s SIMOREG DC Master 6RA70 Series Application SIMOREG as a field supply unit Microprocessor-Based Converters from 6kW to 2500kW for Variable-Speed DC Drives Edition 03
Edition 03 04.05 NOTE This application documentation does not purport to handle or take into account all of the equipment details or versions or to cover every conceivable operating situation or application. If you require more detailed information, or if special problems occur, which are not handled in enough detail in this document, please contact your local Siemens office. The contents of this application documentation are not part of an earlier or existing agreement or legal contract and neither do they change it. The actual purchase contract represents the complete liability of the A&D Variable-Speed Drives Group of Siemens AG. The warrant conditions, specified in the contract between the two parties, is the only warranty which will be accepted by the A&D Variable-Speed Drives Group. The warranty conditions specified in the contract are neither expanded nor changed by the information provided in this application documentation. WARNING These converters contain hazardous electrical voltages and control rotating mechanical components (drives). Death, serious bodily injury or substantial damage to property will occur if the instructions in the relevant operating manuals are not observed. Only qualified personnel who are thoroughly familiar with all safety notices contained in the operating instructions as well as erection, operating and maintenance instructions must be allowed to work on these devices. Successful and safe operation of this equipment is dependent on careful transportation, proper storage and installation as well as correct operation and maintenance. The reproduction, transmission or use of this document or contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved. We have checked that the contents of this publication agree with the hardware and software described herein. Nonetheless, differences might exist and therefore we cannot guarantee that they are completely identical. The information given in this publication is reviewed at regular intervals and any corrections that might be necessary are made in the subsequent printings. Suggestions for improvement are welcome at all times. SIMOREG is a registered trademark of Siemens Siemens AG 2000-2005 All rights reserved
04.05 Edition 03 0 Contents 1 Applications 4 2 Block Diagrams 5 2.1 Version 1: Field supply with an internal setpoint 5 2.2 Version 2: Field supply with an external setpoint 6 2.3 Version 3: Field supply + armature supply 7 3 Parameter Lists 8 3.1 Version 1: Field supply with an internal setpoint 8 3.2 Version 2: Field supply with an external setpoint 8 3.3 Version 3: Armature supply + field supply 9 3.4 Armature supply + field supply + field reversal 10 4 Startup, Optimization 11 4.1 Version 1: Field supply with an internal setpoint 11 4.2 Version 2: Field supply with an external setpoint 11 4.3 Version 3: Armature supply + field supply 11 5 Overvoltage Protection 12 5.1 General information 12 5.2 Protection using varistors 14 5.3 Protection using thyristor modules 15 5.4 Damping resistors Rs 16 5.5 Magnetic field energy for Siemens motors 16 Page Siemens AG 3-18
Edition 03 04.05 1 Applications The SIMOREG DC Master devices of the 6RA70 series are used for the armature and field supply of DC motors. The internal half-controlled bridge circuit of the field power section permits supply to motors with up to 40 A (85A with 6RA7096 and higher, 2200 to 3000 A armature current) rated field current. If higher field supply currents are required, you can use a 6RA70 one-quadrant unit. In that case, the fully controlled threephase bridge circuit normally intended for the armature supply is used for the field supply. Here are four different applications: Version 1: Version 2: Version 3: Version 4: The 6RA70 unit functions completely autonomously. A fixed internal field current setpoint is set. Field weakening is not possible. The 6RA70 unit is given an external analog field current setpoint. Field weakening can have an external source with this setpoint. The field supply unit (slave) functions in conjunction with a 6RA70 armature supply unit (master). Signals are exchanged via a peer-to-peer interface. The armature unit generates the current setpoint for the field supply unit and receives the current actual value and fault signals from it. Field weakening, incl. automatic optimization, is possible. As for version 3, but including field reversal In order to allow contactless switchover, the field supply unit must be designed as a 4Q device! In all four cases, it is not necessary to activate option S00. This application is valid as of firmware version V1.9 WARNING If the armature power section is used for the field supply, always include overvoltage protection to protect the converter valves because if the input voltage fails the energy in the field circuit cannot be reduced. Please note that the overvoltage protection must be effective in both polarities for version 4 with field reversal! So as not to load the overvoltage protection unnecessarily, ensure that the field current is already 0 when setting the pulse inhibit, e.g. by activating the zero-speed excitation because otherwise the residual energy of the field has to be eliminated via the overvoltage protection. 4-18 Siemens AG
04.05 Edition 03 2 Block Diagrams 2.1 Version 1: Field supply with an internal setpoint 3AC Field supply 1U1 1V1 1W1 3U1 3W1 X171:34 Switchover to zero-speed field Switch-on X171:36 X171:37 X171:38 Ramp-function generator Speed controller Torque limitation Current controller Precontrol Armature control set Armature current control Field current setpoint (P401) Field control set Field current control EMF controller Precontrol Current limitation Current controller Precontrol 1C1 (1D1) 1D1 (1C1) M Overvoltage protection Siemens AG 5-18
Edition 03 04.05 2.2 Version 2: Field supply with an external setpoint 3AC Field supply 1U1 1V1 1W1 3U1 3W1 X171:34 Switchover to zero speed field Switch-on X171:36 X171:37 X171:38 Ramp-function generator Speed controller Torque limitation Current controller Precontrol Armature control set Armature current control External field current setpoint X174:4 Field control set Field current control EMF controller Precontrol Current limitation Current controller Precontrol 1C1 (1D1) 1D1 (1C1) M Overvoltage protection 6-18 Siemens AG
04.05 Edition 03 2.3 Version 3: Field supply + armature supply 2AC 400V 3AC 3AC Armature supply 1U1 1V1 1W1 3U1 3W1 Field supply 1U1 1V1 1W1 3U1 3W1 Ramp-function generator Speed controller Torque limitation Current controller Precontrol Armature control set X171:34 X171:37 X171:38 Ramp-function generator Speed controller Torque limitation Current controller Precontrol Armature control set Armature current control X172 Peer-to-peer X172 56 link 58 Armature current control Field current 57 59 Field current control EMF controller Current limitation Current controller Precontrol Precontrol Field control set Field current actual value 58 59 56 57 Field current control EMF controller Torque limitation Current controller Precontrol Precontrol Field control set 1C1 (1D1) 1D1 (1C1) 1C1 (1D1) 1D1 (1C1) M Overvoltage protection Siemens AG 7-18
Edition 03 04.05 3 Parameter Lists 3.1 Version 1: Field supply with an internal setpoint Field supply unit P076.001 Adaptation device rated DC armature. = Normalization of the actual field current P076.002 Adaptation device rated DC field. Setting irrelevant because not used. P078.001 Setting of line-to-line power section rated system voltage P079 1 P082 0 P083 4 P084 2 P100 P102 P153 3 P179 >0 Enable long pulses armature trigger set. Required with field supply from the armature terminals Internal field not used Speed actual value freely interconnectable Current-controlled operation Rated armature current = In that case, the exciter current of the motor Setting irrelevant because not used Required with large inductances at the armature terminals Additional alpha W pulses (approx. 3...7). Depending on the magnitude of the inductance. P401 Setpoint operating field 100% = Nominal device current of the armature circuit P402 Setpoint zero-speed field 100% = Nominal device current of the armature circuit P430.001 B0010 Injection zero-speed field via binary input Term.X171: 36 1... zero-speed field P431.001 K0402 Routing setpoint zero-speed field P433 K0401 Routing setpoint operating field P601.003 K0209 Routing field current setpoint P609 K0000 Source speed actual value P820.007 42 Masking of fault message "Tacho fault" P821.001 35 Masking of alarm message "Drive blocked" 3.2 Version 2: Field supply with an external setpoint Field supply unit P076.001 Adaptation device rated DC armature. = Normalization of the actual field current P076.002 Adaptation device rated DC field. Setting irrelevant because not used. P078.001 Setting of line-to-line power section rated system voltage P079 1 P082 0 P083 4 P084 2 P100 P102 P153 3 P179 >0 P402 Enable long pulses armature trigger set. Required with field supply from the armature terminals Internal field not used Speed actual value freely interconnectable Current-controlled operation Rated armature current = In that case, the exciter current of the motor Setting irrelevant because not used Required with large inductances at the armature terminals Additional alpha W pulses (approx. 3...7). Depending on the magnitude of the inductance. Current setpoint for zero-speed field. 100% = Nominal device current of the armature circuit P430.001 B0010 Injection zero-speed field via binary input Term.X171: 36 1... zero-speed field P431.001 K0402 Routing setpoint zero-speed field P433 K0011 Routing setpoint operating field. Analog setpoint from Term.X174: 4 P601.003 K0209 Routing field current setpoint P609 K0000 Source speed actual value P820.007 42 Masking of fault message "Tacho fault" P821.001 35 Masking of alarm message "Drive blocked" 8-18 Siemens AG
04.05 Edition 03 3.3 Version 3: Armature supply + field supply Armature supply unit Field supply unit P076.001 Adaptation device rated DC armature P076.001 Adaptation device rated DC armature. = Normalization of the actual field current P076.002 Adaptation device rated DC field CAUTION! Do not change factory setting! P078.001 Adaptation of line-to-line power section rated system voltage P078.002 not used P078.002 not used P081 0 or 1, as required, EMF-dependent field weakening P082 24 External field power module, ON via signal "Auxiliaries ON " P076.002 Adaptation device rated DC field. Setting irrelevant because not used. P078.001 Adaptation of line-to-line power section rated system voltage P079 1 P082 0 P083 4 Enable long pulses armature trigger set. Required with field supply form the armature terminals Internal field not used Speed actual value freely interconnectable P084 1 Speed-controlled operation P084 2 Current-controlled operation P094 P097 0 OFF delay of the auxiliaries The time set here must be longer than the time entered in P258 for the field current reduction. Field current setpoint set to zero in response to fault message (available as of software version V2.13) P097 1 Field current setpoint not set to zero in response to fault message, but no increase in field current setpoint is permitted P102.001 rated field current Settable up to 600 A as of software version V2.03 P257.001 Zero-speed field The value should be left as FS=0.0 because no energy then has to be eliminated via the overvoltage protection when the field supply unit is switched off. P258.001 Delay time with aut. field current reduction The time set here must be shorter than the time entered in P094 for the OFF delay of the auxiliaries. P612 K6001 Actual excitation current value from field supply unit via peer-to-peer P655.001 B6200 Trigger "OFF 2" with fault of the field supply unit P102.001 Setting irrelevant because not used P153.001 3 Required with large inductances at the armature terminals P179.001 >0 Additional Alpha W pulses with enabled second pulses (approx. 3...7) Depending on the magnitude of the inductance. P601.003 K6001 Field current setpoint P609 K0000 Source speed actual value P654.001 B6200 ON command P661.001 B6200 Pulse enable P790 5 Peer-to-peer selection P790 5 Peer-to-peer selection P791 2 Number of words transmitted P791 2 Number of words transmitted P793 8 Recommended baudrate P793 8 Recommended baudrate P795 1 Bus termination ON P795 1 Bus termination ON P794.001 K0268 Field current setpoint P794.001 K0117 Absolute value of actual field current P794.002 K6020 Routing auxiliaries "ON" P794.002 K6020 Routing fault bit P797 0.3-0.5s Telegram failure time. If a fault occurs when the electronics supply is switched on during initialization Set a longer time P797 0.3-0.5s Telegram failure time. If a fault occurs when the electronics supply is switched on during initialization Set a longer time U117.001 B0251 Auxiliaries "ON" U117.001 B0107. Routing fault bit P820.007 5 Masking of fault message "Fault in the field circuit" P820.007 42 Masking of fault message "Tacho fault" U838 xxxx Rated direct current of external field unit according to P821.001 35 Masking of alarm message "Drive blocked" parameter r072.2 of external field unit Siemens AG 9-18
Edition 03 04.05 NOTICE If a fault occurs on the field supply unit, the armature supply unit is switched off with "OFF 2" (voltage disconnection). 3.4 Armature supply + field supply + field reversal The following settings must be made in addition to those shown in Subsection 3.3: P580.1 Bxxxx Source for command "Direction of rotation reversal using field reversal" Section 8 / Sheet G200 P581.1 Bxxxx Source for command "Braking with field reversal" Section 8 / Sheet G200 U117.002 B260 Selection field torque direction 1 U117.003 B261 Selection field torque direction 2 P180.001 K0001 +100% pos. current limit for field direction 1 P181.001 K0000 0% neg. current limit for field direction 1 P182.001 K0000 0% pos. current limit for field direction 2 P183.001 K0003-100% neg. current limit for field direction 2 P500.001 K0193 Excitation current setpoint after limitation P601.003 134 Divergent from Subsection 3.3, set factory setting K0134 here P644.001 K6001 Excitation current setpoint of armature device P671.001 B6201 B260 of armature device, enable pos. direction of rotation P672.001 B6202 B261 of armature device, enable neg. direction of rotation P694.001 B6202 B261 of armature device, switchover torque limits 10-18 Siemens AG
04.05 Edition 03 4 Startup, Optimization NOTE If, during optimization for feedforward control and closed-loop current control, the value range of P110 (armature circuit resistance > 32.767Ohms) or of P111 (armature circuit inductance > 327.67mH) is exceeded, the maximum possible value is entered in the relevant parameter and output at the end of optimization F050. You can then read the details in the monitoring parameter r047 (display of the fault diagnostic memory). P155 (armature controller P-gain) and P156 (armature controller reset time) are always correctly set despite that. Optimization should be repeated with a warm field winding because the resistance of the field circuit largely depends on the operating temperature. 4.1 Version 1: Field supply with an internal setpoint Setting of the parameters acc. to the list from Section 3.1 Perform optimization for feedforward control and current controller (P051=25) For procedure to follow, see Section 7.5 of the instruction manual of the 6RA70. 4.2 Version 2: Field supply with an external setpoint Procedure as in Section 4.1 4.3 Version 3: Armature supply + field supply Setting of the parameters acc. to the list from Section 3.2 Exception: P179. This parameter must not be set until the current controller has been optimized (applies to firmware versions up to and including V2.0). Please keep to the following sequence when performing automatic optimization: Field supply unit Procedure: Connect P654 and P661 with B0421. Start optimization for feedforward control and current controller, i.e. set P051=25 Input commands "Start" and "Enable operation" by specifying P421=1 (avoids the need to activate the armature supply unit, optimization run can be aborted with P421=0 if required). Wait for the end of the optimization run. Set optimum values for P161 and P179, check current suppression using oscilloscope or the Trace Monitor (Trace2 / U_armature) (component of SIMOVIS or DriveMonitor) Check the optimization run settings, optimize again afterwards if required by assessing the step response or recording the control loop parameters using an oscilloscope or Trace Monitor. Siemens AG 11-18
Edition 03 04.05 Armature supply unit Procedure: P082=0 Set for the duration of the optimization run P051=25 because the internal field is not used and cannot therefore be optimized. Secure the field control unit against switch-on, e.g. by setting P421=B0000 P051=25 Perform optimization run for feedforward control and current controller (armature). P082 Set back to the original value. P654/P661 of the field control unit to be set to B0001 (permanent enable of the field control unit). P051=26, 27, 28, 29 Perform optimization runs for speed controller, field weakening, and friction or inertia compensation, as required (see the instruction manual for 6RA70 Section 7.5) Check the optimization run settings, optimize again afterwards if required by assessing the step response or recording the control loop parameters using an oscilloscope or Trace Monitor. P654/P661 of the field control unit to be set back to B6200. Additional settings if required, process-oriented commissioning. 5 Overvoltage Protection 5.1 General information WARNING Overvoltage protection is absolutely necessary in this application because, for example, in the event of a power failure the thyristors block and an overvoltage arises due to the energy contained in the field (switch-off of an inductor). That can cause destruction of the thyristors in the SIMOREG unit. The overvoltage protection therefore has the task of limiting the voltage to a defined value and to eliminate the energy contained in the field. The following protective circuit components are available: SIOV metal oxide varistors (for low field currents) Thyristor modules Silicon carbide varistors NOTICE Metal oxide varistors (SIOV, MOV, ZnO,...) are designed to discharge high-energy pulses very quickly. The energy is converted to heat, stored in the volume of the varistor and slowly dissipated via the varistor surface. As they are less thermally conductive than silicon carbide varistors and more sensitive to thermal overloads, metal oxide varistors are very restricted in their application for the high energies and long time constants typical of energy dissipation in an excitation circuit. (The voltage-limiting capability of a varistor subjected to thermal overload will be permanently impaired. Repeated thermal overloading may destroy the varistor as there is a risk that the limiting voltage will drop to the operating voltage range). It is also necessary to use a damping resistor Rs which has the purpose of damping the overvoltages that arise with a small direct current due to the intermittent current chopping, oscillation, or undershooting of the protection thyristor holding current. 12-18 Siemens AG
04.05 Edition 03 Maximum limiting voltage for rating overvoltage protection Maximum permissible limiting voltage dependent on motor field winding (maximum limiting voltage for Siemens motors is 2000 V), and the rated supply voltage for the converter, the lower value must be selected. Rated supply voltage for 6RA70 converter at 1U1, 1V1, 1W1 3AC Limiting voltage DC 400V 1350V 460V, 575V 1550V 690V 1700V 830V 2100V 950V 2500V Magnetic energy content of field winding for rating overvoltage protection The energy content for Siemens motors is shown in Subsection 5.5; if the energy content is not known, it can be calculated on the basis of the field winding inductance. W = L * I exc 2 /2, R exc = U exc / I exc, L = 2 * W / I exc 2, W : Magnetic energy content in watt seconds L : Inductance of field winding in henry I exc : Rated excitation current in amperes (see motor rating plate) R exc : Resistance of excitation winding in ohms U exc : Rated excitation voltage in volts (see motor rating plate) Siemens AG 13-18
Edition 03 04.05 5.2 Protection using varistors 6RA70 Field supply unit 1C1 1D1 Rs Varistor U Field winding Rs...Damping resistor Metal oxide varistors with low energy content of field winding: Up to 420 V rated supply voltage (for 400 V 6RA70 units): Up to 400 : Varistor SIOV-B32K460 made by Epcos: http://www.epcos.com Up to 2000 : Varistor SIOV-B80K460 Up to 500 V rated supply voltage (for 460 V and 575 V 6RA70 units) Up to 400 : Varistor SIOV-B32K550 Up to 2000 : Varistor SIOV-B80K550 Silicon carbide varistors with high energy content of field winding: Silicon carbide varistors can be supplied, for example, by Conradty in Nuremberg. Silicon carbide varistors (e.g. of type series 820SB) are disk-shaped and can be connected in series or parallel depending on the voltage and current requirement. There are no standard types. Dimensioning is a service offered by Conradty and requires the following data: Application Type of converter circuit (B6C) Network voltage (nominal value + tolerance) Mean value of the output direct voltage Rated field current/voltage Magnetic field energy Maximum limitation voltage Frequency of operating cycles Operating duration Ambient temperature Source: C. Conradty Nürnberg GmbH & Co.KG D-90549 Röthenbach Postfach 1263 Tel: +49 (0)911 5708-0 Fax: +49 (0)911 5708-211 (Status November 2004) 14-18 Siemens AG
04.05 Edition 03 5.3 Protection using thyristor modules 6RA70 Field supply unit 1C1 1D1 Rs BOD Rv + - Field winding Rv...Series resistor (if required) Rs...Damping resistor The following thyristor protection modules can be supplied by Siemens: Up to 420 V rated supply voltage (for 400 V 6RA70 units): Order number: E89110-F2439-L1 (suitable for both current directions, 4Q) Up to 500 V rated supply voltage (for 460 V and 575 V 6RA70 units): Order number: E89110-B2350-L1 (suitable for one current direction 1Q. Two must be used in inverseparallel connection for 4Q). The resistors Rs and Rv are not supplied with the thyristor protection modules. Thyristor protection modules are used in fields with an energy content > 2000 and field currents up to approx. 500A. They are only suitable for protection in the event of a fault. If an overvoltage arises, the thyristor is fired via a BOD element (breakover diode) and remains conductive until the field energy has been eliminated and the holding current of the thyristor is exceeded. In order to prevent the field unit from supplying the gated thyristor when the supply recovers, the automatic restart function for the 6RA70 should be deactivated (set P086 = 0). The following values are required to dimension the suppressor network: Largest operating load current Time constant τ of the free-wheeling circuit L τ = R L Inductance of the field winding of the motor [H] R Summated resistance field winding + supply leads + series resistance (if required) [Ω] τ Time constant [s] The magnitude of current and duration of current flow together determine the thermal load of the protection thyristor. For the permissible currents depending on the time constant and information for rating a series resistance, see the instruction manual for the overvoltage protection module E89110. Documentation can be obtained from: SIEMENS ERL F98 SEDM Frauenauracherstrasse 98 D - 91056 Erlangen Tel: +49 (0)9131 18 82329 Fax: +49 (0)9131 18 84463 (Status November 2004) Siemens AG 15-18
Edition 03 04.05 5.4 Damping resistors Rs Dimensioning for B6C circuit: 1.35 UL [V] RS [ Ω ] 0.5 [A] 2 UFN [V] PV [W] = 2...3 RS [ Ω] UL... Line-to-line voltage at three-phase AC connection of converter PV...Power loss of RS UFN...Nominal field voltage 5.5 Magnetic field energy for Siemens motors Mean values of magnetic field energy [] with full excitation and forced-air cooling: 1GF 1GF 1GF 1GF 1GF... 5 102 3,5... 5 112 5,5... 5 132 21 5 162 45 6 162 115 5 104 5... 5 114 8,5... 5 134 30 5 164 60 6 164 150 5 106 7... 5 116 12... 5 136 35 5 166 75 6 166 190 5 108 10... 5 182 100... 6 186 185 5 252 340 6 256 540 5 312 730... 5 184 125... 6 188 220 5 254 430 6 258 690 5 314 910... 5 202 140... 6 206 250 5 282 480 6 286 780 5 352 980... 5 204 170... 6 208 300... 5 284 600 6 288 950 5 354 1190... 5 222 220... 6 226 360... 5 224 280... 6 228 450... 7 351 850... 7 401 1400... 5 402 1220... 7 451 1350... 5 500 1260... 7 352 960... 7 402 1650... 5 404 1500... 7 452 1650... 5 501 1740... 7 353 1200... 7 403 1850... 5 406 1700... 7 453 2000... 5 502 2060... 7 354 1380... 7 404 2200... 7 454 2400... 5 503 2480... 7 355 1710... 7 405 2700... 7 455 3100... 5 504 3070... 5 631 2740... 5 632 3430... 5 633 4140... 5 634 4680... 5 635 5890 16-18 Siemens AG
04.05 Edition 03 Siemens AG 17-18
Edition 03 04.05 SIMEA Siemens Industrial Manufacturing Engineering and Applications PO Box 83, A-1211 Wien Siemens AG, 2000-2005 Subject to change without prior notice SIMOREG DC Master Application of SIMOREG as a field supply unit Printed in Austria