginespeedsetpoint" output when the ECO power management functions are deactivated. The user can control a specific deactivation using the "boinenable" input. This may be desirable, for example, in service cases, when the fixed "rinmaxoperatingspeed" speed can be used. In addition, an internal deactivation of all ECO power management functions can be forced when a SIMOTION software under-licensing for SIMOCRANE is determined. As soon as an error is displayed in one of the two status words "boutinputerrors1" or "boutinputerrors2", the ECO software also switches to "rinmaxoperatingspeed" as the speed setpoint for the combustion engine for safety reasons. The output of the speed defined in this parameter as constant value ensures that the operating company can continue to use its crane application. The only restriction is the loss of the power management functions and so the loss of the fuel-saving functions. Type Parameter Value range 500 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number Operating Instructions, 12/

44 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint Notes The speed defined in this parameter must be chosen carefully. Because no powerdependent speed control occurs for the deactivation of the ECO power management functions, this speed must guarantee all power requirements of the crane. If an unrestricted crane operation should remain available, we recommend that the combustion-engine speed is specified at its rated power. In the ideal case, this value should match the "rinspeedvalue10" value entered in DCC_Speeds. Other constellations are conceivable. The user is responsible for assigning the parameters correctly; Empirical value: 1,800 rpm. NOTICE Combustion-engine overload Observe the rated speed defined by the manufacturer of the combustion engine. If a higher value is entered, the user is required to make the appropriate interlocks or monitoring of the crane movements and/or power to avoid overloading the combustion engine. Incorrect parameterization can cause damage to the combustion engine rinenginemaxspeed combustion engine maximum speed The "rinenginemaxspeed" parameter defines the maximum permitted speed of the deployed combustion engine. If the defined maximum speed is exceeded, protective measures are automatically initiated internally to reduce the actual speed value of the combustion engine. The speed must be positive because a combustion-engine shaft turns only in one direction. The deployment of a combustion engine for the ECO application on cranes produces an operating range between 500 and 3,000 rpm. The actual maximum speed then lies at approximately 2000 rpm. The entered value is checked. If it lies outside the permitted value range, the largest possible value (for overshooting) or the smallest possible value (for undershooting) is accepted automatically. An error message also appears at boutinputerrors1 resulting in power management being deactivated. The software can be used only when a correct value is entered. NOTICE Maximum speed This value must be lower than the maximum mechanical speed of the combustion engine. 44 Operating Instructions, 12/2012

45 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint Figure 4-3 Overspeed diagram Type Parameter Value range 500 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number Notes Empirical value: 1,850 rpm rinmaxtowingspeed combustion engine maximum towing speed This parameter defines the maximum permitted mechanical towing speed of the combustion engine. The input is passed to the "routmaxtowingspeed" output. There is no evaluation within the DCC_Setpoint block. Type Parameter Value range 500 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number Operating Instructions, 12/

46 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint Notes The objective is that the user makes all ECO-specific settings directly with the ECO software. This prevents a multiple interconnection and reduces the complexity because the corresponding limits do not need to be specified in the drive or elsewhere. Note The storage of the excessive energy does not belong to the SIMOCRANE V1.0 function scope rinmaxtowingpower combustion engine maximum towing power This parameter defines the desired maximum towing power via the combustion engine. The input is passed to the "routmaxtowingpower" output. There is no evaluation within the DCC_Setpoint block. Type Parameter Value range 0 to 100 Sign Positive Unit Power in kilowatt [kw] Resolution 32-bit floating-point number Notes The objective is that the user makes all ECO-specific settings directly with the ECO software. This prevents a multiple interconnection and reduces the complexity because the corresponding limits do not need to be specified in the drive or elsewhere rinenginetowingspeed speed for combustion engine towing operation You can use the "rinenginetowingspeed" parameter to specify the desired speed setpoint for the combustion engine when it makes the transition to towing operation. Type Parameter Value range 500 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number Notes The empirical value is 500 rpm. 46 Operating Instructions, 12/2012

47 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint rinreleasespeedtowing release speed of towing operation for combustion engine You can use the "rinreleasespeedtowing" parameter to control the hoisting gear reduced speed from which the combustion engine towing operation is released. Figure 4-4 Hoisting-gear release speed for combustion-engine towing-operation diagram Type Parameter Value range -3,000 to 0 Sign Negative Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number Notes Revolutions of around -1,000 rpm have proven to be an appropriate threshold for ECO RTG cranes with Siemens equipment. Operating Instructions, 12/

48 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint rinmaxdifferencespeed maximum deviation of the actual speed value from the speed setpoint of the combustion engine This parameter defines the maximum permissible deviation between the speed setpoint and the actual speed value of the combustion engine. It serves as a starting point for the "Engine Support" function. This function is required to prevent overloading and stalling the engine. The Engine Support function has three levels. It responds to the "rinmaxdifferencespeed" input. The value specified there defines the maximum permitted deviation between the actual speed value and the speed setpoint of the combustion engine. The initiation is done using the "boutstatusword1" status word. Engine Support level 1 is activated if the following applies: The difference between "routenginespeedsetpoint" and "rinengineactspeed" exceeds the threshold value for Engine Support level 1 (rinmaxdifferencespeed/2). The values output in "routhoramptime" and "routgaramptime" can be used to lengthen the startup times of the associated hoisting gear and crane travelling-gear drives. Bit 3 of the status word causes the initiation in this case. Bit 4 initiates the second level. The difference between "routenginespeedsetpoint" and "rinengineactspeed" exceeds the threshold value for Engine Support level 2 (rinmaxdifferencespeed). The startup of the drives can be frozen in the second level. The speed does not further increase. The rounding times of the drives can also be reduced. Bit 5 initiates the third level. The difference between "routenginespeedsetpoint" and "rinengineactspeed" exceeds the threshold value for Engine Support level 3 (1.5 * rinmaxdifferencespeed). Engine Support level 3 can be used to freeze the hoisting gear power, for example. The three-level Engine Support function can also be customized with an application solution. The three bits can be used accordingly as trigger for the initiation. The three-level variant named above serves as user example. Other solutions are conceivable. 48 Operating Instructions, 12/2012

49 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint Figure 4-5 Maximum actual speed deviation diagram Type Parameter Value range 0 to 1,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number Operating Instructions, 12/

50 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint rinprectrlspeedlvl hoisting-gear speed for the precontrol-speed supplementarysetpoint threshold The "rinprectrlspeedlvl" parameter defines a threshold value. This threshold value together with the deflection of the hoisting-gear lifting-direction master switch precontrols the combustion-engine speed. The combustion engine is also already precontrolled when the current speed of the hoisting gear is still negative but the crane driver has already initiated a lifting action with the master switch. Figure 4-6 rinprectrlspeedlvl diagram Type Parameter Value range -3,000 to 3,000 Sign Positive, negative Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number 50 Operating Instructions, 12/2012

51 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint rinhomaxdiff difference between the hoisting-gear speed and the threshold value You can use the "rinhomaxdiff" parameter to specify the maximum permissible deviation between the speed setpoint and the actual speed value of the hoisting gear. If this difference is exceeded, the "rinhoaddprectrlvalue" value is added automatically to the precontrol speed. Figure 4-7 Threshold-value difference diagram Type Parameter Value range 0 to 3,000 Sign Positive, negative Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number See also Chapter rinhoaddprectrlvalue additional speed precontrol setpoint for hoistinggear actions (Page 52). Operating Instructions, 12/

52 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint rinhoaddprectrlvalue additional speed precontrol setpoint for hoisting-gear actions By default, the combustion engine speed is precontrolled corresponding to the set values, via the "rinhoprectrlspeed" input. There are, however, certain situations on the crane that require a larger precontrol value, such as when the hoisting gear is further accelerated while it is still turning. The maximum power of the hoisting gear is then available very quickly. Consequently, for safety reasons, the combustion-engine speed may already be precontrolled in line with a larger value in this case. The "rinhoaddprectrlvalue" parameter defines the value that is added to the normal precontrol speed. Figure 4-8 Additional setpoint diagram Type Parameter Value range 0 to 1,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number See also Chapter rinhomaxdiff difference between the hoisting-gear speed and the threshold value (Page 51). 52 Operating Instructions, 12/2012

53 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint rinhoprectrlspeed precontrol speed for hoisting-gear actions The "rinhoprectrlspeed" parameter defines the precontrol speed for hoisting-gear actions. Precontrol of the combustion-engine speed is always required in cases where the combustion engine should provide a high absolute power and is operating below the speed required for this. This can be the case, for example, when the combustion engine is operating at no-load speed. A hoisting-gear action requires a large amount of electrical power. To accelerate the combustion engine as fast as possible to its required operating speed, the combustionengine speed is precontrolled for the relevant crane actions. The associated precontrol value is output directly as a setpoint. In general, the higher precontrol value dominates. This means that when both initiation conditions for the precontrol are initiated (boinmchoenable and boinmcgaenable) and the values differ (e.g. rinhoprectrlspeed = 1,300 rpm; ringaprectrlspeed = 1,400 rpm), the higher value is output as a speed setpoint to the combustion engine via output "routenginespeedsetpoint"; therefore, this would be 1,400 rpm. Type Parameter Value range 500 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number Notes Sensible precontrol speeds are normally in the 1,200 to 1,800 rpm range. The higher speeds permit the combustion engine to respond to additional power demands caused by electrical drives and consumers on the crane without more significant interruptions. Lower precontrol values such as 1,200 rpm mean lower fuel consumption, but also a reduction in system stability. When ECO technology is deployed for non-lifting applications, the "rinhoprectrlspeed" parameter is used as the first precontrol value. The "ringaprectrlspeed" parameter can be used as second precontrol value. In crane applications, simultaneous operation of hoisting gear and crane travelling gear that is not subject to speed reductions must be checked. The total power from the unlimited hoisting-gear and crane travelling-gear power is normally larger than the power provided by the combustion engine/generator. NOTICE Power limitation The limitation of the individual drive powers is made at the application level. This includes not only the power distributions but also safety-relevant blockings. For example, it may make sense to reduce the crane travelling-gear speed or inhibit the crane travelling gear altogether if the hoisting gear is active. Operating Instructions, 12/

54 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint rinhooffdelaytime combustion-engine delay time after hoisting-gear actions (hoisting) The "rinhooffdelaytime" parameter defines the delay time of the combustion engine after hoisting-gear actions at an increased speed that corresponds to the value of the precontrol speed (rinhoprectrlspeed) for hoisting-gear actions. This prevents stalling the combustion engine in the case of rapidly repeating hoisting-gear actions while the hoisting gear still has a speed greater than zero and so does not need to accelerate from zero speed to the maximum speed first. Type Parameter Value range 0 to 600 Sign Positive Unit Seconds [s] Resolution 32-bit floating-point number rinhoramptimevalue hoisting-gear ramp time (hoist) You can use the "rinhoramptimevalue" parameter to scale the ramp time of the hoistinggear converter. In normal operation, the crane runs with its standard ramp time. This can be, for example, five seconds, which corresponds to 100 percent. To actively prevent stalling the combustion engine, interventions in the ramp time of the hoisting gear may be necessary. In this case, the ramp time is extended to reduce load on the combustion engine and prevent stalling. This is done by passing the set percentage value (rinhoramptimevalue) to the hoistinggear inverter when the support function is initiated. The rinhoramptimevalue of 150 percent so extends the standard ramp time named as example from 5 to 7.5 seconds. The percentage value is forwarded to the hoisting gear when Engine Support level 1 is reached. At the hoisting gear, it must be linked to the project-specific variable. Type Parameter Value range 10 to 1,000 Sign Positive Unit Percent Resolution 32-bit floating-point number Notes The empirical value is 150%. Values under 100% reduce the ramp time in the case of Engine Support; therefore, it does not make sense to use these. 54 Operating Instructions, 12/2012

55 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint rinhoinhibittowingspeed inhibit combustion-engine towing operation for hoisting gear The towing operation of the combustion engine must always be inhibited for certain load situations. You can use the "rinhoinhibittowingspeed" parameter to determine the point from which towing operation for the combustion engine is released. This parameter defines a speed threshold for the hoisting gear. Once the actual speed of the hoisting gear exceeds the threshold set for the "rinhoinhibittowingspeed" parameter, the block logic prevents towing operation automatically, even when the total electrical power of the crane is briefly negative and would initiate a towing operation. This improves the general system safety. Figure 4-9 Inhibit towing operation diagram Type Parameter Value range -3,000 and 3,000 Sign Positive, negative Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number Notes The empirical value is 100 rpm. Operating Instructions, 12/

56 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint ringaprectrlspeed precontrol speed for crane travelling-gear actions The ringaprectrlspeed" parameter defines the precontrol speed for crane travelling-gear movements. Precontrol of the combustion-engine speed is always required in cases where the combustion engine should provide a high absolute power and is operating below the speed required for this. This can be the case, for example, when the combustion engine is operating at no-load speed. A crane travelling-gear action requires a large amount of electrical power. To accelerate the combustion engine as fast as possible to its required operating speed, the combustion-engine speed is precontrolled for the relevant crane actions. The associated precontrol value is output directly as a setpoint. Sensible precontrol speeds are normally in the 1,200 to 1,800 rpm range. The higher speeds permit the combustion engine to respond to additional power demands caused by electrical drives and consumers on the crane without more significant interruptions. Type Parameter Value range 500 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number Notes Refer to the appropriate section in Chapter rinhoprectrlspeed precontrol speed for hoisting-gear actions (Page 53) ringaoffdelaytime combustion-engine delay time after crane travelling-gear actions (gantry) The "ringaoffdelaytime" parameter defines the delay time of the combustion engine after crane travelling-gear movements at an increased speed that corresponds to the value of the precontrol speed (ringaprectrlspeed) for crane travelling-gear actions. This prevents stalling the combustion engine in the case of rapidly repeating additional crane travellinggear actions while the crane travelling gear still has a speed greater than zero and so does not need to accelerate from zero speed to the maximum speed first. Type Parameter Value range 0 to 600 Sign Positive Unit Seconds [s] Resolution 32-bit floating-point number 56 Operating Instructions, 12/2012

57 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint ringaramptimevalue crane travelling-gear ramp time (gantry) You can use the "ringaramptimevalue" parameter to scale the ramp time of the crane travelling-gear converter. In normal operation, the crane runs with its standard ramp time. This can be, for example, eight seconds, which corresponds to 100 percent. To actively prevent stalling the combustion engine, interventions in the ramp time of the crane travelling gear may be necessary. In this case, the ramp time is extended to reduce load on the combustion engine and prevent stalling. This is done by passing the set percentage value (ringaramptimevalue) to the crane travelling-gear inverter when the support function is initiated. The ringaramptimevalue of 150 percent so extends the standard ramp time named as example from 8 to 12 seconds. The percentage value is forwarded to the hoisting gear when Engine Support level 1 is reached. At the hoisting gear, it must be linked to the project-specific variable. Type Parameter Value range 10 to 1,000 Sign Positive Unit Percent Resolution 32-bit floating-point number Notes The empirical value is 150%. Values under 100% reduce the ramp time in the case of Engine Support; therefore, it does not make sense to use these rinmaxposrfgcap value of the maximum positive increase for the preventative intervention of the open-loop control You can use the "rinmaxposrfgcap" parameter to define the positive increase speed of changes to the speed setpoint of the combustion engine at the "routenginespeedsetpoint" output. This takes effect if the following conditions are fulfilled at the same time: The current crane power is greater than or equal to 10 kw The difference between the current speed of the combustion engine and the speed setpoint is greater than 50 rpm The increase of the speed setpoint increments can be further limited for supporting interventions of the ECO software, which are required when the speed setpoint differs greatly from the actual speed. Type Parameter Value range 0 to 5,000 Sign Positive Unit Speed change [rpm] per second [rpm/sec] Resolution 32-bit floating-point number Operating Instructions, 12/

58 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint Notes The value 0 limits the change to zero (no change permitted). The value 5,000 represents the maximum positive change that is then forwarded without delay to the combustion engine. If an error occurs, the new speed setpoint for the combustion engine should be forwarded with the least possible delay to the combustion engine. Consequently, the value 2,500 is used as example rinmaxposrfgstd default value for the maximum positive increase You can use the "rinmaxposrfgstd" parameter to define the positive increase speed of changes to the speed setpoint of the combustion engine at the "routenginespeedsetpoint" output. This increase acts in normal operation. The speed-change increase can be limited should this be required by the application. Type Parameter Value range 0 to 5,000 Sign Positive Unit Speed change [rpm] per second [rpm/sec] Resolution 32-bit floating-point number Notes The value 0 limits the change to zero (no change permitted). The value 5,000 represents the maximum positive change that is then forwarded without delay to the combustion engine rinmaxnegrfgcap value of the maximum negative increase for the preventative intervention of the open-loop control You can use the "rinmaxposrfgcap" parameter to define the negative increase speed of changes to the speed setpoint of the combustion engine at the "routenginespeedsetpoint" output. This takes effect if the following conditions are fulfilled at the same time: The current crane power is greater than or equal to 10 kw The difference between the current speed of the combustion engine and the speed setpoint is greater than 50 rpm This increase acts in the event of an error when the overspeed-protection function is initiated. The increase of the speed setpoint increments can be further changed for supporting interventions of the open-loop control, which are required when the speed setpoint differs greatly from the actual speed. 58 Operating Instructions, 12/2012

59 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint Type Parameter Value range -5,000 to 0 Sign Negative Unit Speed change [rpm] per second [rpm/sec] Resolution 32-bit floating-point number Notes The value 0 limits the change to zero (no change permitted). The value -5,000 represents the maximum negative change that is then forwarded without delay to the combustion engine. If an error occurs, the new speed setpoint for the combustion engine should be output with the least possible delay to the combustion engine. Consequently, the value -2,500 is used as example rinmaxnegrfgstd default value for the maximum negative increase You can use the "rinmaxnegrfgstd" parameter to define the negative increase speed of changes to the speed setpoint of the combustion engine at the "routenginespeedsetpoint" output. This increase acts in normal operation. The speed-change increase can be limited should this be required by the application. Type Parameter Value range -5,000 to 0 Sign Negative Unit Speed change [rpm] per second [rpm/sec] Resolution 32-bit floating-point number Notes The value 0 limits the change to zero (no change permitted). The value -5,000 represents the maximum negative change that is then forwarded without delay to the combustion engine. Operating Instructions, 12/

60 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint Outputs routenginespeedsetpoint speed-setpoint specification for the combustion engine The "routenginespeedsetpoint" output provides the speed setpoint relevant for the combustion engine. This is controlled load-dependent and ensures the correct operation of the ECO application. It requires all parameters to have the correct settings. Type Output Value range 0 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number Target interconnection Project-specific variable combustion-engine speed setpoint Notes SIMOTION must be used to implement the project-specific application software for forwarding the speed setpoint to the combustion engine. An implementation on the CAN bus using additional intermediate steps, such as a SIMATIC S7 programmable logic controller, is not recommended. The speed setpoint must be forwarded to the combustion engine without delay. Increasing the number of involved units increases the cycle time. Experience has shown that a cycle time of 10 ms between SIMOTION and the combustion engine is recommended routmaxtowingspeed combustion-engine speed limitation in towing operation The output supplies the maximum permitted mechanical speed of the combustion engine during towing operation. The output specifies the value that is parameterized at the "rinmaxtowingspeed" input. Type Output Value range 0 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number Target Project-specific variable speed-limitation generator for motorized operation interconnection 60 Operating Instructions, 12/2012

61 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint Notes The objective is that the user makes all ECO-specific settings directly with the ECO software. This prevents multiple interconnection and reduces the complexity because the corresponding limits do not need to be specified in the drive or elsewhere. Interconnection is carried out at the generator drive. Here, the speed for motorized operation can be limited using this value. For additional application notes, see Chapter rinmaxtowingspeed combustion engine maximum towing speed (Page 45) routmaxtowingpower combustion-engine power limitation in towing operation The output supplies the maximum permitted mechanical power of the combustion engine during towing operation. The output specifies the value that is parameterized at the "rinmaxtowingpower" input. Type Output Value range 0 to 100 Sign Positive Unit Power in kilowatt [kw] Resolution 32-bit floating-point number Target Project-specific variable power-limitation generator for motorized operation interconnection Notes The objective is that the user makes all ECO-specific settings directly with the ECO software. This prevents multiple interconnection and reduces the complexity because the corresponding limits do not need to be specified in the drive or elsewhere. Interconnection is carried out at the generator drive. Here, the maximum power for motorized operation can be limited using this value. For additional application notes, see Chapter rinmaxtowingpower combustion engine maximum towing power (Page 46) routhoramptime hoisting-gear ramp time (hoist) You can use the "routhoramptime" output to transfer the factor for scaling the ramp time to the hoisting-gear converter. In normal operation, the crane runs with its standard ramp time. This can be, for example, five seconds, which corresponds to 100 percent. To actively prevent stalling the combustion engine, interventions in the ramp time of the hoisting gear may be necessary. In this case, the ramp time is extended to reduce load on the combustion engine and prevent stalling. This is done by passing the set percentage value (rinhoramptimevalue) to the hoistinggear converter when the support function is initiated. The rinhoramptimevalue of 150 percent so extends the standard ramp time named as example from 5 to 7.5 seconds. The percentage value is forwarded to the hoisting gear when Engine Support level 1 is reached. At the hoisting gear, it must be linked to the project-specific variable. Operating Instructions, 12/

62 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint Type Output Value range 10 to 1,000 Sign Unit Resolution Target interconnection Positive Percent 32-bit floating-point number Project-specific variable hoisting gear ramp time (e.g. on SINAMICS or SIMATIC S7) Notes The empirical value is 150%. Values under 100% reduce the ramp time in the case of Engine Support; therefore, it does not make sense to use these routgaramptime crane travelling-gear ramp time (gantry) You can use the "routgaramptime" output to transfer the factor for scaling the ramp time to the crane travelling-gear converter. In normal operation, the crane runs with its standard ramp time. This can be, for example, eight seconds, which corresponds to 100 percent. To actively prevent stalling the combustion engine, interventions in the ramp time of the crane travelling gear may be necessary. In this case, the ramp time is extended to reduce load on the combustion engine and prevent stalling. This is done by passing the set percentage value (ringaramptimevalue) to the crane travelling-gear converter when the support function is initiated. The rinhoramptimevalue of 150 percent so extends the standard ramp time named as example from 8 to 12 seconds. The percentage value is forwarded to the hoisting gear when Engine Support level 1 is reached. At the hoisting gear, it must be linked to the project-specific variable. Type Output Value range 10 to 1,000 Sign Positive Unit Percent Resolution 32-bit floating-point number Target interconnection Project-specific variable crane travelling-gear ramp time (e.g. on SINAMICS or SIMATIC S7) Notes The empirical value is 150%. Values under 100% reduce the ramp time in the case of Engine Support; therefore, it does not make sense to use these. 62 Operating Instructions, 12/2012

63 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint boutstatusword1 SIMOCRANE status word 1 The "boutstatusword1" output contains the status information for the SIMOCRANE ECO Technology. The individual Boolean signals can be evaluated or visualized, for example, by a Crane Management System or a higher-level controller. The individual bits are assigned as follows in the "True" state: Table 4-1 Bit no. Bit 0 Bit 1 Bit 2 boutstatusword1 Description SIMOCRANE ECO software activated using "boinenable". SIMOCRANE ECO software deactivated automatically because of under-licensing. Purchase and install a SIMOCRANE license. Combustion-engine overspeed reached. Maximum combustion-engine speed defined in parameter "rinenginemaxspeed" reached during operation. Overspeed-protection function of ECO software initiated. Check the installation and mechanical components of the combustion engine. Remove the cause of overspeed being initiated. Bit 3 Bit 4 Bit 5 Bit 6-15 Engine Support level 1 initiated. Engine Support level 2 is initiated if the following applies: The difference between output "routenginespeedsetpoint" and input "rinengineactspeed" exceeds half the threshold value defined in parameter "rinmaxdifferencespeed" (rinmaxdifferencespeed/2). Remove the cause of the combustion-engine overload. Engine Support level 2 initiated. Engine Support level 2 is initiated if the following applies: The difference between output "routenginespeedsetpoint" and input "rinengineactspeed" exceeds the threshold value defined in parameter "rinmaxdifferencespeed" (rinmaxdifferencespeed). Remove the cause of the combustion-engine overload. Engine Support level 3 initiated. Engine Support level 3 is initiated if the following applies: The difference between output "routenginespeedsetpoint" and input "rinengineactspeed" exceeds the threshold value defined in parameter "rinmaxdifferencespeed" by one and a half times (1.5*rInMaxDifferenceSpeed). Remove the cause of the combustion-engine overload. Spare Operating Instructions, 12/

64 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint boutinputerrors1 SIMOCRANE status word 2 The "boutinputerrors1" output forwards the status for the incorrect parameterization of the following parameters. Table 4-2 Bit no. Bit 0 boutinputerrors1 Description rinengineactspeed: If an error occurs, the value 0 rpm is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check data transmission between the combustion engine and SIMOTION. The current actual value for the "rinengineactspeed" input may only be within the defined value range (0 to 3,000). The actual speed of the combustion engine may not be negative. Make sure that a negative value is not provided to the ECO software (for example, when the combustion engine is switched off or started). A corresponding limitation can be set in an additional application within DCC, for example. Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Spare rinextspeedrequest: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check the externally specified speed setpoint that you are issuing to the ECO software via the "rinextspeedrequest" input. This may only be within the defined value range (0 to 3,000). boinmchoenable: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check the interconnection with the "boinmchoenable" input. Only a Boolean variable may be connected here. boingahoenable: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check the interconnection with the "boinmcgaenable" input. Only a Boolean variable may be connected here. rinhospeedsetpoint: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the speed setpoint of the hoisting gear has been correctly wired with the "rinhospeedsetpoint" input. Check whether the value range (-3,000 to 3,000) is being adhered to. 64 Operating Instructions, 12/2012

65 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint Bit no. Bit 6 Description rinhoactspeed: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the actual speed of the hoisting gear has been correctly wired with the "rinhoactspeed" input. Check whether the value range (-3,000 to 3,000) is being adhered to. Bit 7 Bit 8 Bit 9 rinactualcranepower: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the "routactualcranepower" output of the DCC_Speeds block has been correctly wired with the "rinactualcranepower" input of the DCC_Setpoint block. rinenginespeed: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the "routenginespeed" output of the DCC_Speeds block has been correctly wired with the "rinenginespeed" input of the DCC_Setpoint block. rinmaxoperatingspeed: If an error occurs, the value 3,000 is issued as the speed setpoint via the "routenginespeedsetpoint" output in cases where the upper limit of the value range has been violated. If a value that is lower than the lower limit is entered, "500" is output in the event of an error. Check whether the correct parameter setting has been made. Check whether the value range (500 to 3,000) is being adhered to. Bit 10 rinenginemaxspeed: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (500 to 3,000) is being adhered to. Bit 11 rinmaxtowingspeed: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (500 to 3,000) is being adhered to. Operating Instructions, 12/

66 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint Bit no. Bit 12 Description rinmaxtowingpower: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (0 to 100) is being adhered to. Bit 13 rinenginetowingspeed: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (500 to 3,000) is being adhered to. The value in this parameter should be lower than the value in DCC_Speeds "rinspeedvalue1". Bit 14 rinreleasespeedtowing: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (-3,000 to 0) is being adhered to. Bit 15 rinmaxdifferencespeed: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (0 to 1,000) is being adhered to. 66 Operating Instructions, 12/2012

67 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint boutinputerrors2 SIMOCRANE status word 3 The "boutinputerrors2" output forwards the status for the incorrect parameterization of the following parameters. Table 4-3 Bit no. Bit 0 boutinputerrors2 Description rinprectrlspeedlvl: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (-3,000 to 3,000) is being adhered to. Bit 1 rinhomaxdiff: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (0 to 3,000) is being adhered to. Bit 2 rinhoaddprectrlvalue: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (0 to 1,000) is being adhered to. Bit 3 rinhoprectrlspeed: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (500 to 3,000) is being adhered to. Bit 4 rinhooffdelaytime: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (0 to 600) is being adhered to. Bit 5 rinhoramptimevalue: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (10 to 1,000) is being adhered to. Operating Instructions, 12/

68 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint Bit no. Bit 6 Description rinhoinhibittowingspeed: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (-3,000 to 3,000) is being adhered to. Bit 7 Bit 8 Spare ringaprectrlspeed: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (500 to 3,000) is being adhered to. Bit 9 ringaoffdelaytime: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (0 to 600) is being adhered to. Bit 10 ringaramptimevalue: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (10 to 1,000) is being adhered to. Bit 11 Bit 12 Spare rinmaxposrfgcap: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (0 to 5,000) is being adhered to. Bit 13 rinmaxposrfgstd: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (0 to 5,000) is being adhered to. 68 Operating Instructions, 12/2012

69 Parameter assignment/addressing (DCC library) 4.4 DCC_Setpoint Bit no. Bit 14 Description rinmaxnegrfgcap: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (-5,000 to 0) is being adhered to. Bit 15 rinmaxnegrfgstd: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (-5,000 to 0) is being adhered to. Operating Instructions, 12/

70 Parameter assignment/addressing (DCC library) 4.5 DCC_Speeds 4.5 DCC_Speeds Brief description The DCC_Speeds block contains the evaluation and input of power and fuel consumption characteristic curves, referred to as the contour curve diagrams of a combustion engine. Version V1.0 of DCC_Speeds is envisaged for fuel-electrical applications Objective The characteristic curve fields of the combustion engine, referred to as the contour curve diagrams, provide information about the ideal speed at the requested power. These values are used to parameterize the ECO software. The required parameters are entered for the DCC_Speeds block. Note Ensure that you enter the correct values for the polygon parameters! The input parameters must be assigned in ascending order. Proper operation of the block cannot be guaranteed if you do not set the parameters correctly Detailed description The DCC_Speeds block calculates the required combustion-engine speed setpoint using the total electrical power of all consumers for an ECO application. Small power levels can be served by small speeds. Mid-range and high power levels require appropriately higher speeds. The combustion-engine speed varies between the specific no-load speed and the maximum operating speed. The user enters the values for the desired speed for the requested power. The input is based on the technical specifications and documentation of the combustion engine manufacturer (this information must be available). The so-called contour curve diagrams, in particular, provide information about the optimum fuel-saving speed for the associated power. Because the attached generator must be able to provide the required electrical power at the selected speed, the characteristic curve fields for the combustion engine and the generator must match. Great care must be taken with the design to ensure the ECO software works correctly and to maximum effect. 70 Operating Instructions, 12/2012

71 Parameter assignment/addressing (DCC library) 4.5 DCC_Speeds Overview Figure 4-10 DCC_Speeds, connections Inputs rinmaxpower ECO application maximum power You can use the "rinmaxpower" parameter to define the maximum available electrical power of the entire system. This maximum available electrical power must be available from the combustion engine, with losses factored in. The software limits the speed setpoint calculation for the combustion engine to this maximum power. Type Parameter Value range 0 to 1,500 Sign Positive Unit Kilowatt [kw] Resolution 32-bit floating-point number Operating Instructions, 12/

72 Parameter assignment/addressing (DCC library) 4.5 DCC_Speeds rinactualcranepower current total power of all application electrical consumers You must interconnect the current total power of all the electrical consumers in the ECO application with the "rinactualcranepower" input. A positive value implies energy creation by the combustion engine/generator combination. A negative value indicates that the generated energy from the electrical drives exceeds the consumption of the other drives. The DCC_Speeds block evaluates the current power. The ideal speed appropriate for the entered power and speed values of the selected combustion engine is output. It is forwarded to the DCC_Setpoint block via "routenginespeed". Type Input Value range -1,500 to 1,500 Sign Positive, negative Unit Kilowatt [kw] Resolution 32-bit floating-point number Target Project-specific variable total electrical power of all consumers interconnection Notes Braking resistors must always be designed for the full regenerative energy level. Combustion engine towing is not always released. In such cases, the resistors have to absorb all the regenerative energy rinminpower ECO application minimum power You can use the "rinminpower" parameter to define the minimum power to be generated by the generator. This is based on the power requirements of the consumers that are permanently switched on. Type Input Value range 0 to 1,500 Sign Positive Unit Kilowatt [kw] Resolution 32-bit floating-point number Target None interconnection Notes The form, number and power of the auxiliary consumers can vary from application to application. For example, air-conditioners are being used increasingly in warm regions. They increase the minimum power that the combustion engine must provide at all times. The definition of this value ensures the automatic provision of power. This parameter is used to enter the anticipated minimum power value that can be reached by the consumers that are permanently switched on. 72 Operating Instructions, 12/2012

73 Parameter assignment/addressing (DCC library) 4.5 DCC_Speeds rinefficiency efficiency of complete application You use the "rinefficiency" parameter to define the efficiency of the converter assembly and generator in use. When calculating the speed setpoint for the combustion engine in the "routenginespeed" output, the specified losses must be accounted for. For the purpose of operating the connected consumers (e.g. hoisting gear), it is assumed that the combustion engine can provide the required power with any losses taken into account. Type Parameter Value range 75 to 100 Sign Positive Unit % Resolution 32-bit floating-point number Note The empirical value for the SINAMICS converter and generator is 88% rinpowervalue1 power value 1 (X coordinate 1) Combustion-engine characteristic curve field input from the documentation (contour curve diagram). Type Parameter Value range 0 to 1,500 Sign Positive Unit Kilowatt [kw] Resolution 32-bit floating-point number rinspeedvalue1 speed value 1 (Y coordinate 1) Combustion-engine characteristic curve field input from the documentation (contour curve diagram). Type Parameter Value range 0 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number Operating Instructions, 12/

74 Parameter assignment/addressing (DCC library) 4.5 DCC_Speeds rinpowervalue2 power value 2 (X coordinate 2) Combustion-engine characteristic curve field input from the documentation (contour curve diagram). Type Parameter Value range 0 to 1,500 Sign Positive Unit Kilowatt [kw] Resolution 32-bit floating-point number rinspeedvalue2 speed value 2 (Y coordinate 2) Combustion-engine characteristic curve field input from the documentation (contour curve diagram). Type Parameter Value range 0 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number rinpowervalue3 power value 3 (X coordinate 3) Combustion-engine characteristic curve field input from the documentation (contour curve diagram). Type Parameter Value range 0 to 1,500 Sign Positive Unit Kilowatt [kw] Resolution 32-bit floating-point number rinspeedvalue3 speed value 3 (Y coordinate 3) Combustion-engine characteristic curve field input from the documentation (contour curve diagram). Type Parameter Value range 0 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number 74 Operating Instructions, 12/2012

75 Parameter assignment/addressing (DCC library) 4.5 DCC_Speeds rinpowervalue4 power value 4 (X coordinate 4) Combustion-engine characteristic curve field input from the documentation (contour curve diagram). Type Parameter Value range 0 to 1,500 Sign Positive Unit Kilowatt [kw] Resolution 32-bit floating-point number rinspeedvalue4 speed value 4 (Y coordinate 4) Combustion-engine characteristic curve field input from the documentation (contour curve diagram). Type Parameter Value range 0 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number rinpowervalue5 power value 5 (X coordinate 5) Combustion-engine characteristic curve field input from the documentation (contour curve diagram). Type Parameter Value range 0 to 1,500 Sign Positive Unit Kilowatt [kw] Resolution 32-bit floating-point number rinspeedvalue5 speed value 5 (Y coordinate 5) Combustion-engine characteristic curve field input from the documentation (contour curve diagram). Type Parameter Value range 0 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number Operating Instructions, 12/

76 Parameter assignment/addressing (DCC library) 4.5 DCC_Speeds rinpowervalue6 power value 6 (X coordinate 6) Combustion-engine characteristic curve field input from the documentation (contour curve diagram). Type Parameter Value range 0 to 1,500 Sign Positive Unit Kilowatt [kw] Resolution 32-bit floating-point number rinspeedvalue6 speed value 6 (Y coordinate 6) Combustion-engine characteristic curve field input from the documentation (contour curve diagram). Type Parameter Value range 0 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number rinpowervalue7 power value 7 (X coordinate 7) Combustion-engine characteristic curve field input from the documentation (contour curve diagram). Type Parameter Value range 0 to 1,500 Sign Positive Unit Kilowatt [kw] Resolution 32-bit floating-point number rinspeedvalue7 speed value 7 (Y coordinate 7) Combustion-engine characteristic curve field input from the documentation (contour curve diagram). Type Parameter Value range 0 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number 76 Operating Instructions, 12/2012

77 Parameter assignment/addressing (DCC library) 4.5 DCC_Speeds rinpowervalue8 power value 8 (X coordinate 8) Combustion-engine characteristic curve field input from the documentation (contour curve diagram). Type Parameter Value range 0 to 1,500 Sign Positive Unit Kilowatt [kw] Resolution 32-bit floating-point number rinspeedvalue8 speed value 8 (Y coordinate 8) Combustion-engine characteristic curve field input from the documentation (contour curve diagram). Type Parameter Value range 0 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number rinpowervalue9 power value 9 (X coordinate 9) Combustion-engine characteristic curve field input from the documentation (contour curve diagram). Type Parameter Value range 0 to 1,500 Sign Positive Unit Kilowatt [kw] Resolution 32-bit floating-point number rinspeedvalue9 speed value 9 (Y coordinate 9) Combustion-engine characteristic curve field input from the documentation (contour curve diagram). Type Parameter Value range 0 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number Operating Instructions, 12/

78 Parameter assignment/addressing (DCC library) 4.5 DCC_Speeds rinpowervalue10 power value 10 (X coordinate 10) Combustion-engine characteristic curve field input from the documentation (contour curve diagram). Type Parameter Value range 0 to 1,500 Sign Positive Unit Kilowatt [kw] Resolution 32-bit floating-point number Note This value defines the rated power of the combustion engine rinspeedvalue10 speed value 10 (Y coordinate 10) Combustion-engine characteristic curve field input from the documentation (contour curve diagram). Type Parameter Value range 0 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number Note This value defines the highest speed. This should match the maximum speed, which is specified in DCC_Setpoint in the "rinmaxoperatingspeed" parameter. The combustion engine achieves its rated power at this speed. 78 Operating Instructions, 12/2012

79 Parameter assignment/addressing (DCC library) 4.5 DCC_Speeds Outputs routactualcranepower current total power of all application electrical consumers The "routactualcranepower" output supplies the current total power of all electrical consumers for the ECO application. This output must be connected to the "DCC_Setpoint" block. For the exact target interconnection, refer to the following table. A positive value implies energy creation by the combustion engine/generator combination. A negative value indicates that the generated energy from the electrical drives exceeds the consumption of the other drives. The DCC_Speeds block evaluates the current power. The ideal speed appropriate for the entered power and speed values of the selected combustion engine is output. It is forwarded to the DCC_Setpoint block via "routenginespeed". Type Output Value range -1,500 to 1,500 Sign Positive, negative Unit Kilowatt [kw] Resolution 32-bit floating-point number Target interconnection SIMOCRANE V1.0 DCC block setpoint "rinactualcranepower" input Notes Refer to the appropriate section in Chapter rinactualcranepower current total power of all application electrical consumers (Page 72) routenginespeed optimum speed setpoint specification for further calculations The "routenginespeed" output supplies the speed setpoint for the DCC_Setpoint block required for the current crane power. The calculation is made using the parametrized polygon definition. Type Output Value range 0 to 3,000 Sign Positive Unit Revolutions per minute [rpm] Resolution 32-bit floating-point number Target interconnection DCC_Setpoint "rinenginespeed" input; see Chapter rinenginespeed combustion-engine speed specification from the power requirement (Page 43) Operating Instructions, 12/

80 Parameter assignment/addressing (DCC library) 4.6 Interconnection of the DCC blocks 4.6 Interconnection of the DCC blocks Figure 4-11 Example for the DCC blocks interconnection The DCC blocks are interconnected by the user. The parameter values are preassigned during the engineering phase using the selected configuration and design. The inputs and outputs are also linked with the project-specific variables. An optimization is performed during the commissioning. This may change the values of some parameters in order to permit the largest-possible fuel saving while retaining stable operation. 80 Operating Instructions, 12/2012

81 Parameter assignment/addressing (DCC library) 4.7 Setup and uninstallation of the ECO DCC Library 4.7 Setup and uninstallation of the ECO DCC Library The SIMOCRANE package includes a DVD which contains the ECO DCC Library and the standard project. Setup 1. Ensure that all SCOUT and Step 7 programs are closed. 2. Now install the new ECO DCC Library by running the Setup from the DVD. 3. Open your project. 4. Right-click to select "D435-2" and open the settings for "Select Technology Packages". Select the following technology package: TPcrane_eco_dcc_library_SIMOTION_4_3 5. Close the window by clicking "OK". 6. Open a DCC chart then select Options Block Types and delete all imported libraries from the chart by clicking the "<<" button. 7. Import into the DCC chart all libraries installed in SCOUT by clicking the ">>" button and click on "Apply" 8. Save and compile the project. This completes the update of the ECO DCC Library. Uninstallation Select Control Panel Add or Remove Programs and uninstall the "SIMOCRANE ECO Technology" program as shown in the figure below. Figure 4-12 uninstallation Operating Instructions, 12/

82 Parameter assignment/addressing (DCC library) 4.7 Setup and uninstallation of the ECO DCC Library 82 Operating Instructions, 12/2012

83 Alarm, error and system messages Error messages SIMOCRANE is equipped with an error message system. Two different types of messages are available: The ECO software status is issued via Statusword1. In addition, ECO software can recognize incorrect parameterizations via both the InputErrors1 and InputErrors2 words. Pending errors are displayed with a logical one. A manual reset can be carried out as soon as the error has been corrected by the user. The reset is only possible when the cause of the error has been resolved. The ECO functions are deactivated as long as the error is pending. Instead, the speed setpoint specified as the fixed speed setpoint in "rinmaxoperatingspeed" is passed to the combustion engine. If errors occur with respect to "rinmaxoperatingspeed" or "rinengineactspeed", ensure that other speed setpoints are issued. In an error occurs in "rinmaxoperatingspeed", 3,000 rpm is issued via "routenginespeedsetpoint" in cases where the upper limit of the value range has been violated. On the other hand, 500 rpm is issued as soon as the lower limit of "rinmaxoperatingspeed" is violated. If an error occurs in "rinengineactspeed", the value 0 rpm is issued as the speed setpoint via the "routenginespeedsetpoint" output for safety reasons. It can be acknowledged as soon as the error has been corrected. Once it has been acknowledged successfully, the ECO functions are reactivated and a variable setpoint is issued. Operating Instructions, 12/

84 Alarm, error and system messages 5.2 boutstatusword1 SIMOCRANE status word boutstatusword1 SIMOCRANE status word 1 The "boutstatusword1" output contains the status information for the SIMOCRANE ECO Technology. The individual Boolean signals can be evaluated or visualized, for example, by a Crane Management System or a higher-level controller. The individual bits are assigned as follows in the "True" state: Table 5-1 Bit no. Bit 0 Bit 1 Bit 2 boutstatusword1 Description SIMOCRANE ECO software activated using "boinenable". SIMOCRANE ECO software deactivated automatically because of under-licensing. Purchase and install a SIMOCRANE license. Combustion-engine overspeed reached. Maximum combustion-engine speed defined in parameter "rinenginemaxspeed" reached during operation. Overspeed-protection function of ECO software initiated. Check the installation and mechanical components of the combustion engine. Remove the cause of overspeed being initiated. Bit 3 Bit 4 Bit 5 Bit 6-15 Engine Support level 1 initiated. Engine Support level 2 is initiated if the following applies: The difference between output "routenginespeedsetpoint" and input "rinengineactspeed" exceeds half the threshold value defined in parameter "rinmaxdifferencespeed" (rinmaxdifferencespeed/2). Remove the cause of the combustion-engine overload. Engine Support level 2 initiated. Engine Support level 2 is initiated if the following applies: The difference between output "routenginespeedsetpoint" and input "rinengineactspeed" exceeds the threshold value defined in parameter "rinmaxdifferencespeed" (rinmaxdifferencespeed). Remove the cause of the combustion-engine overload. Engine Support level 3 initiated. Engine Support level 3 is initiated if the following applies: The difference between output "routenginespeedsetpoint" and input "rinengineactspeed" exceeds the threshold value defined in parameter "rinmaxdifferencespeed" by one and a half times (1.5*rInMaxDifferenceSpeed). Remove the cause of the combustion-engine overload. Spare 84 Operating Instructions, 12/2012

85 Alarm, error and system messages 5.3 boutinputerrors1 SIMOCRANE status word boutinputerrors1 SIMOCRANE status word 2 The "boutinputerrors1" output forwards the status for the incorrect parameterization of the following parameters. Table 5-2 Bit no. Bit 0 boutinputerrors1 Description rinengineactspeed: If an error occurs, the value 0 rpm is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check data transmission between the combustion engine and SIMOTION. The current actual value for the "rinengineactspeed" input may only be within the defined value range (0 to 3,000). The actual speed of the combustion engine may not be negative. Make sure that a negative value is not provided to the ECO software (for example, when the combustion engine is switched off or started). A corresponding limitation can be set in an additional application within DCC, for example. Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Spare rinextspeedrequest: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check the externally specified speed setpoint that you are issuing to the ECO software via the "rinextspeedrequest" input. This may only be within the defined value range (0 to 3,000). boinmchoenable: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check the interconnection with the "boinmchoenable" input. Only a Boolean variable may be connected here. boingahoenable: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check the interconnection with the "boinmcgaenable" input. Only a Boolean variable may be connected here. rinhospeedsetpoint: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the speed setpoint of the hoisting gear has been correctly wired with the "rinhospeedsetpoint" input. Check whether the value range (-3,000 to 3,000) is being adhered to. Operating Instructions, 12/

86 Alarm, error and system messages 5.3 boutinputerrors1 SIMOCRANE status word 2 Bit no. Bit 6 Description rinhoactspeed: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the actual speed of the hoisting gear has been correctly wired with the "rinhoactspeed" input. Check whether the value range (-3,000 to 3,000) is being adhered to. Bit 7 Bit 8 Bit 9 rinactualcranepower: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the "routactualcranepower" output of the DCC_Speeds block has been correctly wired with the "rinactualcranepower" input of the DCC_Setpoint block. rinenginespeed: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the "routenginespeed" output of the DCC_Speeds block has been correctly wired with the "rinenginespeed" input of the DCC_Setpoint block. rinmaxoperatingspeed: If an error occurs, the value 3,000 is issued as the speed setpoint via the "routenginespeedsetpoint" output in cases where the upper limit of the value range has been violated. If a value that is lower than the lower limit is entered, "500" is output in the event of an error. Check whether the correct parameter setting has been made. Check whether the value range (500 to 3,000) is being adhered to. Bit 10 rinenginemaxspeed: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (500 to 3,000) is being adhered to. Bit 11 rinmaxtowingspeed: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (500 to 3,000) is being adhered to. 86 Operating Instructions, 12/2012

87 Alarm, error and system messages 5.3 boutinputerrors1 SIMOCRANE status word 2 Bit no. Bit 12 Description rinmaxtowingpower: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (0 to 100) is being adhered to. Bit 13 rinenginetowingspeed: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (500 to 3,000) is being adhered to. The value in this parameter should be lower than the value in DCC_Speeds "rinspeedvalue1". Bit 14 rinreleasespeedtowing: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (-3,000 to 0) is being adhered to. Bit 15 rinmaxdifferencespeed: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (0 to 1,000) is being adhered to. Operating Instructions, 12/

88 Alarm, error and system messages 5.4 boutinputerrors2 SIMOCRANE status word boutinputerrors2 SIMOCRANE status word 3 The "boutinputerrors2" output forwards the status for the incorrect parameterization of the following parameters. Table 5-3 Bit no. Bit 0 boutinputerrors2 Description rinprectrlspeedlvl: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (-3,000 to 3,000) is being adhered to. Bit 1 rinhomaxdiff: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (0 to 3,000) is being adhered to. Bit 2 rinhoaddprectrlvalue: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (0 to 1,000) is being adhered to. Bit 3 rinhoprectrlspeed: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (500 to 3,000) is being adhered to. Bit 4 rinhooffdelaytime: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (0 to 600) is being adhered to. Bit 5 rinhoramptimevalue: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (10 to 1,000) is being adhered to. 88 Operating Instructions, 12/2012

89 Alarm, error and system messages 5.4 boutinputerrors2 SIMOCRANE status word 3 Bit no. Bit 6 Description rinhoinhibittowingspeed: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (-3,000 to 3,000) is being adhered to. Bit 7 Bit 8 Spare ringaprectrlspeed: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (500 to 3,000) is being adhered to. Bit 9 ringaoffdelaytime: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (0 to 600) is being adhered to. Bit 10 ringaramptimevalue: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (10 to 1,000) is being adhered to. Bit 11 Bit 12 Spare rinmaxposrfgcap: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (0 to 5,000) is being adhered to. Bit 13 rinmaxposrfgstd: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (0 to 5,000) is being adhered to. Operating Instructions, 12/

90 Alarm, error and system messages 5.4 boutinputerrors2 SIMOCRANE status word 3 Bit no. Bit 14 Description rinmaxnegrfgcap: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (-5,000 to 0) is being adhered to. Bit 15 rinmaxnegrfgstd: If an error occurs, the value in the "rinmaxoperatingspeed" parameter is issued as the speed setpoint via the "routenginespeedsetpoint" output. Check whether the correct parameter setting has been made. Check whether the value range (-5,000 to 0) is being adhered to. 90 Operating Instructions, 12/2012

91 ECO RTG standard application 6 You can find a standard application for an ECO RTG crane on the product DVD. This standard application comprises ready-to-use configured application software. This solution is "ready-to-run" for users who only want to set the necessary parameters. This can be considered a "ready-to-apply" basis for large-scale adaptations and expansions, offering a high degree of expansibility and flexibility. The application description in this chapter aims to help the user to correctly carry out the interconnections between the controller, drive, and combustion engine. Scope of functions This chapter describes Basic Technology function modules and their interaction with the two DCC blocks. The application software has a modular structure. An overview of function modules, their operating modes, and the most important technology functions used is shown in the tables in this chapter. You can find more information in the Operating Instructions for SIMOCRANE Basic Technology, Chapter 1. Table 6-1 Overview, function modules, axes and operating modes Function module Number of axes Control mode Modes of operation Hoist 1 Speed-controlled Positioning Trolley 1 Speed-controlled Positioning AUTOMATIC MANUAL SPEED_CONTROLLED (jogging) SWAYCONTROL EASY_POSITIONING AUTOMATIC MANUAL SPEED_CONTROLLED (jogging) SENSORLESS EMERGENCY SWAYCONTROL EASY_POSITIONING Gantry 4 Speed-controlled MANUAL SENSORLESS EMERGENCY EASY_POSITIONING Only the most important crane-specific technology functions are shown in the following table: Operating Instructions, 12/

92 ECO RTG standard application Table 6-2 Overview, crane-specific technology functions No. Function/block Brief description 1 Load-dependent field weakening/ DCC_LoadDependField Weak_1/ DCC_LoadDependingField Weak 2 Prelimit switch (selectable limiting)/ DCC_PreLimitSwitch Using this DCC block, a supplementary speed setpoint is calculated dependent on the load. This speed increase for partial loads above the rated speed is required for cranes to increase the handling capacity. The velocity of the drive can be influenced using this DCC block when a predefined pre-limit switch is reached. 3 Start pulse/dcc_startpulse_1/ DCC_StartPulse 4 Master switch/dcc_masterswitch_1/ DCC_MasterSwitch 5 Overspeed monitoring/ DCC_OverSpeed 6 Setpoint monitoring/ DCC_Monitoring 7 Time-optimized positioning for a single axis 8 Master-slave closed-loop torque control Using this DCC block, "load sag" when starting hoisting gear with a suspended load is either prevented or reduced. Using this DCC block, the drive can be moved with a fine sensitivity for manual positioning using a master switch, which is directly connected. For hoisting gear applications, using this DCC block, an overspeed condition is monitored or a setpoint-actual value deviation is detected (this is not a fail-safe function). This DCC block is used to monitor whether the velocity, acceleration or deceleration have been reduced. Further, it is monitored whether the drive is in field weakening. Using this system function, the drive can be moved to the target position as quickly as possible with the specified maximum velocity and acceleration/deceleration. Master-slave operation is used if two motors are connected to a common shaft. The master operates either closed-loop position controlled or closed-loop speed controlled depending on the operating mode. The slave only operates closed-loop torque controlled. The master sends the torque as torque setpoint to the slave. 9 Synchronous operation Synchronous operation control is used if two motors are connected to a common load. Depending on the operating mode, the master and slave operate either closed-loop position controlled or closed-loop speed controlled. The slave receives a speed or position setpoint depending on the operating mode from the master via a gear (gear ratio 1 : 1). The functional scope has been expanded with the implementation of flying homing, offset compensatory control and offset mode. 10 Basic positioner This is a positioning that does not use a position controller of the axis but rather FB_OperationMode is calculated in the FB library; it is suitable for systems that tend to be subject to mechanical vibrations, such as a rope-drawn trolley on STS cranes. 92 Operating Instructions, 12/2012

93 ECO RTG standard application 6.1 Precondition Application of crane-specific technology Function module Crane-specific technology Hoist Time-optimized positioning Basic positioning Load-dependent field weakening Start pulse Switchover of the ramp-function generator in the field-weakening range and when selecting heavy-duty operation Prelimit switch Non-linear setpoint of the master switch Brake test Trolley Time-optimized positioning Basic positioning Switchover of the ramp-function generator in the field-weakening range and when selecting heavy-duty operation Prelimit switch Non-linear setpoint of the master switch Traction control Flying referencing Brake test Gantry Time-optimized positioning Basic positioning Switchover of the ramp-function generator in the field-weakening range and when selecting heavy-duty operation Non-linear setpoint of the master switch Prelimit switch 6.1 Precondition SIMATIC STEP 7 Version 5.5 SIMOTION SCOUT Version 4.3 SIMOCRANE Basic Technology V3.0 ECO V1.0 Basic knowledge of SIMATIC STEP 7 and SIMOTION SCOUT Operating Instructions, 12/

94 ECO RTG standard application 6.2 Hardware configuration 6.2 Hardware configuration SIMOTION Our application example uses communication via PROFINET. An I-Device must be configured in SIMOTION. The combustion engine is connected to SIMATIC via a CAN PN converter. If a fast CPU is not available (cycle time > 20 ms), a direct connection between the combustion engine and SIMOTION is recommended. Figure 6-1 I-Device in SIMOTION HW config 94 Operating Instructions, 12/2012

95 ECO RTG standard application 6.2 Hardware configuration Note You can find information about generating an I-Device in the online help for hardware configuration. Figure 6-2 I-Device in SIMATIC HW config You can now add this I-Device to the SIMATIC hardware configuration. In addition to the I- Device, our example also includes a CAN PN converter connected to PROFINET. Operating Instructions, 12/

96 ECO RTG standard application 6.3 Interface (communication) 6.3 Interface (communication) Note The complete communication between SIMATIC, SIMOTION, and SINAMICS will not be presented in this chapter; only the expansions for the ECO RTG application will be discussed. The basis for communication between SIMATIC, SIMOTION, and SINAMICS is presented in the SIMOCRANE Basic Technology V3.0 Operating Instructions. The communication between the higher-level SIMATIC S7 controller and the drive-related SIMOTION D435-2 DP/PN controller is established via PROFIBUS DP/PROFINET RT (up to max. 32 PZD for each drive). Up to 244 bytes per direction can be transferred using PROFIBUS DP. Up to 1,400 bytes per direction can be transferred using PROFINET RT. The SINAMICS Control Unit drive is integrated in the drive-based SIMOTION D. Communication between both (SIMOTION and SINAMICS) works in the same way as with PROFIBUS DP, but with Motion Control expansion up to a maximum of 32 PZD per drive (according to the PROFIdrive profile for drive technology). SIMOTION DP/PN has three PROFIBUS DP interfaces (two DP interfaces and one DP integrated interface). The communication for PROFIBUS operation between SIMATIC and SIMOTION D435-2 DP/PN for Basic Technology is configured on DP 1. Communication between SIMOTION and SINAMICS is permanently configured on integrated DP. In PROFIBUS operation, the DP 2 interface is reserved for communication between SIMATIC and SIMOTION D435-2 DP/PN involving the pendulum control system or other options. Note PROFIBUS and PROFINET, PROFIdrive Profile Drive Technology, PROFIBUS User Organization e. V. Haid-und-Neu-Straße 7, D Karlsruhe order no Version 4.0 August 2005 See SIMOCRANE SC standalone Operating Instructions, edition 01/2012 on the pendulum control system SIMOTION D435-2 DP/PN has two PROFINET interfaces (an integrated PN interface with three ports and an interface with the CBE20-2 options board) and assumes the role of a PROFINET I/O controller. The communication between SIMATIC and SIMOTION D435-2 DP/PN for Basic Technology and Advanced Technology is configured at port 1 for PROFINET RT operation. Note The definition of the frame for Advanced Technology is not part of this documentation. 96 Operating Instructions, 12/2012

97 ECO RTG standard application 6.3 Interface (communication) Task distribution The following list provides an overview of task distribution between SIMATIC S7, SIMOTION, and SINAMICS. SIMATIC S7: Overview of the crane I/O signal processing Control of infeed Safety-related monitoring Setpoint and control commands for main drives Setpoint and control commands for auxiliary drives Brake control (optional) SIMOTION: Crane technology in DCC Setpoint generator, position control, synchronous operation, and communication with the drives in the TO Communication with SIMATIC and SINAMICS in Motion Control Chart (MCC) Sequence control (monitoring, use of Operation Mode, troubleshooting, etc.) in MCC Additional crane-specific functions in MCC, such as cornering movement, brake test, flying homing, offset mode, auto-setting, etc. The use of a Web-based tool (WebStart) for commissioning and diagnostics is possible as of version Basic Technology V3.0. SINAMICS: Speed control Current control Monitoring, if required Brake control (optional) Requirements In order to establish disturbance-free communication between these three parties, the reference data in SIMATIC, SIMOTION, and SINAMICS modules must be identically configured. The reference data must be normalized to the maximum data. The following parameters are involved in the modules: Operating Instructions, 12/

98 ECO RTG standard application 6.3 Interface (communication) SIMATIC: Reference speed Reference voltage Reference current Reference torque Reference power SIMOTION: TypeOfAxis.SetPointDriverInfo.DriveData.maxSpeed: Drive speed TypeOfAxis.MaxVelocity.maximum: Maximum permitted velocity value MCC Interface "axis"_nominalvelocity, _nominalcurrent, _nominalvoltage, _nominaltorque, _nominalpower SINAMICS: p2000 = reference speed reference frequency ( p1082 = maximum speed) p2001 = reference voltage p2002 = reference current p2003 = reference torque r2004 = reference power Note All reference data must be normalized to their particular maximum value: nmax = 100 % = nrated + nfw (maximum speed = rated speed + field weakening speed) IMax = 100 % = Irated + Ioverload (maximum current = rated current + overload current) MMax = 100 % = Mrated + Moverload (maximum torque = rated torque + overload torque) Note A script is created to fetch all reference values from the SINAMICS and enter them in SIMOTION; also refer to the SIMOCRANE Basic Technology V3.0 operating instructions, Chapter "Commissioning > General", "Script files" section The definition for the relationship between the percentage value and hexadecimal value is shown in the following table and in the following diagram. If only positive values are used in the process data, then the value range is doubled; this means that the range starts at 0 and can be increased up to 65,535 (UINT, 0 to FFFF). 98 Operating Instructions, 12/2012

99 ECO RTG standard application 6.3 Interface (communication) Table 6-3 Relationship between hexadecimal value and percentage value 1 word: Connector Percentage value Hexadecimal value 0 16# # #7FFF # #C #1 Figure 6-3 Representing the value range of a word After the coupling has been established, data transfer between SIMATIC and SIMOTION must be configured. 16 process data items must be configured for every node (TO). The address areas for communication between SIMATIC and SIMOTION are defined as follows in the document "CraneSoft-7". Drives PROFIBUS address I/O address area Hoist Hoist Trolley Trolley Crane travelling gear Crane travelling gear Crane travelling gear Crane travelling gear Application extensions Operating Instructions, 12/

100 ECO RTG standard application 6.3 Interface (communication) SIMATIC S7 SIMOTION Table 6-4 Additional communication from SIMATIC to SIMOTION PZD Signal name Unit Remarks See the SIMOCRANE Basic Technology V3.0 Operating Instructions 15 Steering setpoint % Additional setpoint for the crane travelling gear in the RTG project 16 Application_control_word_3_S7 - See below, table "Application_control_word_3_S7" 17 Speed controller gain factor Kp % Adjustment of the speed controller adaptation limits for Kp 18 Speed controller integral time Tn % Adjustment of the speed controller adaptation limits for Tn Free - Free Figure 6-4 Diagram of the traversing direction 100 Operating Instructions, 12/2012

101 ECO RTG standard application 6.3 Interface (communication) Table 6-5 Application_control_word_3_S7 Bit Signal name 1 signal 0 Enable rampfunction generator 1 Ramp-function generator bypass steering 0 signal Remarks Yes No The ramp-function generator is enabled for the steering function with the high signal. Yes No The ramp-function generator is bypassed for the steering function with the high signal. 2 Droop enable Yes No The droop function in SINAMICS is enabled with the high signal. 3 Bit slave selection for master crane travelling gear 1 4 Bit slave selection for master crane travelling gear 3 5 Free Yes No Free Free Yes No Free Yes No The slave of crane travelling gear 1 is selected with the high signal (only travelling gear 2 or travelling gear 4). Yes No The slave of crane travelling gear 3 is selected with the high signal (only travelling gear 2 or travelling gear 4). Note Travelling gear 1 and travelling gear 3 are always masters in the application. Travelling gear 2 and travelling gear 4 are slaves of travelling gear 1 or travelling gear 3 depending on the wheel position. SIMOTION SIMATIC S7 Table 6-6 Additional communication from SIMOTION to SIMATIC PZD Signal name Unit Remarks See the SIMOCRANE Basic Technology V3.0 Operating Instructions 15 Set acceleration % Set acceleration 16 Application_status_word_3_S7 - See below, Table "Application_status_word_3_S7" 17 Current setpoint velocity according to ramp-function generator 18 Current setpoint velocity according to position controller % Current setpoint velocity according to ramp-function generator without steering signal for crane travelling gear % Current setpoint velocity according to position controller for trolley Free - Free Operating Instructions, 12/

102 ECO RTG standard application 6.3 Interface (communication) Table 6-7 Application_control_word_3_S7 Bit Signal name 1 signal 0 signal 0 Free Yes No Free 1 Free Yes No Free 2 Free Yes No Free 3 Slave connected to master travelling gear 1 4 Slave connected to master travelling gear 3 5 Free Yes No Free Free Yes No Free Remarks Yes No The high signal is used to show that the slave is connected to the master travelling gear 1 (only travelling gear 2 or travelling gear 4). Yes No The high signal is used to show that the slave is connected to the master travelling gear 3 (only travelling gear 2 or travelling gear 4). Selecting master-slave operation Master-slave operation is selected with a high signal. This signal executes a leading/following drive function (rigid coupling). The selection is described in detail in the "Master-slave operation control mode" chapter in the SIMOCRANE Basic Technology V3.0 Operating Instructions. Table 6-8 Selecting master-slave operation Control word/status word Bit Description Master (e.g. Crane_travelling _gear_1) Application_control_word _1 Application_control_word _2 Selecting master-slave operation TRUE 13 SlaveMode FALSE TRUE Slave (e.g. Crane_travelling_ gear_2) TRUE Table 6-9 Master-slave operation feedback Control word/ status word Application_control_word _1 Application_control_word _2 Bit Description Master (e.g. Crane_travelling_ gear_1) Message, master- TRUE slave operation active 13 SlaveModeActive FALSE TRUE Slave (e.g. Crane_travelling _gear_2) TRUE 102 Operating Instructions, 12/2012

103 ECO RTG standard application 6.3 Interface (communication) Table 6-10 Communication between SINAMICS AUX converter and SIMOTION PZD Description Parameter no. Parameter value 1 Status word 1 P r Not used P Not used P Status word 2 P r Output voltage smoothed P r25 6 Output frequency P r66 7 Output current smoothed P r27 8 Current fault P r Current warning P r Not used P Not used P Temperature converter P r37(0) 13 Not used P Output voltage P r72 15 Output current P r68(0) 16 Output power smoothed P r82(1) Not used In status word 1, bit 14 deviates from the default setting and is connected to the internal "pulse frequency OK" signal from the DCC chart of the converter. Table 6-11 Communication between SIMOTION and SINAMICS AUX converter PZD Description Parameter no. Parameter value 1 Control word 1 ON/OFF1 P840 r Control word 1 OFF2 P844 r Control word 1 reset P2103 r Control word 1 pulse enable P852 r Voltage setpoint P r Not used Table 6-12 Communication between SINAMICS generator converter and SIMOTION PZD Description Parameter no. Parameter value 1 Status word 1 P r & 3 Speed actual value P r Status word 2 P r Output voltage smoothed P r25 6 DC link voltage smoothed P r26 Operating Instructions, 12/

104 ECO RTG standard application 6.3 Interface (communication) PZD Description Parameter no. Parameter value 7 Output current smoothed P r Not used 12 Maximum temperature converter P r37(0) 13 Output power smoothed with p45 P r82(1) 14 Motor temperature P r35 15 Torque-generating current setpoint P r77 16 Output current P r68(1) 17 Engine torque P r80(1) 18 Speed setpoint/actual-value difference P r64 19 Speed setpoint P r62 20 Output voltage P r72 21 Current fault P r Current warning P r Torque-generating actual current value P r79 24 Speed controller integral action time P r Output power smoothed with 100 ms P r Not used Table 6-13 Communication between SIMOTION and SINAMICS generator converter PZD Description Parameter no. Parameter value 1 Control word 1 as motor as motor 2-7 Not used 8 Additional voltage setpoint P3511 r or r2050.8; see description 9-31 not used 104 Operating Instructions, 12/2012

105 ECO RTG standard application 6.4 Description of the standard application 6.4 Description of the standard application The application example is based on SIMOTION D435-2 PN. Communication with the crane controller is via PROFINET. A SIMATIC S7 319 PN is used as a controller. Communication with the combustion engine is achieved in SIMATIC S7 via a PROFINET CAN bus converter. In addition to the standard configuration of SIMOCRANE for the drives, three other frames are used here for controlling the ECO functionality: engine, generator, and auxiliary. Engine SIMOTION -> S7 The data for the combustion engine is transferred to this frame. Because each manufacturer makes different data available, the frame format can differ. The following data is relevant for to function correctly. The speed setpoint (r32engine_speed_set) is sent from SIMOTION to S7 on word 2. In S7, the value must be converted to the correct format for the combustion engine in question, and then forwarded to the combustion engine via the CAN PN converter. Note Communication to the combustion engine is established via CAN bus. The frame format differs depending on the manufacturer. The user is therefore required to create a suitable frame. To provide additional options to avoid stalling when using a weak combustion engine, there are factors to extend the ramp time for the hoisting gear and crane travelling gear if the setpoint/actual-value difference of the combustion engine is too large. This factor is transferred to word 5 for the hoisting gear and word 6 for the crane travelling gear. It can be between 100 and 300 and must be connected using the application with the ramp times for the drives in the controller. Bit 3 is also set in status word 2. If this intervention is still not sufficient and the setpoint/actual-value difference of the combustion engine continues to increase, then bit 4 is set in status word 2, which means that further interventions in the crane's power consumption can be initiated, e.g. the velocity can be frozen. If this intervention is also not sufficient and the setpoint/actual-value difference continues to increase, then bit 5 is set in status word 2, which means that, for example, the drives can be shut down. Status word 2 is sent to the controller on word 7. Information about incorrect parameter values is sent to the controller on words 8 and 9. S7 -> SIMOTION The current velocity of the combustion engine is sent to SIMOTION on word 2. The remaining combustion-engine values are not used for in this version. Operating Instructions, 12/

106 ECO RTG standard application 6.4 Description of the standard application Generator The standard frame for a drive is used for communicating with the generator. The user only receives information about this if a different frame assignment has been used. SIMOTION -> S7 Word 15 inverter temperature Word 16 generator temperature S7 -> SIMOTION Word 4 additional setpoint for DC-link voltage Word 5 external speed setpoint for the combustion engine Word 9 ECO control word The generator is controlled using the "GeneratorControl" program. The scaling values must be entered in the program's interface area. The "Gen_enable_DCvoltage" and "Gen_enable_speed" values may also have to be adapted to the combustion engine/generator block. You set the lower limits, above which the generator can be switched on. Gen_enable_DCvoltage : REAL := 150; Gen_enable_speed : REAL := 500; Generator_1_NominalSpeed : REAL := 2000; // of p2000 Generator_1_NominalVoltage : REAL := 1000; // of p2001 Generator_1_NominalCurrent : REAL := 885; // of p2002 Generator_1_NominalPower : REAL := 400; // of p2004 The DC-link set point is specified in SINAMICS parameter p3510. It is also possible to specify an additional setpoint via the controller. This is transferred to SIMOTION on word 4 of the controller. It is also possible to either override this setpoint directly, or smooth it using a ramp-function generator. This is achieved through the selection for parameter p3511. If r2050(7) is connected, the value is used directly; for r2050(8), the value comes in the DCC chart GeneratorD_1 via a ramp-function generator. The external speed setpoint can be used to specify a fixed speed for the combustion engine in service operation, for instance. The generator is switched on using bit 0 from control word 1 of SIMATIC S7. Bits 1 and 2 of the control word can be fixed to "1". Bit 3 is used to deactivate the generator for a test mode. It must normally be set to "1". 106 Operating Instructions, 12/2012

107 ECO RTG standard application 6.4 Description of the standard application Auxiliary SIMOTION -> S7 Word 1 status word. Only bits 0, 1, 2, and 9 are used. Bit 0: Converter running and no off is activated Bit 1: Output voltage > 360 V Bit 2: Converter running Bit 9: Control requested Word 3 status word 2 from converter. Word 4 error and warning word from the converter Word 5 output frequency Word 7 output current Word 8 output voltage Word 9 output power Word 10 power unit temperature S7 -> SIMOTION Word 1 control word to the converter. Only two bits are used. Bit 6 is used to specify a reduced output voltage This can be necessary, for example, to reduce the inrush current when connecting a transformer. Bit 7 is used for acknowledging SINAMICS errors. The auxiliary converter controller is processed in SIMOTION in the "Auxiliary" program. It is switched on using fixed specified limits. Some parameters must be pre-assigned in the variable definition area. Auxiliary_OutputVoltage : REAL := 440.0; // Output voltage setpoint Reduced_OutputVoltage : REAL := 390.0; // Reduced output voltage Aux_1_NominalVoltage : REAL := 250.0; // of p2001 Aux_1_NominalFrequency : REAL := 60.0; // of p2000 Aux_1_NominalCurrent : REAL := 200.0; // of p2002 Aux_1_NominalPower : REAL := 75.0; // of r2004 The value from "Aux_1_NominalFrequency" is specified as the nominal frequency. Operating Instructions, 12/

108 ECO RTG standard application 6.4 Description of the standard application Commissioning Overview Note Polarity The polarity rules must be observed: Hoisting gear: Lifting velocity is POSITIVE and the position values are ascending. Lowering velocity is NEGATIVE and the position values are descending. Travelling gear: Travelling to the right, the velocity is POSITIVE and the position values are ascending. Travelling to the left, the velocity is NEGATIVE and the position values are descending. Trolley: Travelling forwards, the velocity is POSITIVE and the position values are ascending. Travelling backwards, the velocity is NEGATIVE and the position values are descending. Two concepts for commissioning 1. The required functionality of the actual crane goes beyond the standard application. The user is very knowledgeable about SIMOTION/SINAMICS and is in a position to adapt the existing standard application "ready-to-apply" to the requirements. 2. The standard application covers the functional requirements of the actual crane. The user is not so knowledgeable about SIMOTION/SINAMICS and user is supplied with a "readyto-run" standard configuration. This only has to be downloaded into SIMOTION D435 and then commissioning can start. The "ready-to-run" procedure is described in this chapter. 108 Operating Instructions, 12/2012

109 ECO RTG standard application 6.4 Description of the standard application You can find an overview regarding the commissioning sequence in the following diagram: Figure 6-5 Commissioning overview Requirements WARNING Hazardous voltage The system must be in a no-voltage state when checking the subsequently described prerequisites for commissioning All DRIVE-CLiQ nodes must be connected with one another precisely as was created in the project (reference and actual topology must match). The commissioning engineer is responsible for ensuring that the motors are correctly connected. The encoder must be correctly connected. Only connect in parallel drives of the same type and manufacturer in order to guarantee identical drive data and symmetrical load distribution. Master-slave-coupled motors must have the same reference variables, i.e. p2000, p2001, p2002, p2003 and r2004. Note The complete commissioning steps are described in Chapter 8 of the "SIMOCRANE Basic Technology V3.0" Operating Instructions. These must be adhered to during commissioning. Operating Instructions, 12/

110 ECO RTG standard application 6.4 Description of the standard application Setting instructions for the Motor Module and generator Once the emergency-stop circuits for the combustion engine and controller have been checked, the commissioning of the generator can be started. Below is a description of how to commission a generator (in this case: Siemens 1PH8) with SINAMICS Motor Module: 1. In the configurator: Figure 6-6 Control structure settings Activate the "Technology controller" and "Extended messages/monitoring" function modules Select "Speed controller (with encoder)" 110 Operating Instructions, 12/2012

111 ECO RTG standard application 6.4 Description of the standard application 2. For the device connection voltage, select the lowest possible voltage depending on the Motor Module (p0210 is limited internally). The device connection voltage can only be reduced after parameter p0212 has been adapted. Figure 6-7 Drive settings Operating Instructions, 12/

112 ECO RTG standard application 6.4 Description of the standard application 3. Motor type: Synchronous motor, permanently excited Figure 6-8 Motor settings 112 Operating Instructions, 12/2012

113 ECO RTG standard application 6.4 Description of the standard application 4. Enter the motor data according to the rating plate Figure 6-9 Setting the motor data Operating Instructions, 12/

114 ECO RTG standard application 6.4 Description of the standard application 5. Enter the motor data according to the list Figure 6-10 Setting the optional motor data 114 Operating Instructions, 12/2012

115 ECO RTG standard application 6.4 Description of the standard application Figure 6-11 Settings for the motor data equivalent circuit diagrams Operating Instructions, 12/

116 ECO RTG standard application 6.4 Description of the standard application 6. Activate complete calculation of the motor/controller data (later optionally via expert list) Figure 6-12 Activating complete calculation 116 Operating Instructions, 12/2012

117 ECO RTG standard application 6.4 Description of the standard application 7. Select the connected encoder. Figure 6-13 Selecting the encoder 8. Leave the rest of the items set to the defaults or select the frame corresponding to the hardware configuration. Operating Instructions, 12/

118 ECO RTG standard application 6.4 Description of the standard application Settings via expert list p (Flying restart is always active) p (Torque control) p3422 Set to the value for the total connected capacitance in the DC link. Capacitance examples: Motor Module MLFB Capacitance Generator 6SL3720-1TE mf Hoist drive 6SL3720-1TE mf Braking unit 6SL3720-1TE mf Auxiliary 6SL3120-1TE mf p3510 (DC-link voltage setpoint in volts) Optimize the closed-loop control for the DC link via p3560 (Vdc closed-loop controller proportional gain) and p3562 (Vdc closed-loop controller integral time). The value of p3560 should be in the value range 60% - 200% and the value of p3562 should be in the range 50% - 90%. Procedure 1. Enter the generator data according to the data sheet. 2. Preset the standard frame assignment for switching on (control word and status word). 3. Set the parameters for the DC-link voltage closed-loop control (cancel enabling of torque closed-loop control, DC-link voltage setpoint and disabling of voltage-controlled operation). 4. Adjust the switch-on and the offset of the commutation angle offset p0431 in 60 increments until the generator no longer drops out with an encoder error Commissioning the infeed A SINAMICS S120 Motor Module in chassis frame size is provided for the infeed. The Motor Module increases the alternating voltage generated by the generator to a stabile set value for the DC link. The following steps must be carried out during commissioning: 1. Enter the generator data from the data sheet. 2. Select the standard frame for presetting the switch-on (control word and status word). 3. Set the parameters for the DC-link voltage closed-loop control (cancel enabling of torque closed-loop control, DC-link voltage setpoint and disabling of voltage controller operation). 4. Set the current limit to ZERO (p0640 = 0, make a note of the old setting). 5. Activate travel to a fixed stop to eliminate errors (p1545 = 1). 6. Obtain operating rights via the operator panel (activate "ENABLE"). 118 Operating Instructions, 12/2012

119 ECO RTG standard application 6.4 Description of the standard application 7. Turn drive with a velocity of approx. 250 rpm. The velocity should be greater than the speed stored in the motor model changeover speed for encoderless operation (p1755). 8. Switch the drive on, the drive turns with "IN OPERATION WITHOUT CURRENT". 9. Read out the current value of the motor model flux angle differential in parameter r The new commutation angle is calculated as follows: p r1778 = p Stop the drive and switch it off via the operator panel (deactivate "ENABLE"). 12. Set parameter p0010 to 4 "Encoder commissioning", then enter the newly calculated value (see above) in parameter p Set parameter p0010 to 0 "Ready". 14. Set current limit p0640 to the old value. 15. Deactivate travel to fixed stop, reset p1545 = Save RAM to ROM. If the commissioning steps indicated above do not produce the desired result, you can try using the steps detailed below: 1. Set current limit p0640 to a small value to avoid torque surges. 2. Change commutation angle p0431 in 60 increments until no errors occur during switchon. 3. Take a reading of motor model flux angle differential r1778 in operation and add it to commutation angle p0431. (The drive must be stopped and p0010 = 4) 4. Set parameter p0010 to 0 "Ready". 5. Reset current limit p0640 back to the old value and check motor model flux angle differential r Save RAM to ROM. Note Phase relation The trim does not work if the phase relation is incorrect. Then swap the phase sequence with p1820 = 1 or swap the cable on the converter. Operating Instructions, 12/

120 ECO RTG standard application 6.4 Description of the standard application Commissioning the auxiliary power supply frequency converter Because always calculates the optimum speed for the required power, the generator frequency which is produced is constantly changing. A fixed frequency is however necessary so that the auxiliary power supply can work without failures. As the voltage generated by the converter is nonsinusoidal, a sine-wave filter is required for operation. We also recommend using a transformer downstream of the sine-wave filter. The auxiliary power supply frequency converter is operated in "U/f control" mode with independent voltage setpoint (parameter p1300 = 19). The voltage setpoint for the U/f characteristic curve must be specified separately using the ram-function generator of the technology controller so that the magnetizing current of the transformer does not cause an overcurrent error. The setpoint for the frequency must be fixed. The hardware selection and the parameter settings must match each other so that no resonant circuit problems occur. In this application example, an interlock has been programmed in a DCC block to make sure that the pulse enable is not changed by external influences. If the pulse frequency does not correspond to the specified value, the impulse is locked. CAUTION Incorrect pulse frequencies or filters In principle, the user is solely responsible for the design of their electrical components. Incorrect pulse frequencies or incorrect selection of the filter can cause damage to or failure of components. 120 Operating Instructions, 12/2012

121 ECO RTG standard application 6.4 Description of the standard application Commissioning the ECO software Set the parameters according to the combustion-engine data sheet. This allows you to find the optimum speed for the load range in question. The optimum speed for the required power is entered using a polyline. Figure 6-14 Speed setpoint Check the interconnection of the total power of the generator. For the ECO closed-loop control to function correctly, the generator power must have a positive sign in infeed operation. This must be checked for small loads. For example, at the "rinactualcranepower" input of the DCC_Speeds block. Check the minimum and maximum speed of the combustion engine. The minimum and maximum speed of the combustion engine should be approached at a low load to check whether the mechanical design of the drive train is correct and whether there are any mechanical vibrations. Operating Instructions, 12/

122 ECO RTG standard application 6.4 Description of the standard application SIMOCRANE WebStart SIMOCRANE WebStart is a Web-based tool, i.e. the tool is accessed using a Web browser, such as Internet Explorer. The physical connection to the controller is established via Ethernet, e.g. using a crossover Ethernet cable for direct connection. A notebook that normally serves as client is used essentially only as terminal. You can commission the ECO DCC blocks using WebStart. Note See also the chapter on SIMOCRANE WebStart in the SIMOCRANE Basic Technology V3.0 Operating Instructions Operation and optimization Once a check has been carried out to see whether the ECO closed-loop control is functioning correctly in no-load operation, optimization with load can begin. The parameters of the DCC_Setpoint block from DCC chart GeneratorD_1 are responsible for optimization with load. The rules regarding the sign must be observed to ensure the correct functioning of the block. We recommend that you start with large values for the precontrol and reduce them gradually so as not to overload the combustion engine. If the combustion engine has a maximum speed of 1,800 rpm, for example, then a precontrol speed "rinhoaddprectrlspeed" of 1,600 rpm should be used and an additional speed "rinhoaddprectrlvalue" of 150 rpm for accelerating. The "rinmaxposrfgstd" and "rinmaxnegrfgstd" values limit the rate of change of the setpoint, taking into consideration the actual speed of the combustion engine. Select a large value for the "rinmaxposrfgstd" parameter when you start optimization so that the combustion engine can react quickly to any changes in load. The easiest way of evaluating the behavior of the combustion engine is to carry out a trace recording. The following parameters from the DCC chart GeneratorD_1 DCC_Setpoint object are recommended for this. rinactualcranepower rinengineactspeed rinhoactspeed routenginespeedsetpoint boutstatusword1 Different combustion engines also supply a value for the utilization percentage of the engine. This value also provides good information about the combustion engine reserve to optimize the values. The value for the current crane power should be somewhat smoothed to avoid large jumps. In this example, r32 is used for the generator power and has been smoothed with 100 ms [p2051(24) = 32]. 122 Operating Instructions, 12/2012

123 ECO RTG standard application 6.4 Description of the standard application In the example application, a logic is also implemented, which only changes the precontrol speed in stages. A speed setpoint is only increased if it is at least 20 rpm below the current speed setpoint. It is only lowered if the new speed setpoint is 50 rpm below the current speed setpoint. Figure 6-15 Changing the precontrol speed in stages Operating Instructions, 12/