14 Common Syn0 S

Commissioning Common Functions
Comm_Common page 01
SITRAIN / METAL ACADEMY
Siemens AG 2011 - all rights reserved
DR-SM150
page 02
List of Contents
1.1 Required Software-Tools ........................................................................................ 6
1.2 Drive Firmware ....................................................................................................... 8
1.3 Structure and Content of the CFC ......................................................................... 10
1.4 Getting the PG/PC Installation ready to handle the SM150-project ...................... 12
1.5 Registering Library FBA121 .................................................................................. 14
1.6 Getting the Project ready for the download to the CFC ........................................ 18
1.7 Downloading the Project ........................................................................................ 20
1.9 Exemplary SM150 Application ............................................................................... 22
1.10 Drive Devices, Components and Topology of a typical Project ............................ 24
1.11 Project with three Power Sections in parallel ........................................................ 26
2.1 Checking Cabling and Voltage Supplies ............................................................... 28
2.2 Checking the Communication Network in HW-Config ...................................... 30
2.3 Rebooting the Controllers ...................................................................................... 32
2.4 Checking the Communication Network in NetPro ............................................ 34
2.5 Setting the IP-Address on the PG/PC .................................................................... 36
2.6 Assigning the PG/PC to ETHERNET in NetPro .................................................... 38
2.7 Going Online to D445 and Downloading the Drive Devices ................................. 40
2.8 Defaulting the DC-Master and setting the Node-Address via PMU ...................... 44
2.9 Going Online and Downloading the Project Data via Drive Monitor ..................... 46
2.10 Adapting Parameters to particular Plant Conditions ............................................. 52
2.11 Loading the OP177 ................................................................................................ 56
2.12 General Content and Structure of the DCC-charts ................................................ 66
2.13 Assigning the Code to activate DCC-charts ........................................................ 68
2.14 Clearing faults and alarms on behalf of the DC-Master ........................................ 78
2.15 Clearing faults and alarms (on behalf of the ET200 stations) ............................... 84
2.16 Forcing a control command via ET200 .................................................................. 92
2.18 Adding field messages to the fault monitoring ....................................................... 104
2.19 Selection of the active cooling pump ..................................................................... 108
2.20 Defining properties for the ET200 analog modules ............................................... 112
2.21 Controlling the drives operation via OP177 .......................................................... 114
2.22 Stamping the Power Stack Adapters (PSA) .......................................................... 116
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1.4 Getting the PG/PC Installation ready to handle the SM150-project ...................... 12
1.5 Registering Library FBA121 .................................................................................. 14
1.6 Getting the Project ready for the download to the CFC ........................................ 18
1.7 Downloading the Project ........................................................................................ 20
1.9 Exemplary SM150 Application ............................................................................... 22
1.10 Drive Devices, Components and Topology of a typical Project ............................ 24
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page 01
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1.1 Required Software-Tools ........................................................................................ 6
1.2 Drive Firmware .......................................................................................................
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Comm_Common page 03
Training Rack
ET200 Motor
ET200 Auxiliaries
Control
Electronics
Synchronous Motor
with Induction Motor
DC-Master
Motor
Module
G120 Load Generator Infeed
OP177
Bus Coupler
DR-SM150
page 04
Preface
This training section covers all essential steps of commissioning a SM150 medium voltage converter as used in
rolling-mill applications.
With the inevitable exception of the medium voltage hardware the SM150 training unit is equipped with the same
components as will be found in typical rolling-mill applications of SM150:
- individually controlled power sections for Active Line Module and Motor Module
- original control electronics (processor boards, option components) including the Power Stack Adapters
- separate ET200 stations for the motor periphery (MOT-ET) and the auxiliaries (HIB-ET)
- DC-Master to provide the excitation current for the synchronous motor
- OP177 for local control of the SM150
The programming within the project used for this training is based on an original site project with very few exceptions;
in consequence all steps of commissioning a SM150 converter with synchronous motor can be carried out on the
training unit in quite the same way as at site.
Naturally, the commissioning of the medium voltage hardware cannot be included in this training.
Apart from the training for which this material is prepared it can well be used as guideline and reference material for
plant commissioning. In this case, however, the particular link of the plant periphery to the drive controllers (via PLC,
TMxx, ) has to be considered and the plant periphery has to be included in the commissioning sequence as well.
Wherever you do any commissioning work, please strictly observe the five safety rules.
- Switch off the power supply on all poles
- Verify the de-energized condition
- Ensure against unauthorized re-energizing (lock-out, tag-out)
- Ground and short circuit the power terminals on all poles
- Cover or fence off adjacent live components
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With the inevitable exception of the medium voltage hardware the SM150 training unit is equipped with the same
components as will be found in typical rolling-mill applications of SM150:
- individually controlled power sections for Active Line Module and Motor Module
- original control electronics (processor boards, option components) including the Power Stack Adapters
- separate ET200 stations for the motor periphery (MOT-ET) and the auxiliaries (HIB-ET)
- DC-Master to provide the excitation current for the synchronous motor
- OP177 for local control of the SM150
The programming within the project used for this training is based on an original site project with very few exceptions;
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page 03
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Synchronous Motor
with Induction Motor
Comm_Common page 05
Software Tools and Licenses
Simotion CFC
Active Line Module
and Motor Module
DC-Master OP177
SIMATIC Manager
SIMOTION SCOUT
STARTER integrated
DRIVE ES
DriveMonitor
WinCC flexible
DR-SM150
page 06
1 Preparatory Steps
1.1 Required Software-Tools
To have access to the programming of a SM150-converter as used in rolling-mill applications a number of software-
tools and their respective licenses have to be installed on the PG/PC. At the PG/PC used for the training these tools
and licenses are installed already.
Verify that all the required software-tools are installed and that the respective licenses are available.
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1.1 Required Software-Tools
tools and their respective licenses have to be installed on the PG/PC. At the PG/PC used for the training these tools
and licenses are installed already.
Verify that all the required software-tools are installed and that the respective licenses are available.
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page 05
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Comm_Common page 07
Matching the Software Tool to the Firmware
Content of the Compact Flash Card
Version of the Tool SIMOTION SCOUT
DR-SM150
page 08
1.2 Drive Firmware
As a general rule, the versions of the software-tools have to match the drives firmware. This applies in particular to
the version of SIMOTION SCOUT in relation to the firmware of the SM150.
Create file directory SCOUT: > Temp_Trainee; if it should already exist, delete all its content.
Using Explorer and a card reader, copy the entire content of the Flash Card of SIMOTION D445 to directory
SCOUT:\ Temp_Trainee\D445_CFC.
Execute the routine remove hardware safely (button at the right end of the bottom line) before removing the CFC and
the card reader; put the D445 CFC back into controller D445.
Open tool SCOUT and verify that the version of SIMOTION SCOUT and the firmware of the SM150 are a matching
pair.
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Create file directory SCOUT: > Temp_Trainee; if it should already exist, delete all its content.
Using Explorer and a card reader, copy the entire content of the Flash Card of SIMOTION D445 to directory
SCOUT:\ Temp_Trainee\D445_CFC.
Execute the routine remove hardware safely (button at the right end of the bottom line) before removing the CFC and
the card reader; put the D445 CFC back into controller D445.
Open tool SCOUT and verify that the version of SIMOTION SCOUT and the firmware of the SM150 are a matching
pair.
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s a general rule, the versions of the software-tools have to match the drives firmware. This applies in particular to
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page 07
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Comm_Common page 09
Hardware Description Data, Ident-Files and User Data
Vector-related ACX-data and Ident-file for the Motor-Module Power Stack (PSA)
Infeed-related ACX-data and Ident-file for the Line-Module Power Stack (PSA) / port X105
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DR-SM150
page 10
1.3 Structure and Content of the CFC
Check the content of the Compact Flash Card to identify the Hardware Description Data, the Ident-files both for the
Infeed and for the Motor Module and the User Data:
A) Hardware Description Data (DESCxxxx.ACX) define converter properties such as power section data (voltage,
current) and the actual value monitoring on the PSA
B) Ident-files (ident_xx.bin) assign the allocation of the PSA to its application as Infeed for SM150, Motor Module
for SM150, Motor Module for GM150 etc.
C) User Data (PSxxxxxx.ACX) contain the parameterization of the individual objects of the drive devices Infeed,
Motor Module and Simotion programming (PSxxxx00.ACX to PSxxxx99.ACX).
In case of parallel Infeeds, the data for the second Infeed (port X104) respectively the third Infeed (port X103) are
located in \Data\14\... respectively in \Data\13\...
Check whether file fba121V23_0_simotion4_1_1.zip is available on C:\Programme\Siemens\Step7\u7umc\data\dcc
(file fba has to be installed on the same drive as SCOUT; SCOUT must be installed on drive C only!).
If this library already exists on your PG/PC, then please delete it to be able to go through the steps required for its
registering (not a normal approach, just for the sake of training).
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current) and the actual value monitoring on the PSA
B) Ident-files (ident_xx.bin) assign the allocation of the PSA to its application as Infeed for SM150, Motor Module
for SM150, Motor Module for GM150 etc.
C) User Data (PSxxxxxx.ACX) contain the parameterization of the individual objects of the drive devices Infeed,
Motor Module and Simotion programming (PSxxxx00.ACX to PSxxxx99.ACX).
In case of parallel Infeeds, the data for the second Infeed (port X104) respectively the third Infeed (port X103) are
located in \Data\14\... respectively in \Data\13\...
Check whether file fba121V23_0_simotion4_1_1.zip is available on C:\Programme\Siemens\Step7\u7umc\data\dcc
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heck the content of the Compact Flash Card to identify the Hardware Description Data, the Ident-files both for the
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page 09
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Vector-related ACX-data and Ident-file for the Motor-Module Power Stack (PSA)
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Comm_Common page 11
Running the Project on the PG/PC
deletes the old compilation in full
deletes modifications only
left
mouse
click
right mouse click >
open object
DR-SM150
page 12
1.4 Getting the PG/PC Installation ready to handle the SM150-project
As (typically) found in plant commissioning the SM150-project is provided as a zipped file (project archive) for the
training as well. Here it is part of the CFC-content by the name Yas_syn0.zip in file 0_Training.
Open the SIMATIC Manager and delete project Yas_Syn0 if it should already exist (File > Delete > Yas_Syn0 > OK).
Now retrieve project Yas_syn0.zip from file Temp_Trainee > 0_Training into the prompted directory
(SCOUT:\Programme\Siemens\Step7\S7Proj).
Select any one of the three SM150 drive devices you find via Yas_Syn0 > Obermotor G2 (Yask_CX32 / Infeed,
Yask_SINAMICS_Vector / Motor Module, D445_Master / SIMOTION program) and open SCOUT:
- left mouse click (lMC) on the drive device in the navigator-section and
- right mouse click (rMC) on the drive device in the worksheet-section > Open Object
In SCOUT start the routine Save project and REcompile all. You will observe that the compilation output lists a
considerable number of error messages. These error messages indicate that a library required for the compilation of
DCC-charts used in the project is missing. Specifically it is the library FBA121 which contains DCC functions used in
rolling-mill applications.
The project for the SM150 can only be compiled and downloaded if this library is available (registered) on the PG/PC.
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Open the SIMATIC Manager and delete project Yas_Syn0 if it should already exist (File > Delete > Yas_Syn0 > OK).
Now retrieve project Yas_syn0.zip from file Temp_Trainee > 0_Training into the prompted directory
(SCOUT:\Programme\Siemens\Step7\S7Proj).
Select any one of the three SM150 drive devices you find via Yas_Syn0 > Obermotor G2 (Yask_CX32 / Infeed,
Yask_SINAMICS_Vector / Motor Module, D445_Master / SIMOTION program) and open SCOUT:
- left mouse click (lMC) on the drive device in the navigator-section and
- right mouse click (rMC) on the drive device in the worksheet-section > Open Object
In SCOUT start the routine Save project and
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1.4 Getting the PG/PC Installation ready to handle the SM150-project
As (typically) found in plant commissioning the SM150-project is provided as a zipped file (project archive) for the
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old compilation in full
ons only
Comm_Common page 13
Registering the DCC-Library FBA121
before
inserting
the
library
Enter
Enter
Enter
after
inserting
the
library
DR-SM150
page 14
1.5 Registering Library FBA121
Exit SCOUT to be able to register library FBA121 (processes u7bt04ax.exe or u7wwbfax.exe must not be running!).
Register the library as follows:
- copy the library fba121V23_0_simotion4_1_1.zip from your source to directory
Programme\Siemens\Step7\u7umc\data\dcc
- call up the DOS-prompt (Start > Programme > Zubehr > Eigabeaufforderung)
- call directory programme\siemens\step7\u7umc\data\dcc
- ask for the content via dir
- request the registry of the library via inst_dcc_lib fba121v23_0_simotion4_1_1
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- copy the library fba121V23_0_simotion4_1_1.zip from your source to directory
Programme\Siemens\Step7\u7umc\data\dcc
- call up the DOS-prompt (Start > Programme > Zubehr > Eigabeaufforderung)
- call directory programme\siemens\step7\u7umc\data\dcc
- ask for the content via dir
- request the registry of the library via inst_dcc_lib fba121v23_0_simotion4_1_1
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xit SCOUT to be able to register library FBA121 (processes u7bt04ax.exe or u7wwbfax.exe must not be running!).
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page 13
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Comm_Common page 15
Importing required DCC-Libraries
mark library TPfba121 library is imported
DR-SM150
page 16
After the successful installation close the DOS-prompt and select the library in SCOUT:
- right mouse click (RMC) on D445 > Select technology packages
- in addition to already marked technology packages select fba121_SIMOTION. and dcblib_SIMOTION. > OK
Now update the DCC-libraries in SCOUT > DCC:
- open any of the DCC-charts in D445 > PROGRAMS
- access the import of libraries via Options > Block Types > OK
- mark library TPfba121_SIMOTION, transfer it to Imported libraries ( button >> ), mark library
TPdcblib_SIMOTION, transfer it to Imported libraries and Accept the request of the Import of the two libraries
- ignore the warning messages
- exit the DCC-chart
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- open any of the DCC-charts in D445 > PROGRAMS
- access the import of libraries via Options > Block Types > OK
- mark library TPfba121_SIMOTION, transfer it to Imported libraries ( button >> ), mark library
TPdcblib_SIMOTION, transfer it to Imported libraries and Accept the request of the Import of the two libraries
- ignore the warning messages
- exit the DCC-chart
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After the successful installation close the DOS-prompt and select the library in SCOUT:
- right mouse click (RMC) on D445 > Select technology packages
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library is imported
Comm_Common page 17
Getting the Project Ready for the Download to the CFC
deletes the old
compilation in full
DR-SM150
page 18
1.6 Getting the Project ready for the download to the CFC
In SCOUT again start the routine Save project and REcompile all. Once finished without errors, initiate the step
Check consistency.
If no consistency errors are signaled, the project (the user directories for the Infeed rsp. the Motor Module and the
Simotion programming) is ready to be downloaded to the CFC either via D445 with the CFC inserted or directly to the
CFC via card-reader.
For either of the two approaches, the CFC has to have a Simotion specific boot section (invisible via card-reader)
and the firmware for Sinamics SM150. At this step of training these preconditions are satisfied.
In the given situation user files for the Infeed and the Motor Module already exist on the CFC; they will subsequently
be overwritten by the download of the project (with no user files on the CFC these files will appear only after having
them loaded to the file system followed by a power-on initialization).
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Simotion programming) is ready to be downloaded to the CFC either via D445 with the CFC inserted or directly to the
CFC via card-reader.
For either of the two approaches, the CFC has to have a Simotion specific boot section (invisible via card-reader)
and the firmware for Sinamics SM150. At this step of training these preconditions are satisfied.
In the given situation user files for the Infeed and the Motor Module already exist on the CFC; they will subsequently
be overwritten by the download of the project (with no user files on the CFC these files will appear only after having
them loaded to the file system followed by a power-on initialization).
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1.6 Getting the Project ready for the download to the CFC
In SCOUT again start the routine Save project and
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page 17
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Comm_Common page 19
Downloading the Project to the CFC
only for Simotion technology,
irrelevant for SM150
DR-SM150
page 20
1.7 Downloading the Project
Insert the CFC in the card-reader and connect it to one of the USB-ports of the PG/PC; identify which directory is set
up for the Compact Flash Card.
Directory for SIMOTION_D: . . . . . . .
Download project Yas_Syn0 to the CFC:
- in SCOUT, RMC on D445 > Load to file system > Save normally
- button Select target > select the drive identified for the CFC > OK
- acknowledge the request to overwrite the existing user data
Verify that the ACX-data and the Ident-files are located on the CFC (\ADDON\DATA\...) both for the Infeed and for
the Motor Module; else copy them from a suitable source to their respective location.
l.8 AIIcnfIon socIfIc IuIso Infforns >onIy for InformnfIo l.8 AIIcnfIon socIfIc IuIso Infforns >onIy for InformnfIo l.8 AIIcnfIon socIfIc IuIso Infforns >onIy for InformnfIo l.8 AIIcnfIon socIfIc IuIso Infforns >onIy for InformnfIon< n< n< n<
If fho sysfom orfurbnfIons on fho IIno sIdo nnd/or fho hnrmonIc confonf of fho mofor sIdo hnvo fo bo fronfod In n
nrfIcuInr cusfomor socIfIc wny, socInI uIso nfforns mIghf hnvo fo bo downIondod fo fho CIC onco n usor
dIrocfory Is nvnIInbIo cronfod I.o. ns or l.?.
As n ruIo, fho CIC Is rogrnmmod In fuII nf SIIMIS If nof, nIIcnfIon socIfIc uIso nfforns hnvo fo bo
coIod fo fho dIrocforIos ns foIIows
Vocfor .`!SI!`SIAMICSÀTA`!ITAI`0l3ÌCCT`0
Infood .`!SI!`SIAMICSÀTA`l5`!ITAI`040ÌCCT`0 lI.o. `l5` for orf Xl05
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up for the Compact Flash Card.
Directory for SIMOTION_D: . . . . . . .
Download project Yas_Syn0 to the CFC:
- in SCOUT, RMC on D445 > Load to file system > Save normally
- button Select target > select the drive identified for the CFC > OK
- acknowledge the request to overwrite the existing user data
Verify that the ACX-data and the Ident-files are located on the CFC (\ADDON\DATA\...) both for the Infeed and for
the Motor Module; else copy them from a suitable source to their respective location.
l.8 AIIcnfIon socIfIc IuIso Infforns >onIy fo l.8 AIIcnfIon socIfIc IuIso Infforns >onIy fo l.8 AIIcnfIon socIfIc IuIso Infforns >onIy fo
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nsert the CFC in the card-reader and connect it to one of the USB-ports of the PG/PC; identify which directory is set
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page 19
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Comm_Common page 21
Single Line Diagram of a Typical SM150 Rolling Mill Application
DR-SM150
page 22
1.9 Exemplary SM150 Application
The single line diagram above serves as an example for a setup of a SM150 in rolling mill applications :
- Synchronous motor with external DC-excitation and encoder
- DC-excitation provided by a Simoreg DC-Master
- Stator winding fed by Sinamics SM150 (Infeed, Motor Module)
- Signal interface to the field via ET200-S (group Auxiliaries, group Motor)
- Local control via OP177
- Process control via MRG, Basic Automation
- Data link via Profibus and Profinet
The above setup is true for a motor which can be supplied by a single SM150 unit.
For larger power ratings the Infeeds and Motor Modules will be paralleled. Motors of large power ratings mostly
feature two or three groups of stator windings; the number of Infeeds and Motor Modules is then adapted accordingly.
A typical rolling mill stand comprises two motors, an upper motor (Obermotor) and a lower motor (Untermotor). The
above setup will then be found twice, one serving the Obermotor and one serving the Untermotor. An example of
such a project is shown on the next slide.
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- Stator winding fed by Sinamics SM150 (Infeed, Motor Module)
- Signal interface to the field via ET200-S (group Auxiliaries, group Motor)
- Local control via OP177
- Process control via MRG, Basic Automation
- Data link via Profibus and Profinet
The above setup is true for a motor which can be supplied by a single SM150 unit.
For larger power ratings the Infeeds and Motor Modules will be paralleled. Motors of large power ratings mostly
feature two or three groups of stator windings; the number of Infeeds and Motor Modules is then adapted accordingly.
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he single line diagram above serves as an example for a setup of a SM150 in rolling mill applications :
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page 21
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Comm_Common page 23
Drive Devices, Components and Topology of a Typical Project
SINAMICS_Vector_OM_G2
SIMOTION_CX32_OM_G2
HB-A11
HF-A11
HC-A11
HD-A11
HD-A31
HP-A11
HG-A11
HD-A51
DR-SM150
page 24
1.10 Drive Devices, Components and Topology of a typical Project
The control of the Obermotor G2 requires a number of drive devices as shown in the Simatic project:
- Simoreg DC-Master (to provide the DC-excitation for the synchronous motor)
- Simotion CX32 (to control the Infeed of the SM150)
- Sinamics_Vector (to control the Motor Module of the SM150)
- D445_Master (to provide technological control for the individual motor)
Sinamics drive devices consist of a number of components; these are listed separately for the Infeed (CX32) and for
the Motor Module (Sinamics_Vector).
These components are interconnected via Drive-CLiQ; the respective Topology Trees indicate the wiring. (The training
rack is wired identically to a plant application; some additional components are built in but are not connected.)
Verify that the DRIVE-CLiQ wiring as listed in the project topology is set up identically in the SM150 training rack.
Communication networks via Profibus and Profinet are used to link other non-Sinamics components such as OP177,
ET200-S and DC-Master to the overall system (refer to slides in sections to come).
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- Sinamics_Vector (to control the Motor Module of the SM150)
- D445_Master (to provide technological control for the individual motor)
Sinamics drive devices consist of a number of components; these are listed separately for the Infeed (CX32) and for
the Motor Module (Sinamics_Vector).
These components are interconnected via Drive-CLiQ; the respective Topology Trees indicate the wiring. (The training
rack is wired identically to a plant application; some additional components are built in but are not connected.)
Verify that the DRIVE-CLiQ wiring as listed in the project topology is set up identically in the SM150 training rack.
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1.10 Drive Devices, Components and Topology of a t
The control of the Obermotor G2 requires a number of drive devices as shown in the Simatic project:
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page 23
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Comm_Common page 25
Project with Three Power Sections in Parallel
DR-SM150
page 26
1.11 Project with three Power Sections in parallel
To increase the power rating up to three power sections are paralleled both on the line side (Active Line Modules) and
on the motor side (Motor Modules).
While all three power stack adapters for the motor side power sections are controlled by the D445_SINAMICS
controller, one SIMOTION CX32 controller each is assigned to the three power stack adapters of the line side power
sections.
As a standard, each of the three Infeed power sections has its own Voltage Sensing Module.
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on the motor side (Motor Modules).
While all three power stack adapters for the motor side power sections are controlled by the D445_SINAMICS
controller, one SIMOTION CX32 controller each is assigned to the three power stack adapters of the line side power
As a standard, each of the three Infeed power sections has its own Voltage Sensing Module.
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1.11 Project with three Power Sections in parallel
o increase the power rating up to three power sections are paralleled both on the line side (Active Line Modules) and
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page 25
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Comm_Common page 27
Voltage Supplies and Signal Check
Motor
Fan Group
Converter
Cooling
ET200-S
Motor
SM150
Cooling Fans
Control
Voltage
DR-SM150
page 28
2 Basic Commissioning
2.l ChockIng CnbIIng nnd VoIfngo SuIIos >onIy for Informnf 2.l ChockIng CnbIIng nnd VoIfngo SuIIos >onIy for Informnf 2.l ChockIng CnbIIng nnd VoIfngo SuIIos >onIy for Informnf 2.l ChockIng CnbIIng nnd VoIfngo SuIIos >onIy for InformnfIon< Ion< Ion< Ion<
IrIor fo cnrryIng ouf fho wIrIng nnd InsuInfIon fosf nII cIrcuIf bronkors nnd fusod swIfch dIsconnocfors hnvo fo bo
oonod sonsIfIvo oquImonf on fho Innf ond of fho cnbIos hns fo bo dIsconnocfod ns woII.
!ofor fo fho cIrcuIf dIngrnms fo IdonfIfy fho voIfngo IovoI for whIch fho cnbIos nro usod fo know whIch voIfngo fo
chooso for fho InsuInfIon fosf l00V, 500V, l000V, 5000V.
Mnko suro fhnf fho cnbIos fo fho Innf food fho oquImonf ns sfnfod In fho cIrcuIf dIngrnms. Thon ono by ono
connocf onch wIro nf fho Iond sIdo fo ground fho monsurod Imodnnco musf bo vory smnII nIfornnfIvoIy you cnn
monsuro fho Imodnnco bofwoon fwo wIros shorfcIrcuIfod nf fho Iond.
ConfInuo by monsurIng fho InsuInfIon Imodnnco of onch wIro ngnInsf ground usIng nn InsuInfIon mofor fho
Imodnnco musf bo In fho fons of Mognohms.
ow suIy fho nuxIIInry voIfngo fo fho busbnrs In fho cnbInofs nnd chock voIfngo IovoI nnd hnso soquonco.
Thon swIfch on ono cIrcuIf bronkor nffor fho ofhor nnd ono by ono chock fho voIfngo IovoI nnd oInrIfy rs. fho
hnso soquonco nf fho Iond. IquImonf whIch cnn bo dnmngod by nn Incorrocf voIfngo IovoI or oInrIfy shouId bo
dIsconnocfod unfII fho corrocf suIy hns boon vorIfIod.
IIonso obsorvo foIIowIng wnrnIngs
!sIng suIfnbIo mofhods, onsuro fhnf no dnngor cnn nrIso for orsonnoI or mnforInI boforo foodIng voIfngo fo
oquImonf In fho Innf.
Ioforo sfnrfIng fho mofor fnns mnko suro fhnf fho mofor If hns boon cIonnod nnd nInfod ofhorwIso fho nIr
fIow mIghf cnrry foroIgn bodIos Info fho mofor nIr gn ossIbIy IondIng fo n dnmngo of fho InsuInfIon onco fho
mofor rofnfos.
on`f nccof nny comromIsos on fhoso oInfs.
oonod sonsIfIvo oquImonf on fho Innf ond of fho cnbIos hns fo bo dIsconnocfod ns woII.
!ofor fo fho cIrcuIf dIngrnms fo IdonfIfy fho voIfngo IovoI for whIch fho cnbIos nro usod fo know whIch voIfngo fo
chooso for fho InsuInfIon fosf l00V, 500V, l000V, 5000V.
Mnko suro fhnf fho cnbIos fo fho Innf food fho oquImonf ns sfnfod In fho cIrcuIf dIngrnms. Thon ono by ono
connocf onch wIro nf fho Iond sIdo fo ground fho monsurod Imodnnco musf bo vory smnII nIfornnfIvoIy you cnn
monsuro fho Imodnnco bofwoon fwo wIros shorfcIrcuIfod nf fho Iond.
ConfInuo by monsurIng fho InsuInfIon Imodnnco of onch wIro ngnInsf ground usIng nn InsuInfIon mofor fho
Imodnnco musf bo In fho fons of Mognohms.
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2.l ChockIng CnbIIng nnd VoIfngo SuIIos >onIy for Informnf 2.l ChockIng CnbIIng nnd VoIfngo SuIIos >onIy for Informnf 2.l ChockIng CnbIIng nnd VoIfngo SuIIos >onIy for Informnf 2.l ChockIng CnbIIng nnd VoIfngo SuIIos >onIy for Informnf 2.l ChockIng CnbIIng nnd VoIfngo SuIIos >onIy for Informnf 2.l ChockIng CnbIIng nnd VoIfngo SuIIos >onIy for Informnf 2.l ChockIng CnbIIng nnd VoIfngo SuIIos >onIy for Informnf 2.l ChockIng CnbIIng nnd VoIfngo SuIIos >onIy for Informnf 2.l ChockIng CnbIIng nnd VoIfngo SuIIos >onIy for Informnf
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Motor
Fan Group
Comm_Common page 29
HW-Configuration of the Project for the Training Rack
64
32
16
8
4
2
1
address-coding
of ET200S;
i.e. address 17
PROFIBUS-addresses are set
- via switches on the ET200S-stations
- via parameter on the DC-Master
- via interface definition on the MoMo
- via DRIVE-CLiQ port on the ALM
DR-SM150
page 30
2.2 Checking the Communication Network in HW-Config
Open the HW-Configuration (i.e. in SCOUT) and compare the communication network of the project to the actual
connection of the PROFIBUS- and ETHERNET-nodes: RMC on D445 > Open HW configuration.
Note down the PROFIBUS-addresses assigned to the nodes:
- HIB-ET200: . . . . . . . . . . - MOT-ET200: . . . . . . . . . . - DC-Master: . . . . . . . . . .
Verify respectively set these addresses via hardware where possible.
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Note down the PROFIBUS-addresses assigned to the nodes:
- HIB-ET200: . . . . . . . . . . - MOT-ET200: . . . . . . . . . . - DC-Master: . . . . . . . . . .
Verify respectively set these addresses via hardware where possible.
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2.2 Checking the Communication Network in HW-Con
Open the HW-Configuration (i.e. in SCOUT) and compare the communication network of the project to the actual
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page 29
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via switches on the ET200S-stations
- via parameter on the DC-Master
- via interface definition on the MoMo
Comm_Common page 31
Rebooting the Controllers / Connecting the Ethernet Ports
X120
IE1/OP
X130
IE2/NET
An Ethernet port is defined by its IP-address, by a Subnet mask
and (if networked) by the definition of a Standardgateway.
The definition of the Subnet mask depends on the application
class; Subnet mask and IP-address range have to match.
Subnet mask IP-address range class networks / hosts
255.0.0.0 1 to 126 A 126 / 1677721
255.255.0.0 128 to 191 B 16384 / 65534
255.255.255.0 192 to 223 C 2097152 / 254
DR-SM150
page 32
2.3 Rebooting the Controllers
Using the routine Safely Remove Hardware remove the card-reader from the PG/PC and insert the CFC in the D445.
Put all switches on the auxiliaries rack to their lower position and switch on the 24VDC supply to all Simotion and
Sinamics components on the SM150 rack by closing the line-side auxiliary supply breaker Q11 (this reboots the
controllers of the components). Allow approximately 3 minutes for the initialization. If the Drive-CLiQ topology of the
project matches the physical wiring the RUN-LEDs of the Drive-CLiQ components will turn green.
Now also switch on the supply to the auxiliaries rack via its main breaker Q1.
To analyze the nature of fault or alarm messages on the SM150, an online connection with the PG/PC has to be set
up next.
The PG/PC can be connected to the D445 via PROFIBUS or via ETHERNET; presently the ETHERNET connection to
port X130, IE2/NET will be used.
Connect an ETHERNET cable between port IE2/NET of the D445 and an available port of the PG/PC.
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controllers of the components). Allow approximately 3 minutes for the initialization. If the Drive-CLiQ topology of the
project matches the physical wiring the RUN-LEDs of the Drive-CLiQ components will turn green.
Now also switch on the supply to the auxiliaries rack via its main breaker Q1.
To analyze the nature of fault or alarm messages on the SM150, an online connection with the PG/PC has to be set
up next.
The PG/PC can be connected to the D445 via PROFIBUS or via ETHERNET; presently the ETHERNET connection to
port X130, IE2/NET will be used.
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sing the routine Safely Remove Hardware remove the card-reader from the PG/PC and insert the CFC in the D445.
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IE2/NET IE2/
Comm_Common page 33
Communication Network as seen via NetPro
DR-SM150
page 34
2.4 Checking the Communication Network in NetPro
Open the NetPro view (i.e. in SCOUT) and compare the communication network of the project to the actual connection
of the PROFIBUS- and ETHERNET-nodes: Project > Open NetPro.
In addition to the existing hardware NetPro shows a SIMATIC PC Station and a SIMODRIVE 611U. Remove the
SIMODRIVE 611U from the network: (rMC) SIMODRIVE 611U > Delete > Yes > Yes.
Note down the PROFIBUS- and ETHERNET-addresses assigned to the nodes
(via right mouse click on node connection > Object Properties):
- HIB-ET200: . . . . . . . . . . .
- MOT-ET200: . . . . . . . . . . .
- DC-Master: . . . . . . . . . . .
- PG/PC_MPI: . . . . . . . . . . .
- PG/PC_DP: . . . . . . . . . . .
- PG/PC_ETHERNET: . . . . . . . . . . . . . . . . . . . . . . .
- OP177_ETHERNET: . . . . . . . . . . . . . . . . . . . . . . .
- OP177_MPI, DP: . . . . . . . . . . .
- D445_DP1: . . . . . . . . . . .
- D445_DP2/MPI: . . . . . . . . . . .
- D445_IE1/OP: . . . . . . . . . . . . . . . . . . . . . . .
- D445_IE2/NET: . . . . . . . . . . . . . . . . . . . . . . .
- D445_CBE30: . . . . . . . . . . . . . . . . . . . . . . .
In addition to the existing hardware NetPro shows a SIMATIC PC Station and a SIMODRIVE 611U. Remove the
SIMODRIVE 611U from the network: (rMC) SIMODRIVE 611U > Delete > Yes > Yes.
Note down the PROFIBUS- and ETHERNET-addresses assigned to the nodes
(via right mouse click on node connection > Object Properties):
- HIB-ET200:
- MOT-ET200: . . . . . . . . . . .
- DC-Master:
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Open the NetPro view (i.e. in SCOUT) and compare the communication network of the project to the actual connection
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Comm_Common page 35
Setting the IP-Address on the PG/PC
Enter
DR-SM150
page 36
2.5 Setting the IP-Address on the PG/PC
Follow the sequence Start > Einstellungen > Netzwerkverbindungen and doubleclick on LAN-Verbindung; open the
properties menu via button Eigenschaften. Scroll down to Internetprotokoll (TCP/IP), mark it and again continue via
button Eigenschaften.
Now assign the subnet-mask and the IP-address to a setting compatible with the definition of the ETHERNET port
IE2/NET of the D445 :
. . . . . . . . . . . . . . . . . . . . . .
Test the communication by pinging the D445 in the DOS-prompt: ping IP-address.
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Now assign the subnet-mask and the IP-address to a setting compatible with the definition of the ETHERNET port
IE2/NET of the D445 :
. . . . . . . . . . . . . . . . . . . . . .
Test the communication by pinging the D445 in the DOS-prompt: ping IP-address.
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2.5 Setting the IP-Address on the PG/PC
ollow the sequence Start > Einstellungen > Netzwerkverbindungen and doubleclick on LAN-Verbindung; open the
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Comm_Common page 37
Assigning the PG/PC to ETHERNET in NetPro
Network > Save and Compile
DR-SM150
page 38
2.6 Assigning the PG/PC to ETHERNET in NetPro
In NetPro the PG/PC is connected both to an MPI-network and to an ETHERNET-network.
To enable an online connection to the D445, the link to the ETHERNET-network has to be activated:
- right mouse click (RMC) on PG/PC > Object Properties
- acknowledge the change of assignment via button Yes
- in tab Assignment of menu Properties PG/PC, section Configured Interfaces select
Ethernet Service Noteboo
- in section Interface Parameter Assignments select TCP/IP Intel 825666MC Gigab...
(this selection has to match the device name for the LAN-Verbindung selected above)
- define this selection as Assigned via button Assign > OK
- mark the assigned interface, verify that the checkmark next to Active is inserted and terminate the assignment
by pressing button OK
The assigned connection of the PG/PC to the D445 is highlighted in yellow.
Any change of assignment in NetPro will become effective only after NetPro has been Saved and Compiled: Network
> Save and Compile (the warning message points at missing ET200-hardware for the Obermotor which is not used
in the training rack; close the warning message).
Exit program NetPro by Network > Exit
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- right mouse click (RMC) on PG/PC > Object Properties
- acknowledge the change of assignment via button Yes
- in tab Assignment of menu Properties PG/PC, section Configured Interfaces select
Ethernet Service Noteboo
- in section Interface Parameter Assignments select TCP/IP
this selection has to match the device name for the LAN-Verbindung selected above)
- define this selection as Assigned via button Assign > OK
- mark the assigned interface, verify that the checkmark next to Active is inserted and terminate the assignment
by pressing button OK
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2.6 Assigning the PG/PC to ETHERNET in NetPro
n NetPro the PG/PC is connected both to an MPI-network and to an ETHERNET-network.
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Comm_Common page 39
Going Online to D445 and Downloading the Drive Devices
connect to
target system
download to
target system
DR-SM150
page 40
2.7 Going Online to D445 and Downloading the Drive Devices
Return to SCOUT and request the online mode. The consistency plugs have to indicate the online state for drive
device D445_Master (closed plugs); data inconsistency, however, will be signaled (red-green).
Generate consistency by downloading drive device D445_Master.
You will notice that the download of the D445 is aborted with a fatal error as regards the I/O-definitions.
Open the HW-Configuration to identify the addresses assigned to the still existing nodes
(left mouse click on node address range pops up on bottom):
HIB-ET200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOT-ET200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC-Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MoMo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Find out which variables of the I/O-container are not supported by hardware by checking the I/O-variables for
addresses not specified in the HW-Config.:
missing addresses:
variable name address range column position
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . to . . . . . . . . . . . . . . . . . . . . . . . to . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . to . . . . . . . . . . . . . . . . . . . . . . . to . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . to . . . . . . . . . . . . . . . . . . . . . . . to . . . . . . . . . .
Variables by the name pn_pda are assigned to the SIMATIC PC Stationwhich is not available in hardware but is
still part of the project (refer to NetPro).
Variables by the name pn_drv are assigned to SIMODRIVE 611U which has been removed in NetPro.
In Offline mode delete the 611U-variables (pn_drv) from the I/O-container and activate the function Save and
Compile. You will notice the error message error in source U2COMCBE.
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Generate consistency by downloading drive device D445_Master.
You will notice that the download of the D445 is aborted with a fatal error as regards the I/O-definitions.
Open the HW-Configuration to identify the addresses assigned to the still existing nodes
(left mouse click on node
IB-ET200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOT-ET200 . . . . . . . . . . . . . . . . . . . . .
DC-Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALM . . . . . . . . . . . . . . . . . . . . . . .
MoMo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.7 Going Online to D445 and Downloading the Drive
Return to SCOUT and request the online mode. The consistency plugs have to indicate the online state for drive
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Comm_Common page 41
Finding the Reference address / module / terminal / bit
address references in I/O-container
any DCC-chart
DR-SM150
page 42
To easily find the blocks of chart U2COMCBE which use the variables pn_drv, open any DCC chart, select menu
Chart Reference Data and open the listing of Cross Reference Chart Elements Address.
Search for one of the variables pn_drv_piw and double click on it; the chart page showing this variable and its wiring
to a DCC-block is opened automatically.
Now delete all 8 inputs to block RCB100 (left Mouse Click on input signal line > Delete Interconnection). Follow the
same approach to delete the chart output to the variables pn_drv_pqw.
Compile the modified chart U2COMCBE: Cart > Compile > Chart as program > Compile individual chart > OK.
Once more Save and Compile the project and check its consistency. If consistency is still not given, follow the above
approach once more to delete the offending links to the variables in question.
Again Save and Compile the project, check its consistency and then download the D445 again. Be sure to have the
function Copy RAM to ROM executed for device D445_Master.
Reboot the drive (power off/on) and continue by downloading the Motor Module and the Infeed. After completion of the
downloads all three drive devices have to indicate data-consistency (green-green). Dont forget to have a Copy RAM
to ROM executed at the end of the download of devices SIMOTION_CX32 and SINAMICS_Vector.
If a drive device changes to disconnected (red-red) in the sequence of downloading, reconnect it as follows:
- mark the drive device in question
- open the function menus via right mouse click
- left mouse click on Connect online
device changes to offline requested (white-white)
- again open the function menus via right mouse click
- left mouse click on Connect online
device changes to online mode (green-green)
Open the Alarm-tab in SCOUT and try to acknowledge all faults. You will notice that fault Excitation group signal fault
(this fault is quite logical as the DC-Master has not yet been commissioned) persists.
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earch for one of the variables pn_drv_piw and double click on it; the chart page showing this variable and its wiring
Now delete all 8 inputs to block RCB100 (left Mouse Click on input signal line > Delete Interconnection). Follow the
same approach to delete the chart output to the variables pn_drv_pqw.
Compile the modified chart U2COMCBE: Cart > Compile > Chart as program > Compile individual chart > OK.
Once more Save and Compile the project and check its consistency. If consistency is still not given, follow the above
approach once more to delete the offending links to the variables in question.
Again Save and Compile the project, check its consistency and then download the D445 again. Be sure to have the
function Copy RAM to ROM executed for device D445_Master.
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To easily find the blocks of chart U2COMCBE which use the variables pn_drv, open any DCC chart, select menu
Chart Reference Data and open the listing of Cross Reference Chart Elements
earch for one of the variables pn_drv_piw and double click on it; the chart page showing this variable and its wiring
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Comm_Common page 43
Defaulting the DC-Master and Setting the Node-Address via PMU

Increasing / decreasing
- the parameter number
- the index number
- the value
/
Change from parameter level to
value indication and vice versa
Change from parameter level to
index level and vice versa
Change from index level to
value indication and vice versa
P234 17.20
P150 i 001
56.37 i 001
Acknowledging a fault
last
indication
F036
P
P
P
P
P +
Shifting fault or alarm
messages to the background

P +
Recalling fault or alarm
messages from the background
F036
P0623
o11.0
A537
P0623
o11.0
DR-SM150
page 44
2.8 Defaulting the DC-Master and setting the Node-Address via PMU
As a standard, the DC-Master for the SM150 synchronous motor application is pre-commissioned at SIEMENS and
the parameter file provided within the project will require only minor modification at site (i.e. the optimization of the
armature current controller for the synchronous motor excitation).
Start by defaulting the DC-Master to factory settings using its ParaMeterizing Unit (PMU):
- shift eventual fault and alarm messages to the background
- scroll to parameter P051 (access level) and set the value to P051 = 21 (default request; after execution of this
routine an internal offset tuning is carried out automatically (indication P051 = 22) and
- after some seconds delay P051 reads P051 = 40 service level for commissioning)
- scroll to P918 to set the PROFIBUS address as defined in NetPro: P918 = . . . . . . . . .
- scroll to P927 to extend the parameterization authority to SST1 + PMU + PROFIBUS: P927 = 7
Switch the power supply for the DC-Master (F001) off and on again to activate the new PROFIBUS address;
acknowledge eventual fault messages.
Profibus alarm A83 will persist since settings for the Profibus communication still have to be parameterized.
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Start by defaulting the DC-Master to factory settings using its
- shift eventual fault and alarm messages to the background
- scroll to parameter P051 (access level) and set the value to P051 = 21 (default request; after execution of this
routine an internal offset tuning is carried out automatically (indication P051 = 22) and
- after some seconds delay P051 reads P051 = 40
scroll to P918 to set the PROFIBUS address as defined in NetPro: P918 = . . . . . . . . .
- scroll to P927 to extend the parameterization authority to SST1 + PMU + PROFIBUS: P927 = 7
Switch the power supply for the DC-Master (F001) off and on again to activate the new PROFIBUS address;
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2.8 Defaulting the DC-Master and setting the Node-Address via PMU
As a standard, the DC-Master for the SM150 synchronous motor application is pre-commissioned at SIEMENS and
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Comm_Common page 45
Tool Drive Monitor
offline online
RAM
online
EEPROM
tracer
parameter list as used
to open Drive Monitor
complete
parameter list
complete
parameter list
empty
parameter list
upload
download
upload download
left mouse click
right mouse click
online
RAM
online
EEPROM
Copy RAM to ROM
P971 = 1
DR-SM150
page 46
2.9 Going Online and Downloading the Project Data via Drive Monitor
Within the project view of the SIMATIC Manager the DC-Master is listed in addition to the three drive devices.
Navigate to the parameter list (or lists) provided for the DC-Master:
- in the navigator-section successively doubleclick on DC-Master CBP2, SIMOREG DC MASTER and
Parameter
- right mouse click on the parameter list DC_Yas_Trainee_Delta in the worksheet-section > Open Object
The tool for the DC-Master, Drive Monitor, is opened.
- right mouse click on the parameter list DC_Yas_Trainee_Delta in the worksheet-section > Open Object
The tool for the DC-Master, Drive Monitor, is opened.
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2.9 Going Online and Downloading the Project Data
Within the project view of the SIMATIC Manager the DC-Master is listed in addition to the three drive devices.
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upload
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download
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Comm_Common page 47
Messages: Differing Firmware and Missing Data Base
The FW-release of the DC-Master used
in the project differs from the FW-version
of the Control Unit.
(FW 3.1 cannot be run on CU-HW 2.2)
Unless the very latest release of Drive Monitor
is used, a missing data base has to be added.
DR-SM150
page 48
In Drive Monitor, click on the list of all offline parameters: a list of the parameters defined in project parameter list
DC_Yas_Trainee_Delta opens and indicates the offline values of these parameters.
Request operating mode online EEPROM (to have changes of parameter values saved in non-volatile fashion);
acknowledge an eventual device identification message.
If the message Device Identification pops up, ignore it by pressing the SW-button OK.
ShouId fhIs fnII fo hnon, n rogrnm udnfo sg?0v3l_dos.oxo for rIvo MonIfor hns fo bo InsfnIIod by coyIng
fho fIIo fo fho dIsk drIvo whIch Is usod for SCO!T ofc. nnd by sfnrfIng fho InsfnIInfIon.
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If the message Device Identification pops up, ignore it by pressing the SW-button OK.
ShouId fhIs fnII fo hnon, n rogrnm udnfo sg?0v3
fho fIIo fo fho dIsk drIvo whIch Is usod for SCO!T ofc. nnd by sfnrfIng fho InsfnIInfIon.
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In Drive Monitor, click on the list of all offline parameters: a list of the parameters defined in project parameter list
DC_Yas_Trainee_Delta opens and indicates the offline values of these parameters.
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page 47
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Comm_Common page 49
Downloading the Parameter File with Drive Monitor
DR-SM150
page 50
Now download the project file DC_Yas_Trainee_Delta to the EEPROM (the download of a complete file takes
considerably longer than the download of a delta file, which contains only those parameters whose values are other
than default values); close the eventual device identification message with button Download.
If the download is executed with only a very small number n of errors (indicated by [OKxxx: E<0: n>]), call up the
Details with the respective button. Analyze the reason for the error; mostly the errors result from different versions of
the tool Drive Monitor and the Firmware of the DC-Master and can be ignored.
On the DC-Master programming numerous Free Function Blocks are used. These Free Function Blocks have to be
enabled either temporarily (for test operation with a maximum test time of 500 operating hours) or permanently via
PIN-code.
For a temporary enable parameter U977 is set to U977 = 1500 (the parameterized value 1500 is reset to 0
automatically). Parameter n978 indicates the remaining hours of test operation in its last three digits
(e.g. n978 = 1372 372 h of test operation still available).
For a permanent enable parameter U977 is set to U977 = PIN-number; in this case n978 indicates n978 = 2000.
Check whether the training racks DC-Master is enabled temporarily or via PIN.
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Details with the respective button. Analyze the reason for the error; mostly the errors result from different versions of
the tool Drive Monitor and the Firmware of the DC-Master and can be ignored.
On the DC-Master programming numerous Free Function Blocks are used. These Free Function Blocks have to be
enabled either temporarily (for test operation with a maximum test time of 500 operating hours) or permanently via
PIN-code.
For a temporary enable parameter U977 is set to U977 = 1500 (the parameterized value 1500 is reset to 0
automatically). Parameter n978 indicates the remaining hours of test operation in its last three digits
(e.g. n978 = 1372
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Now download the project file DC_Yas_Trainee_Delta
considerably longer than the download of a delta file, which contains only those parameters whose values are other
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Comm_Common page 51
Adapting Parameters to particular Plant Conditions
DR-SM150
page 52
2.10 Adapting Parameters to particular Plant Conditions
You will notice that F021 is signaled and cannot be acknowledged. Using the DC-Master faults list and the plant
function diagrams for the DC-Master, find out which plant monitoring is responsible for this fault (F021):
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lacking board CUD2, this monitoring input (simulated by switch S3) is hardware-wired to terminal 36 of board CUD1
instead. Change the software wiring to evaluate terminal 36/CUD1 instead of terminal 42/CUD2 on the input for the
fault indication F021 (DONT reassign the wiring on U113 as yet!):
P . . . . . . . . . . . = . . . . . . . . . . .
Switch on switch S3 and acknowledge fault F021.
Following the same approach, eliminate alarm A021 by assigning a constant H instead of the configured evaluation
of the digital input on the input for the alarm indication A021 (DONT reassign the wiring on U113 as yet!):
P . . . . . . . . . . . = . . . . . . . . . . .
PROFIBUS messages Alarm A83 / Fault F82 persist because SIMOTION D445 is not sending any PROFIBUS-
telegrams as yet.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lacking board CUD2, this monitoring input (simulated by switch S3) is hardware-wired to terminal 36 of board CUD1
instead. Change the software wiring to evaluate terminal 36/CUD1 instead of terminal 42/CUD2 on the input for the
fault indication F021 (DONT reassign the wiring on U113 as yet!):
P . . . . . . . . . . . = . . . . . . . . . . .
Switch on switch S3 and acknowledge fault F021.
Following the same approach, eliminate alarm
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2.10 Adapting Parameters to particular Plant Conditions
is signaled and cannot be acknowledged. Using the DC
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Comm_Common page 53
Uploading the Parameterization as Delta-File
DR-SM150
page 54
Upload the parameterization of the DC-Master as a delta file by the name DC_Yas_Trainee_Delta_1.
Copy file DC_Yas_Trainee_Delta_1 to your listing of DC-Master files in explorer as follows:
SIMATIC Manager > (rMC) DC_Yas_Trainee_Delta_1 > Export parameters > Drive Monitor > C: > Temp_Trainee >
0_Training > DC_Master_Files > Save.
Go offline with the DC-Master and exit the tool Drive Monitor (View > Offline / File > Exit).
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Go offline with the DC-Master and exit the tool Drive Monitor (View > Offline / File > Exit).
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Upload the parameterization of the DC-Master as a delta file by the name DC_Yas_Trainee_Delta_1.
Copy file DC_Yas_Trainee_Delta_1 to your listing of DC-Master files in explorer as follows:
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Comm_Common page 55
F7
F7 / System
Preparing the OP177 to load Data via ETHERNET
DR-SM150
page 56
2.11 Loading the OP177
PROFIBUS messages Alarm A083 / Fault F82 cannot be cleared as a consequence of the still persisting Excitation
group signal fault of the Motor Module. To follow up on this fault, Simotion messages have to be analyzed which is
most comfortably done via OP177.
To load the OP177 via one of the available interfaces, the interface in question has to be assigned to the PG/PC. As
the current interface assignment of the PG/PC reads ETHERNET, the OP177 will be loaded via ETHERNET. Since
the online connection to the D445 will no longer be maintained in this situation, disconnect the SCOUT project from
the target system (go offline).
Connect the PG/PC to the OP177 both physically and in NetPro; note down the IP-Address on the PG/PC:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The selection of the type of interface, the interface settings and the preparation of a data transfer are done in the
menu Transfer of the OP177.
If fho OIl?? Is oworod u for fho vory fIrsf fImo, fho !ondor oons u nufomnfIcnIIy In fhIs cnso ross fho
SWbuffon ConfroI InnoI.
If the OP177 has been used already, the previously defined faceplate opens up; in this case press HW-button
F7/System and then the SW-button System Control.
Scroll down to menu Transfer, double-click on it and adapt the Transfer Settings on the OP177 to enable the
communication with the PG/PC via ETHERNET.
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most comfortably done via OP177.
To load the OP177 via one of the available interfaces, the interface in question has to be assigned to the PG/PC. As
the current interface assignment of the PG/PC reads ETHERNET, the OP177 will be loaded via ETHERNET. Since
the online connection to the D445 will no longer be maintained in this situation, disconnect the SCOUT project from
the target system (go offline).
Connect the PG/PC to the OP177 both physically and in NetPro; note down the IP-Address on the PG/PC:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The selection of the type of interface, the interface settings and the preparation of a data transfer are done in the
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Comm_Common page 57
Loading the Project to the OP177 (WinCC via SIMATIC Manager)
DR-SM150
page 58
Set the OP177 to the state Transfer > Connecting to host.
In SIMATIC Manager, start WinCC flexible, select Project > Transfer > Transfer Settings, define Mode =
ETHERNET and the IP-Address of the OP177.
Start the transfer with the assigned button; select the existing password list to be overwritten (else the password list
has to be overwritten via WinCC flexible by a separate command).
If the data transfer is finished, close WinCC flexible without saving the changes to the current project.
Now connect an ETHERNET cable between D445, port IE1/OP and OP177 : the feedback values for Nact, TQact, etc.
on the OP177 screen read 0 (instead of the #### as before the connection to the D445).
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Start the transfer with the assigned button; select the existing password list to be overwritten (else the password list
has to be overwritten via WinCC flexible by a separate command).
If the data transfer is finished, close WinCC flexible without saving the changes to the current project.
Now connect an ETHERNET cable between D445, port IE1/OP and OP177 : the feedback values for Nact, TQact, etc.
on the OP177 screen read 0 (instead of the #### as before the connection to the D445).
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Set the OP177 to the state Transfer > Connecting to host.
In SIMATIC Manager, start WinCC flexible, select Project > Transfer > Transfer Settings, define Mode =
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Comm_Common page 59
Loading the Project to the OP177 (direct Call of WinCC)
called up via Project > Transfer > Options
DR-SM150
page 60
Ior InformnfIon onIy nof n sfo of fho curronf frnInIng.
As an alternative, the OP177 data can also be transferred if WinCC flexible is opened by itself. In this case some
definitions for the interface have to be entered in a menu accessed via Project > Transfer > Communication Settings.
The MPI connection between PG/PC and OP177 is then tested using a menu called up via Project > Transfer >
Options. Additionally the project data for the OP177 have to be selected by separately opening the project containing
the OP177 settings before starting the data transfer via Project > Transfer > Transfer Settings as above.
Options. Additionally the project data for the OP177 have to be selected by separately opening the project containing
the OP177 settings before starting the data transfer via Project > Transfer > Transfer Settings as above.
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As an alternative, the OP177 data can also be transf
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Comm_Common page 61
Updating the OP177
called up via Project > Transfer > OS Update
DR-SM150
page 62
If the versions of the OP177 and of the project are not compatible, the download is rejected. In this case the OP177
has to be updated using a menu called up via Project > Transfer > OS Update.
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If the versions of the OP177 and of the project are
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Comm_Common page 63
Excitation Group Signal Fault
PROFIBUS
Communication error
x
DR-SM150
page 64
To get a definite idea about the state of the entire system, first switch off the main supply both for the SM150 rack and
the auxiliaries rack and then back on again; the following state should be observed:
- the DC-Master signals F082
- several analog modules of the MOT-ET indicate System Failure
- the D445 reads RDY = red
(as interface DP1 and board CBE30 are part of NetPro but not participating in communication the assigned LEDs
read DP1 = red and OPT = red)
Use another cable to connect the D445, port IE2/Net to the PG/PC and adapt all settings required for the ETHERNET
link between the PG/PC and the D445; verify that an online connection is successful.
necessary steps 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Close the pop-up window Online/Offline comparison without uploading or downloading any of the drive devices) and
in rough identify the persisting fault message:
persisting fault: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Try to acknowledge the fault indicated for the D445: fault Excitation group signal fault persists.
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- the D445 reads RDY = red
(as interface DP1 and board CBE30 are part of NetPro but not participating in communication the assigned LEDs
read DP1 = red and OPT = red)
Use another cable to connect the D445, port IE2/Net to the PG/PC and adapt all settings required for the ETHERNET
link between the PG/PC and the D445; verify that an online connection is successful.
necessary steps 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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To get a definite idea about the state of the entire system, first switch off the main supply both for the SM150 rack and
the auxiliaries rack and then back on again; the following state should be observed:
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Comm_Common page 65
General Content and Structure of the CFC-charts
I/O-Container Signals between drive devices and interfaces
MRG (Basic Automation)
I O INAUX Auxiliary inputs via ET200 I/O
I O AUXCU Auxiliaries Cooling Unit
I O AINF1 Control of Infeed
I O COMCBE Communication to other CPU
I O TMONI Temperature monitoring
I O CPU CPU System Functions
I O AUX1 Start-up Sequence Control
I O DOPAR Parameter Read/Write Logic
I O AUX2 Auxiliaries Control
I O MOPRO Rotor protection
I O MSG Messages to OP177
I O PANEL Communication to OP177
I O OUAUX Auxiliary outputs
INPUT Communication and scaling I O
LCOMRG Commissioning functions I O
CECO Coil eccentricity compens. I O
POSIT Spindle spotting I O
LBCON Load balancing I O
DRVMG Drive Manager I O
OUTPUT Communication and scaling I O
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DRIVE (Infeed / Motor) PDA ET200S (Mot / Aux) DC-Master (Field)
DR-SM150
page 66
2.12 General Content and Structure of the DCC-charts
Additionally to the control of the Infeed (CX32) and of the Motor Module (D445_SINAMICS_Integrated) extensive
additional functionality is provided in D445_SIMOTION via DCC-charts. The diagram above lists the majority of DCC-
charts; to view the entire list, refer to SIMOTION Program > Plne.
The data exchange between the DCC-programs, the Basic Automation / MRG, the Drives Functions / Infeed,
Motor Module, Exciter and the Periphery / ET200 is carried out via System Variables which are assigned to the
process data address codes in the I/O-container.
A detailed list of contents of the individual DCC-charts, each chart containing a large number of sheets (A, B, ) with
six assigned pages is always given on the first page of sheet A.
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dditional functionality is provided in D445_SIMOTION via DCC-charts. The diagram above lists the majority of DCC-
The data exchange between the DCC-programs, the Basic Automation / MRG, the Drives Functions / Infeed,
Motor Module, Exciter and the Periphery / ET200 is carried out via System Variables which are assigned to the
process data address codes in the I/O-container.
A detailed list of contents of the individual DCC-charts, each chart containing a large number of sheets (A, B, ) with
six assigned pages is always given on the first page of sheet A.
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2.12 General Content and Structure of the DCC-char
Additionally to the control of the Infeed ( CX32) and of the Motor Module (
dditional functionality is provided in D445_SIMOTION via DCC-charts. The diagram above lists the majority of DCC-
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ET200S (Mot / Aux)
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Comm_Common page 67
Cross-Reference from OP177-Messages to DC-Charts
A reference to the related page of the DCC-
charts is shown on the OP177 in column
Text once an alarm or a trip is monitored.
The reference (=.WA01) related to the fault is
given in column Text and can be identified
as Comment in the list of all charts assigned
to Plne (charts) of SIMOTION D445.
DR-SM150
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actual messages X
Date Time Text
29/03/11 06:12:33 =.WA01/C1
Error Software Protection
page 68
2.13 Assigning the Code to activate DCC-charts
Checking the indication on the OP177 you will find a message indicating the existence of SEVERAL alarms or faults.
Identify the nature of these alarms or faults by clicking on the symbol :
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
If the messages are in German, change the language to English via key F7/System and the assigned SW-button.
Return to the main faceplate via key F1/Start or [ X ] within the menu.
You will notice that one of the messages reads Error software protection.
Many of the function blocks used in the DCC-charts are especially designed for rolling-mill applications. These blocks
are software-protected and the DCC-charts using these blocks are processed by Simotion only if the correct code is
registered (this code is generated by Siemens on the basis of the serial number of the compact flash card).
The code has to be registered in one of the DCC-charts. Use the information on the OP177 / alarm display to find out
to which chart you have to go to enter the code:
chart: . . . . . . . . . . . . . . . . . . . . . . . . . . .
!
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If the messages are in German, change the language to English via key F7/System and the assigned SW-button.
Return to the main faceplate via key F1/Start or [ X ] within the menu.
You will notice that one of the messages reads Error software protection.
Many of the function blocks used in the DCC-charts are especially designed for rolling-mill applications. These blocks
are software-protected and the DCC-charts using these blocks are processed by Simotion only if the correct code is
registered (this code is generated by Siemens on the basis of the serial number of the compact flash card).
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2.13 Assigning the Code to activate DCC-charts
hecking the indication on the OP177 you will find a message indicating the existence of SEVERAL alarms or faults.
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Comm_Common page 69
Assigning the Code to activate the CFC-charts
Chart Reference Data Compile Download
Test Mode Overview Sheet View
Watch On Watch Off
DR-SM150
page 70
Open DCC-chart CPU, sheet C1 (the project specific name of the chart is U2CPU; U2 is an identifier valid for this
project, CPU is the block name in general).
Select Test Mode, mark block SWP100 and set Watch On. Presently the wired output QKF respectively
BM_ERR_SWP reads value 1 which means Error software protection.
Take a note of the serial numbers SN1 and SN5 (as an example; at site you have to record all serial numbers if the
Code still has to be generated by Siemens):
block U2CPU, serial number SN1: . . . . . . . . . . . . . . . . . . . . . . . . . .
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Take a note of the serial numbers SN1 and SN5 (as an example; at site you have to record all serial numbers if the
Code still has to be generated by Siemens):
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Open DCC-chart CPU, sheet C1 (the project specific name of the chart is U2CPU; U2 is an identifier valid for this
project, CPU is the block name in general).
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page 69
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Comm_Common page 71
Customizing I/Os by assigning Comments
DR-SM150
page 72
Inputs and outputs of function blocks are identified by names which are factory set and cannot be redefined. To
customize these I/Os, however, self defined comments can be assigned. The changeover from I/O-name to I/O-
comment is activated via Options > Customize > Layout. By positioning the cursor on any I/O a tool tip text
providing additional information pops up.
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Inputs and outputs of function blocks are identified by names which are factory set and cannot be redefined. To
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customize these I/Os, however, self defined comments can be assigned. The changeover from I/O-name to I/O-
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Comm_Common page 73
Changing Block Values in DCC-Offline
menu to change block values
in DCC-offline
consistency is restored after the download
DR-SM150
page 74
Set Watch Off, discontinue Test Mode and assign the code numbers for the CFC you are using (refer to the list
below) after a doubleclick on the individual I/O:
Possibility 1) internal serial numbers generated for the Compact Flash Card ST0B8222290000062553 :
SN1: 38423054 SN2: 32323232 SN3: 30303039 SN4: 32363030 SN5: 00333535 SN6: 4F4E5241
Code numbers to be entered in U2CPU / C1 / SWP100
CW1: 16#AC15B40D CW2: 16#FC340A1F CW3: 16#29240982
CW4: 16#17915EA5 CW5: 16#AED72302 CW6: 16#5B34724F
Possibility 2) internal serial numbers generated for the Compact Flash Card ST0BKM02-0000006456 :
SN1: 54534643 SN2: 304D4B42 SN3: 30302D32 SN4: 30303030 SN5: 36353436 SN6: 4F4E5241
CW1: 16#42F36528 CW2: 16#A0109EB5 CW3: 16#B4949D5E
CW4: 16#55B498FA CW5: 16#B4C5726E CW6: 16#DF9D3DF9
SN1: 38423054 SN2: 32323232 SN3: 30303039 SN4: 32363030 SN5: 00313535 SN6: 4F4E5241
CW1: 16#AC15B40D CW2: 16#FC340A1F CW3: 16#29240982
CW4: 16#17915EA5 CW5: 16#671D3513 CW6: 16#1981C50C
To activate these changes, the DCC-chart has to be compiled and downloaded (to download any DCC-chart,
D445_SIMOTION has to be downloaded; the inevitable change from RUN to STOP and back to RUN is requested by
the system whenever applicable).
A few seconds after the download the output BM_ERR_SWP of block SWP100 reads value 0 (no code error)
and fault F082 on the DC-Master clears automatically. The D445 fault Excitation group signal fault, however, still
persists.
SN1: 38423054 SN2: 32323232 SN3: 30303039 SN4: 32363030 SN5: 00333535 SN6: 4F4E5241
CW1: 16#AC15B40D CW2: 16#FC340A1F CW3: 16#29240982
CW4: 16#17915EA5 CW5: 16#AED72302 CW6: 16#5B34724F
Possibility 2) internal serial numbers generated for the Compact Flash Card ST0BKM02-0000006456 :
SN1: 54534643 SN2: 304D4B42 SN3: 30302D32 SN4: 30303030 SN5: 36353436 SN6: 4F4E5241
CW1: 16#42F36528 CW2: 16#A0109EB5 CW3: 16#B4949D5E
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Set Watch Off, discontinue Test Mode and assign the code numbers for the CFC you are using (refer to the list
below) after a doubleclick on the individual I/O:
SN1: 38423054 SN2: 32323232 SN3: 30303039 SN4: 32363030 SN5: 00333535 SN6: 4F4E5241
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consistency is restored after the download
Comm_Common page 75
Changing Block Values in DCC-Online
menu to change block values in DCC-online
(Test Mode and Watch On)
saving data on Compact Flash Card
saving data on PG/PC
close all charts / save and compile the project
DR-SM150
page 76
Contrary to the sequence just followed, most of the modifications of the CFC-programming you might have to carry out
during commissioning will typically be done in online mode (Watch On state; i.e. changing input values). These
changes become effective in the D445_SIMOTION RAM immediately and they are stored in the PG-RAM
automatically.
To save these changes in the non-volatile memory (on CFC), the function Copy RAM to ROM has to be carried out
for D445_SIMOTION.
To update the PG/PC-project with the modifications introduced while in DCC-Online, the function Compile Chart
(saving data of the compiled charts in the PG/PC-project) has to be carried out for all concerned charts.
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To save these changes in the non-volatile memory (on CFC), the function Copy RAM to ROM has to be carried out
for D445_SIMOTION.
To update the PG/PC-project with the modifications i
(saving data of the compiled charts in the PG/PC-project) has to be carried out for all concerned charts.
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Contrary to the sequence just followed, most of the modifications of the CFC-programming you might have to carry out
during commissioning will typically be done in online mode (Watch On state; i.e. changing input values). These
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Comm_Common page 77
Clearing Faults and Alarms on behalf of the DC-Master
Some faults within the exciter circuit are monitored both on the DC-Master and on the OP177 (via DCC-charts)
DC-Master
OP177
DR-SM150
page 78
2.14 Clearing faults and alarms on behalf of the DC-Master
The OP177, which is now indicating the operating state of the hardware components (circuit breakers, exciter unit,
infeed, motor module, motor and auxiliaries) now indicates a good number of faults or alarms.
These faults and alarms now have to be cleared one by one.
Start by following up the fault Trip overvoltage protection excitation DC-side.
PLEASE NOTE that faults and alarms of the drive hardware such as DC-Master, Infeed and Motor Module are
indicated by the respective hardware (Fxx messages for the DC-Master, Alarms via SCOUT for Infeed and Motor
Module) but are also sent to Simotion and are finally displayed on the OP177.
Faults of the exciter hardware are (in part) evaluated by the DC-Master (without being indicated on the DC-Master
itself) and then sent on to Simotion where the fault is picked up to trigger the required action and from where the
message is sent to the OP177.
Refer to the plant function diagrams for the DC-Master and find out which external monitoring device generates the
message Trip overvoltage protection excitation DC-side:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Find out which switch on the training rack is assigned to simulate this condition:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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These faults and alarms now have to be cleared one by one.
Start by following up the fault Trip overvoltage protection excitation DC-side
LEASE NOTE that faults and alarms of the drive hardware such as DC-Master, Infeed and Motor Module are
indicated by the respective hardware (Fxx messages for the DC-Master, Alarms via SCOUT for Infeed and Motor
Module) but are also sent to Simotion and are finally displayed on the OP177.
Faults of the exciter hardware are (in part) evaluated by the DC-Master (without being indicated on the DC-Master
itself) and then sent on to Simotion where the fault is picked up to trigger the required action and from where the
message is sent to the OP177.
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2.14 Clearing faults and alarms on behalf of the DC-Master
The OP177, which is now indicating the operating state of the hardware components (circuit breakers, exciter unit,
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Comm_Common page 79
Measuring Values of Binectors and Connectors (DC-Master)
measuring Binectors
measuring Connectors
(accuracy of 0.1%)
selection: P046.3 = B0210
indication on: r045.03 = 0 / 1
selection: P044.4 = K0193
indication on: r043.04 = xx.x%
DR-SM150
page 80
Go online to the DC-Master and check the logic state of the binector which picks up this external monitoring device:
P . . . . . . . . . . . . = . . . . . . . . . . . .
If you switch on the assigned simulator switch S4 the logic state of the binector still reads a constant L-state.
Adapt the related BiCo-connections for the SICROWBAR considering the fact that the simulator switch is connected
to CUD1, terminal X171:39 instead of CUD2, terminal X161:214:
U350 .1 = . . . . . . . . . . . . . U . . . . . . . . . . . . . = . . . . . . . . . . . . . U . . . . . . . . . . . . . = . . . . . . . . . . . . .
Clear the (simulated) hardware fault by switching on the assigned switch on the auxiliary rack:
the fault is automatically cleared on the OP177; the overall number of faults is decremented by one.
Find the source of the fault Trip overvoltage protection excitation AC-side by referring to the plant function
diagrams for the DC-Master and identifying the I/O-terminal and the assigned binector:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assume the I/O-board CUD2 temporarily missing (which it actually is) and program a software substitute for the
(temporarily) not available binector to the EEPROM:
U . . . . . . . . . . . . . = . . . . . . . . . . . . .
After acknowledging with key F8/ACK fault Trip overvoltage protection excitation AC-side is cleared.
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Adapt the related BiCo-connections for the SICROWBAR considering the fact that the simulator switch is connected
to CUD1, terminal X171:39 instead of CUD2, terminal X161:214:
1 = . . . . . . . . . . . . . U . . . . . . . . . . . . . = . . . . . . . . . . . . . U . . . . . . . . . . .
Clear the (simulated) hardware fault by switching on the assigned switch on the auxiliary rack:
the fault is automatically cleared on the OP177; the overall number of faults is decremented by one.
Find the source of the fault
iagrams for the DC-Master and identifying the I/O-terminal and the assigned binector:
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Go online to the DC-Master and check the logic state of the binector which picks up this external monitoring device:
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measuring Binectors
Comm_Common page 81
Clearing Faults and Alarms on behalf of the DC-Master
Some faults within the exciter circuit are monitored ONLY on the OP177 (via DCC-charts)
OP177
DR-SM150
page 82
Follow the same approach to clear the alarm Alarm earth fault monitoring rotor:
- I/O-terminal and assigned binector: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- temporary substitute: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The alarm Alarm earth fault monitoring rotor is cleared automatically.
Again follow this approach to clear the alarms
- CB earth fault monitoring rotor tripped U . . . . . . . . . . . . . . .
- CB excitation converter fan 1 tripped U . . . . . . . . . . . . . . .
Both alarms are cleared automatically.
Assign the fault Trip earth fault monitoring rotor to the same I/O-terminal through which the DC-Master fault
F021 is generated (simulated via switch S3):
U . . . . . . . . . = . . . . . . . . .
Test the function and clear the indicated faults.
The last message on behalf of the DC-Master reads Overload overvoltage protection excitation DC-side. Once
more refer to the plant function diagrams for the DC-Master and follow the message Overload overvoltage protection
excitation DC-side.
Find out which switch on the training rack is assigned to simulate this condition (this switch simultaneously acts as
E-Stop indication o10.3 on the DC-Master):
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch on the identified simulation switch and verify that a.m. message can be acknowledged on the OP177; also
verify that the operating state of the DC-Master changes from o10.3/E-Stop to o7.1/Waiting for the On command,
that the D445 fault Excitation group signal fault finally clears and that the RDY-LED of CU320-2 turns green.
Save the parameterization you have made in the DC-Master as a delta file by the name DC_Yas_Trainee_Delta_2.
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The alarm Alarm earth fault monitoring rotor is cleared automatically.
Again follow this approach to clear the alarms
CB earth fault monitoring rotor tripped
CB excitation converter fan 1 tripped
Both alarms are cleared automatically.
Assign the fault
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Follow the same approach to clear the alarm Alarm earth fault monitoring rotor
I/O-terminal and assigned binector: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Comm_Common page 83
Clearing Faults and Alarms on behalf of the ET200-Stations
ET200S / Auxiliaries (HIB)
01
PM
02
DI
03
03 . 10
8 x DI
04 . 11
11
DI
12
12
DO
13
16
DO
17
17
DI
18
18 . 31
14 x DI
19 . 32
32
DI
33
33
TM
slot
IM
AX
13
DO
14
14
DO
15
15
DO
16
- A11 - X13 module AX13
Q . 2 Output . Bit 2
terminals 2 (signal)
4 (common)
bit 4 0 5 1
1 5
2 6
bit 6 2 7 3
nibble high low high low
ET200-
terminal
nibble L H H L H L L H
- A11 X18 module AX18
I . 0 Input . Bit 0
3 (common)
The first module after a change of type starts with the Low- nibble.
- A11 X23 module AX23
I . 4 Input . Bit 4
3 (common)
DR-SM150
page 84
2.15 Clearing faults and alarms (on behalf of the ET200 stations)
By now the list of fault or alarm messages has been reduced to 7:
- Switch Off fault cooling pump 1
- Stator transformer 1 oil temperature alarm - Stator transformer 1 oil temperature trip
- Stator transformer 1 Buchholz relay alarm - Stator transformer 1 Buchholz relay trip
- Delayed trip TC7 fast stop request
- Delayed trip TC8 stop rolling request
The last two messages listed are Tripping Combination messages (TCxx). TCxx-messages represent a
summary message which will clear only once the individual messages which are part of the summary message are
cleared.
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- Stator transformer 1 Buchholz relay alarm - Stator transformer 1 Buchholz relay trip
- Delayed trip TC7 fast stop request
- Delayed trip TC8 stop rolling request
The last two messages listed are Tripping Combination messages (TCxx). TCxx-messages represent a
summary message which will clear only once the individual messages which are part of the summary message are
cleared.
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2.15 Clearing faults and alarms (on behalf of the ET200 stations)
By now the list of fault or alarm messages has been reduced to 7:
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bit 4 0
bit
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high low high
ET200-
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Comm_Common page 85
Cross-Reference from OP177-Messages to Circuit Diagrams
A reference to the related page of the circuit
diagrams is shown on the OP177 in column
Text once an alarm or a trip is monitored.
E.g. = D 01 / 02 . 2 the terminal of the
ET200S for the alarm/trip is shown on
page D01, sheet 2, column 2.
actual messages X
Date Time Text
29/10/09 08:45:17 =.D01/02.2
Stator Xformer 1 alarm oil temperature
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DR-SM150
page 86
In the next step, message Stator transformer 1 oil temperature alarm will be cleared. Use the circuit diagrams for
the mill stand and the information provided on the OP177 to find out by which ET200 module and by which of its
inputs the message Stator transformer 1 oil temperature alarm is picked up (follow main transformer system 1).
information of OP177 . . . . . . . . . . . . . . . . . . . . . . . . . circuit diagram / sheet no. . . . . . . . . . . . . . . . . . . . . . . . . . .
ET200 module no. . . . . . . . . . . . . . . . input terminal . . . . . . . . . . . . . . Low nibble, bit no. . . . . . . . . . . . . .
Use the circuit diagram of the Auxiliaries Rack to find out which switch is used to simulate the message above:
switch S . . . . . . . . . .
Switch this switch on to clear message Stator Xformer 1 oil temperature alarm ; the message acknowledges
automatically.
Follow the same procedure to find out which switch simulates message Stator transformer 1 oil temperature trip:
switch S . . . . . . . . . .
Clear the message Stator transformer 1 oil temperature trip; this message has to be acknowledged via OP177
(key F8/ACK).
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information of OP177 . . . . . . . . . . . . . . . . . . . . . . . . . circuit diagram / sheet no. . . . . . . . . . . . . . . .
ET200 module no. . . . . . . . . . . . . . . . input terminal . . . . . . . . . . . . . . Low nibble, bit no. .
Use the circuit diagram of the Auxiliaries Rack to find out which switch is used to simulate the message above:
switch S . . . . . . . . . .
Switch this switch on to clear message Stator Xformer 1 oil temperature alarm ; the message acknowledges
automatically.
Follow the same procedure to find out which switch simulates message
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Stator transformer 1 oil temperature alarm
he mill stand and the information provided on the OP177 to find out by which ET200 module and by which of its
information of OP177 . . . . . . . . . . . . . . . . . . . . . . . . . circuit diagram / sheet no. . . . . . . . . . . . . . . .
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page 85
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Comm_Common page 87
Signal Routing from Charts to Field-Hardware
DR-SM150
Signal to be followed:
e.g. No-Load contactor open command (L-byte, H-nibble, bit 4)
bit 4 0 5 1
1 5
2 6
bit 6 2 7 3
ET200-
terminal
X
X
page 88
Since the Auxiliaries are switched off, Cooling Pump1 has to switched off as well.
Check the feedback message of Cooling Pump 1 on the OP177 via F14/Start up > button Cooling Unit.
You will notice that the status of Cooling Pump 1 reads ON; this mismatch between control and status is also
indicated by message Switch Off fault cooling pump 1.
Use the information on the OP177 to find the chart which processes this message:
information of OP177 . . . . . . . . . . . . . . . . . . . . . . . . . chart . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check the Table of Content for this chart to find the chart section related to this message: chart section . . . . . . . . . .
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Use the information on the OP177 to find the chart w
information of OP177 . . . . . . . . . . . . . . . . . . . . . . . . . chart . . . . . . . . . . . . . . . . . . . . . . . . .
Check the Table of Content for this chart to find the chart section related to this message: chart section . . . . . . . . .
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Since the Auxiliaries are switched off, Cooling Pump1 has to switched off as well.
Check the feedback message of Cooling Pump 1 on the OP177 via F14/Start up > button Cooling Unit.
Switch Off fault cooling pump 1.
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Comm_Common page 89
DR-SM150
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 bit
Status word
7 6 5 4 3 2 1 0 bit
H-byte
X13
7 6 5 4 3 2 1 0 bit
L-byte
3 2 1 0 bit
L-nibble
7 6 5 4 bit
H-nibble
3 2 1 0
7 6 5 4
X14
X15
X16
0 1
2 3
1 5
2 6
4 5
6 7
1 5
2 6
0 1
2 3
1 5
2 6
4 5
6 7
1 5
2 6
AX16 AX15 AX14 AX13
01
PM
02
DI
03
03 . 10
8 x DI
04 . 11
11
DI
12
12
DO
13
slot
IM
AX
13
DO
14
14
DO
15
15
DO
16
nibble L H H L H L H
Relation of DCC-Word to Terminal-No. / Word Byte Nibble
page 90
Which input reads a logic state not in tune with the required control state Cooling Pump 1 = OFF:
block . . . . . . . . . input . . . . . . .
Follow this signal upstream by double-clicking on the signal connection to the left of the block assigned to the signal
line until you reach the variable linking this message to the I/O-container:
variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use the information at the input of block DETM200 to find the page of the circuit diagrams of the mill stand showing
the ET200 input for the (incorrect) message Cooling Pump 1 = ON:
information on block DETM200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
first page in circuit diagram / sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
second page in circuit diagram / sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use this circuit diagram to find out whether the feedback message Cooling Pump 1 = ON corresponds to the control
command Cooling Pump 1 = ON.
feedback message at AX26, terminal 1: logic state = . . . . . . .
control command at module AX . . . . . . . . ., terminal . . . . . . . . ., logic state = . . . . . . .
Check the switching state of contactor K15 (substituting K11 and K13 of the mill stand) in the back of the training rack;
please dont pull any wires!
Tell your trainer what you think is wrong (he will fix it !): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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line until you reach the variable linking this message to the I/O-container:
variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use the information at the input of block DETM200 to find the page of the circuit diagrams of the mill stand showing
the ET200 input for the (incorrect) message Cooling Pump 1 = ON:
information on block DETM200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4 5
6 7
1 5 1 5 1 5 1 5 1 5
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Comm_Common page 91
Signal Transfer between ET200 and SIMOTION via I/O-Container
signal from
ET200
address references in the I/O-container
1 (3)
AX13, terminal 2
L-byte, L-nibble, bit 2 PQ 1600.2
DR-SM150
page 92
2.16 Forcing a control command via ET200
For a clearly defined condition please select Local Mode and Auxiliaries off on the OP177 and acknowledge fault
Switch Off fault cooling pump 1. If necessary press key K9/Local (LED = green) and press key K11/AUX OFF
(LED = green).
Since several alarms and faults still persist, the control of the Auxiliaries (i.e. Cooling Pumps) is blocked. To force
Cooling Pump 1 to ON, ET200 module A11-X16, terminal 2 has to be activated.
To find the chart in which to force Cooling Pump 1 = ON, follow the procedure as follows.
Open the HW-Config and find out which address is assigned to this ET200:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Any signal exchange from ET200 to Simotion is carried out via variables. Use the I/O-container to identify the name of
the variable assigned to the address found above:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supplement the table below to create a cross reference between address, module number, output terminal, bit
number and nibble (refer to the information relating the ET200 terminal numbers to the bit numbers, page 94):
address: 1601. 7 6 5 4 1601. 3 2 1 0 1600.7-4 1600.3-0
module number: X16 X15 X14 X13
bit number:
nibble (H, L): .. ..
output terminal:
Which byte (H, L), nibble (H, L) and bit of the assigned variable represents Cooling Pump 1?
byte . . . . . . . . . . nibble . . . . . . . . . . bit . . . . . . . . . .
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Since several alarms and faults still persist, the control of the Auxiliaries (i.e. Cooling Pumps) is blocked. To force
Cooling Pump 1 to ON, ET200 module A11-X16, terminal 2 has to be activated.
To find the chart in which to force Cooling Pump 1 = ON, follow the procedure as follows.
Open the HW-Config and find out which address is assigned to this ET200:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Any signal exchange from ET200 to Simotion is carried out via variables. Use the I/O-container to identify the name of
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2.16 Forcing a control command via ET200
or a clearly defined condition please select Local Mode and Auxiliaries off on the OP177 and acknowledge fault
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L-byte, L-nibble, bit 2
Comm_Common page 93
Finding the Reference address / variable / chart
1600.0 1600.3
address references in I/O-container
any DCC-chart
AX13, terminal 2 L-byte, L-nibble, bit 2 PQ 1600.2
2 (3)
DR-SM150
page 94
Find out on which DCC-chart and on which page the variable representing Cooling Pump 1 is processed as output:
circuit diagram / page nr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(open any DCC-chart > Options > Chart reference data > View > Cross-ReferencesAddress > select variable >
double-click on this variable to open the DCC-chart showing the variable).
Analyze which bits of the variable in question are on H-state:
hex-value: . . C 0
binary-value: 1 1 0 0 0 0 0 0
The identified ET200 word (for modules X13-X16) is output from block OUP130 (chart OUAUX, sheet C1).
Which hex-value has to be OR-wired in input I2/VM_HMEXFC to permanently switch on the cooling pump:
current binary-value of output QS: 1 1 0 0 0 0 0 0
required binary-value of output QS: 1 1 0 0 0 0 0 0
necessary OR-word at input I2: 0 0 0 0 0 0 0 0
necessary OR-word in hex: .... . 0 0
Activate the Test Mode, set Watch On for blocks OUP150 and OUP130, change input I2/VM_HMEXFC of block
OUP130 to the hex-value you have defined and verify that output Q15 of block OUP150 (Converter cooling pump 1
on command) reads logic H.
Discontinue the forced operation of Cooling Pump 1 by changing input I2, block OUP130 back to 16#0.
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double-click on this variable to open the DCC-chart showing the variable).
Analyze which bits of the variable in question are on H-state:
hex-value: . . C 0
binary-value:
The identified ET200 word (for modules X13-X16) is output from block OUP130 (chart OUAUX, sheet C1).
Which hex-value has to be OR-wired in input I2/VM_HMEXFC to permanently switch on the cooling pump:
current binary-value of output QS:
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circuit diagram / page nr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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AX13, terminal 2
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Comm_Common page 95
Control via PG/PC in parallel to Base Automation (MRG)
X14: high-nibble X13: low-nibble
current hex-value 7 2
current binary value 0 1 1 1 0 0 1 0
required binary value 0 1 1 1 0 1 1 0
necessary OR-word 0 0 0 0 0 1 0 0
dto. In hex 0 4
resulting hex-value 7 6
Correlation of I/Os of ET200 to bits
to be set to high to switch on
the anti condensation heater:
bit 2 (low-nibble) / low-byte
high-byte
16#3B72
16#0000
16#3B72 16#3B
16#72
16#76
16#0004
low-byte
low-nibble high-nibble
ON-command for the anti-condensation heater:
via -X13, terminal 2 = H
via bit 2 (low-nibble) / low-byte
bit 4 0 5 1
1 5
2 6
bit 6 2 7 3
ET200-
terminal
3 B 7 2
bit 15-12 11-8 7-4 3-0
3 (3)
DR-SM150
page 96
2.17 Clearing faults and alarms (on behalf of the ET200 stations); continued
As next step of clearing faults and alarms the still indicated individual messages Stator transformer 1 Buchholz
relay alarm and Stator transformer 1 Buchholz relay trip will have to be followed up.
Use the information provided on the OP177 and the circuit diagrams for the mill-stand to find out by which ET200
module and by which of its inputs Stator Transformer Buchholz Alarm and Stator Transformer Buchholz Trip are
picked up.
ET200 module nr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
input terminal for Alarm: . . . . . . . . . . . . . . for Trip: . . . . . . . . . . . . . .
Find out whether the related hardware inputs are connected to the Buchholz relay (respectively to simulation
switches).
Buchholz alarm: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Buchholz trip : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If some components which are part of the evaluation by Simotion are temporarily not available, the concerned inputs
of the ET200 modules can be temporarily connected to P24V simulating an OK feedback.
If some components will permanently be missing (i.e. a stator transformer without Buchholz relay is used), an
adaptation of the related DCC-chart might be reasonable.
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Stator transformer 1 Buchholz relay trip
se the information provided on the OP177 and the circuit diagrams for the mill-stand to find out by which ET200
module and by which of its inputs Stator Transformer Buchholz Alarm and Stator Transformer Buchholz Trip are
ET200 module nr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
input terminal for Alarm: . . . . . . . . . . . . . . for Trip: . . . . . . . . . . . . . .
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2.17 Clearing faults and alarms (on behalf of the ET200 stations); continued
As next step of clearing faults and alarms the still indicated individual messages
Stator transformer 1 Buchholz relay trip
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to be set to high to switch on
the anti condensation heater:
bit 2 (low-nibble) / low-byte
low-nibble
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Identification of Fault and Alarm Messages sent to OP177
16#0
16#8040
16#0
16#0
16#0
16#0
16#0
16#0
16#8040
16 # 8040 8 0 4 0
1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0
bit number 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
bit
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
DR-SM150
page 98
Fault and alarm messages coming in from the plant (via ET200 stations) are evaluated and processed to initiate
further actions on a larger number of DCC-charts.
In chart MSG, on sheets D4, D5 all messages which are sent to the OP177 are listed; without any fault or alarm
all outputs of the three related blocks have to read 16#0.
Find out which outputs on which block read other than 16#0 and take a note of the value:
block . . . . . . . . . . . . . . . . . . . . . . . . . . output . . . . . . . . . . value . . . . . . . . . .
output . . . . . . . . . . value . . . . . . . . . .
Follow the identified output with the smallest output number all the way to a sheet showing a table with details of the
fault word; proceed as follows:
- single click on the line at the input of the block which corresponds to the output (verify the signal value via tool tip
text to find the matching input)
- double click on the destination reference for the follow-up sheet
Analyze output QS of block FWH210 to find out which bits read a logic H: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Which messages are identified by these bits: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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In chart MSG, on sheets D4, D5 all messages which ar
Find out which outputs on which block read other th
block . . . . . . . . . . . . . . . . . . . . . . . . . . output . . . . . . . . . . value . . . . . . . . . .
Follow the identified output with the smallest output number all the way to a sheet showing a table with details of the
fault word; proceed as follows:
- single click on the line at the input of the block which corresponds to the output (verify the signal value via tool tip
text to find the matching input)
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Fault and alarm messages coming in from the plant (via ET200 stations) are evaluated and processed to initiate
further actions on a larger number of DCC-charts.
In chart MSG, on sheets D4, D5 all messages which ar
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Comm_Common page 99
16# 8 0 4 0
enabling
bit 0 - 3
16#FFFF
16# 7 3 B F
enabling
bit 4 - 7
enabling
bit 8 - 11
enabling
bit 12 - 15
1
1
0
1
from upstream: 16 # 73BF 0 1 1 1 0 0 1 1 1 0 1 1 1 1 1 1
definition NO/NC 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Enabling 1 1 1 1 0 0 0 0 1 1 1 1 1 1 1 1
message to OP177 1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0
dto. In hex 8 0 4 0
*
from page 101
condition from field contact definition signal to OP177 alarm/fault state
H n.o. H L no message
H n.c. L H message
L n.o. H H message
L n.c. L L no message
Enabling / Blocking Groups of Faults
DR-SM150
page 100
Which field messages are evaluated if the group of messages belonging to bit 0 to 3 is enabled:
by bit 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by bit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by bit 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by bit 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exclude all these field messages from being evaluated as messages on the OP177 by blocking the entire group
(nibble) to which they belong.
On block DEN200 (chart AUX1, sheet D2) you can either follow I1 which will eventually lead you to a selection of oil
transformer / dry transformer or you can follow I2 which defines the existence of a stator transformer in general.
In the present step please follow the approach via I2.
Once you have blocked the entire group all messages on the OP177 either reset automatically or can be
acknowledged.
Which field messages are no longer be evaluated in addition to the messages Stator transformer 1 Buchholz relay
alarm and Stator transformer 1 Buchholz relay trip by having blocked the entire group:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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by bit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by bit 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by bit 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exclude all these field messages from being evaluated as messages on the OP177 by blocking the entire group
(nibble) to which they belong.
On block DEN200 (chart AUX1, sheet D2) you can either follow I1 which will eventually lead you to a selection of oil
transformer / dry transformer or you can follow I2 which defines the existence of a stator transformer in general.
In the present step please follow the approach via I2.
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Which field messages are evaluated if the group of messages belonging to bit 0 to 3 is enabled:
by bit 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by bit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1 1 1 1
0 0 0 0
0
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condition from field contact definition signal to OP177 alarm/fault state
no message
H
Comm_Common page 101
Blocking (Enabling) Individual Faults
6
15
16#0
16#F3FF
16#8040
1
1
1
1
1
1
0
1
1
1
0
0
1
1
1
0
1
1
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1
1
1
1
1
1
1
0
0
1
1
1
1
6
15
16#73BF
from upstream: 16# 73BF 0 1 1 1 0 0 1 1 1 0 1 1 1 1 1 1
transfer to OP177 1 1 1 1 0 0 1 1 1 1 1 1 1 1 1 1
OR-word binary 1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0
OR-word in hex 8 0 4 0
16#73BF
messages of bits 10, 11 are blocked downstream via / enable bit 8-11
messages of bits 6, 15 have to be blocked individually
- blocking (output = H no message) is effected by OR-linking the
respective bits with H in case of n.o. contacts
- or by AND-linking the respective bits with L in case of n.c. contacts
*
to page 99
DR-SM150
page 102
If these two messages must not be suppressed, the blocking of an entire group is not permissible. In this case the
messages to be suppressed have to be blocked individually.
To follow this approach, enable the group of messages you have just blocked: the messages Stator Buchholz alarm /
trip show up again.
To find the source of the field messages, follow the input of block FWH210 (chart AUX1, sheet E2) upstream all the
way to a sheet showing a table which lists the individual field messages.
Check the state of the field messages Stator Buchholz alarm / trip on block ETA250 (chart INAUX, D2):
- stator transformer Buchholz no alarm . . . . . . . . .
- stator transformer Buchholz no trip . . . . . . . . .
Assign a suitable word to the OR-gate (block ETA230) to suppress only the a.m. two messages.
required word at OR-gate binary
hex
Again all messages on the OP177 either reset automatically or can be acknowledged.
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To find the source of the field messages, follow the input of block FWH210 (chart AUX1, sheet E2) upstream all the
way to a sheet showing a table which lists the individual field messages.
Check the state of the field messages Stator Buchholz alarm / trip on block ETA250 (chart INAUX, D2):
- stator transformer Buchholz no alarm . . . . . . . . .
- stator transformer Buchholz no trip . . . . . . . . .
Assign a suitable word to the OR-gate (block ETA230) to suppress only the a.m. two messages.
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If these two messages must not be suppressed, the blocking of an entire group is not permissible. In this case the
messages to be suppressed have to be blocked individually.
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Enabling (Groups of) Field Messages
enabling
bit 0 - 3
enabling
bit 4 - 7
enabling
bit 8 - 11
enabling
bit 12 - 15
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DR-SM150
page 104
2.18 Adding field messages to the fault monitoring
Find out which conditions are simulated by switches S13 and S15 on the auxiliaries rack at the input of ET200:
- ET200 module number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- terminal number for S13: . . . . . . . . . . . . . . . . . . . . . . for S15: . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- circuit diagram / page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- simulated condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
In the next step the DCC-programming has to be adapted to have these two messages shown on the OP177 (if the
respective simulation switches are off).
Start on chart AUX1, sheet E2 by analyzing the change of Faultword Hardware 2 at the input of block FWH210 while
simulating the two messages (each message by itself).
S13: change from 16 # . . . . . . . . . . to 16 # . . . . . . . . . . S15: change from 16 # . . . . . . . . . . to 16 # . . . . . . . . . .
Which bits are controlled by the switches? S13: ET200-view bit . . . . . . . DCC-fault-word-view bit . . . . . . .
S15: ET200-view bit . . . . . . . DCC-fault-word-view bit . . . . . . .
Follow the signal upstream to a sheet showing a table which lists the individual field messages.
On block ETA250 (chart INAUX, D2) check the state of these two field messages when switching S13 and S15.
Which setting is presently blocking these two messages from being indicated on the OP177:
responsible nibble in chart AUX1, E2, block . . . . . . . . . . . . . . for the group of messages belonging to bits . . . . . . . . .
Follow this input upstream and enable the nibble for this group of messages.
- setting in chart . . . . . . . . . . . . sheet . . . . . . . . . . block . . . . . . . . . . . . . to value . . . . . . .
- setting in chart . . . . . . . . . . . . sheet . . . . . . . . . . block . . . . . . . . . . . . . to value . . . . . . .
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ET200 module number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- terminal number for S13: . . . . . . . . . . . . . . . . . . . . . . for S15: . . . . . . . . . . . . . . . . . . . . . . .
- circuit diagram / page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- simulated condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
In the next step the DCC-programming has to be adapted to have these two messages shown on the OP177 (if the
respective simulation switches are off).
Start on chart AUX1, sheet E2 by analyzing the change of Faultword Hardware 2 at the input of block FWH210 while
simulating the two messages (each message by itself).
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2.18 Adding field messages to the fault monitoring
which conditions are simulated by switches S13 and S
ET200 module number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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enabling
bit 12 - 15
Blocking Individual Messages
101
DR-SM150
page 106
Depending on the sequence you followed in enabling the nibble for the group of messages different messages will
have been indicated by the OP177.
If you acknowledge the OP177-messages now, you will observe that not only the intended messages Excitation
transformer winding temperature alarm and Excitation transformer winding temperature trip are indicated but
additionally the message Excitation transformer core temperature trip.
Suppress message Excitation transformer core temperature trip individually:
- which bit is responsible: bit . . . . . . .
- which hex value has to be OR-linked to set above bit by itself:
16 # . . . . . . . . . . / on chart INAUX, sheet . . . . . . . . in block . . . . . . . . .
- which hex value has to be set to maintain the previous and add the new suppression: 16 # . . . . . . . . . .
Verify that message Excitation transformer core temperature trip can be acknowledged and that the messages
Excitation transformer winding temperature alarm and Excitation transformer winding temperature trip can be
simulated with switches S13 and S15.
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additionally the message Excitation transformer core temperature trip.
Suppress message Excitation transformer core temperature trip individually:
- which bit is responsible: bit . . . . . . .
- which hex value has to be OR-linked to set above bit by itself:
16 # . . . . . . . . . . / on chart INAUX, sheet . . . . . . . . in block . . . . . . . . .
- which hex value has to be set to maintain the previous and add the new suppression: 16 # . . . . . . . . . .
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Depending on the sequence you followed in enabling the nibble for the group of messages different messages will
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Enabling / Blocking Individual Control Signals
1 + 0 = 1
fans group 1 on
fans group 2 off
16#9F81
16#FFFD
16#9F83
16#9F81
16#FFFF
16#9F83
16#9F83
incoming control request: 16 # 9F83 9 F 8 3
binary coded: 1 0 0 0 1 1 1 1 1 0 0 0 0 0 1 1
required outgoing control request (bin): 1 0 0 0 1 1 1 1 1 0 0 0 0 0 0 1
required outgoing control request (hex): 9 F 8 1
required AND-word (binary): 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 1
required AND-word (hex): F F F D
3
0 0 1 1
0 0 1 1
3
1 1 1 1
F
1 + 2 = 3
fans group 1 on
fans group 2 on
- the incoming control word requires both fan
groups to run
- AND-gate OUP120 can be used to block a
control bit from being handed on downstream
- OR-gate OUP130 can be used to force a
control bit acting downstream if not set in the
incoming control word
DR-SM150
page 108
2.19 Selection of the active cooling pump
Set all switches on the auxiliaries rack such that no alarm or trip is indicated on the OP177; also switch on S10 and
S11 to disable the simulation of yet other fault conditions.
On the OP177 call up the main faceplate (key F1/Start), select Local Mode (key K9/Local) and verify that the
Auxiliaries are switched off (key K11/AUX OFF).
You will observe that the Auxiliaries are off, but ready to be switched on (information about the color code assigned
to the power hardware units on the Start-menu of the OP177 can be accessed via key F5/Help).
Now switch on the Auxiliaries (key K3/AUX ON): you will notice that the LED next to switch S10 lights up (which
indicates Motor fans group 1 = ON) and that after a delay of 10s the ready state of the auxiliaries is indicated on
the OP177.
The DCC-controlled sequence activates Cooling Pump 1 simultaneously with Fan Group 1 once the Auxiliaries
are switched on. As you notice, however, the LED next to S11 doesnt light up (Cooling pump 1 is not switched on)
even though the Auxiliaries are switched on.
Open chart OUAUX and find out whether an ON-command is generated for Cooling Pump 1. You will notice that
Cooling Pump 2 is switched on instead.
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On the OP177 call up the main faceplate (key F1/Start), select Local Mode (key K9/Local) and verify that the
Auxiliaries are switched off (key K11/AUX OFF).
You will observe that the Auxiliaries are off, but ready to be switched on (information about the color code assigned
to the power hardware units on the Start-menu of the OP177 can be accessed via key F5/Help).
Now switch on the Auxiliaries (key K3/AUX ON): you will notice that the LED next to switch S10 lights up (which
indicates Motor fans group 1 = ON) and that after a delay of 10s the ready state of the auxiliaries is indicated on
the OP177.
The DCC-controlled sequence activates Cooling Pump 1 simultaneously with Fan Group 1 once the Auxiliaries
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et all switches on the auxiliaries rack such that no alarm or trip is indicated on the OP177; also switch on S10 and
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0 1 1 1 1 1 0 0 0 0 0 0 1 1 1 1 1 0 0 0 0 0 0
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1 1 1 1 1 1 1 1 0 1
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control bit from being handed on downstream
- OR-gate OUP130 can be used to force a
control bit acting downstream if not set in the
Global Device Variables as Link between OP177 and SIMOTION
DR-SM150
page 110
Follow the control signal Converter cooling pump 1 on command upstream to find out how you can manually switch
over from pump 2 to pump 1. (OUAUX, C1 OUAUX, B2 OUAUX, B1 AUXCU, T1 AUXCU, Q1 < follow
changeover from pump 2 to pump 1> AUXCU, Q4 <follow selection cooling pump 1> AUXCU, D1).
You will observe that the operation of Cooling Pump 1 respectively Cooling Pump 2 is defined via variable
selcp1_2. Since this variable is defined in the group Global device variables, the source for the control of the
Cooling Pumps is found to be the OP177.
To activate one of the two cooling pumps via OP177 proceed as follows:
- access menu Cooling Unit via key F14/Start up > button Cooling Unit
- in line selection of mode use button AUTO in column Selection to get the status MANUAL
- in line selection of pump 1/2 use the blank button in column Selection to get the status PUMP 1.
If the Auxiliaries are switched on, the LED next to switch S11 will now light up, which indicates that Converter
cooling pump 1 is switched on.
Crosscheck this state on the respective DCC-chart as well.
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changeover from pump 2 to pump 1>
ou will observe that the operation of Cooling Pump 1 respectively Cooling Pump 2 is defined via variable
selcp1_2. Since this variable is defined in the group Global device variables, the source for the control of the
Cooling Pumps is found to be the OP177.
To activate one of the two cooling pumps via OP177 proceed as follows:
- access menu Cooling Unit via key F14/Start up > button Cooling Unit
- in line selection of mode use button AUTO in column Selection to get the status MANUAL
- in line selection of pump 1/2 use the blank button in column Selection to get the status PUMP 1.
If the Auxiliaries are switched on, the LED next to switch S11 will now light up, which indicates that Converter
cooling pump 1 is switched on.
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Follow the control signal Converter cooling pump 1 on command upstream to find out how you can manually switch
over from pump 2 to pump 1. (OUAUX, C1 OUAUX, B2
changeover from pump 2 to pump 1> AUXCU, Q4 <follow selection cooling pump 1>
ou will observe that the operation of Cooling Pump 1 respectively Cooling Pump 2 is defined via variable
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Defining Properties for the ET200 Analog Modules
DR-SM150
page 112
2.20 Defining properties for the ET200 analog modules
As you will have noticed, the Motor ET200 station still indicates system fault (message SF on several analog input
modules).
This message typically appears if the analog inputs are fed by signals other than defined as object property for these
modules.
Open the HW-Configuration and set the object properties of an AI-module reading system fault as shown above
(right mouse click on module > Object Properties > tab parameters > click on the right end of line Measuring type >
select required type > OK).
Set the Measuring type of all concerned modules to match the given signal wiring.
To activate these changes in the project, start the routine Save and Compile,
to activate these changes in the D445, download the HW-Configuration: PLC > Download.
After you have followed all steps the system requests you to do the SF-message for the Mot-ET200 station will have
cleared.
Since some changes in the DCC-charts have been carried out in online-mode, they still have to be saved in the
project:
- exit test mode
- compile the DCC-charts (Chart > Compile > Charts as Program > Compile all)
- close all DCC-charts
- Save and Compile the SCOUT-project
Save all your modifications on the Flash Card for - D445_Master . (SIMOTION programming)
- Yask_CX32 (Infeed)
- Yask_SINAMICS(Motor Module)
Save your project by the name Yas_Syn1 and archive this project by the name Yas_syn1 as a zip-file.
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This message typically appears if the analog inputs are fed by signals other than defined as object property for these
Open the HW-Configuration and set the object properties of an AI-module reading system fault as shown above
(right mouse click on module > Object Properties > tab parameters > click on the right end of line Measuring type >
select required type > OK).
Set the Measuring type of all concerned modules to match the given signal wiring.
To activate these changes in the project, start the routine Save and Compile,
to activate these changes in the D445, download the HW-Configuration: PLC > Download.
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2.20 Defining properties for the ET200 analog modu
As you will have noticed, the Motor ET200 station still indicates system fault (message SF on several analog input
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Controlling the Drives Operation via OP177
standard ON-sequence: 1 5
standard OFF-sequence: A E
1 2 3 4 5
A
B C D E 5
DR-SM150
page 114
2.21 Controlling the drives operation via OP177
If the Auxiliaries are switched on, the operating state shown on the OP177 indicates ready to switch on for the main
CB, the exciter CB, the Infeed, the Motor Module and the DC-Master; only the motor still reads not ready to be
switched on.
In the fault free condition an interlocking sequence is predefined for Local Control.
PLEASE NOTE: DONT FOLLOW THESE STEPS AS YET other than suggested! In a plant side commissioning a
good number of measurements, settings and tests still need to be done before the drive can be switched on in full.
- Auxiliaries = ready Exciter, Infeed, Motor Module, Motor = ready
Main CB, Exciter CB = not ready
- K3/AUX ON additionally: Main CB, Exciter CB = ready, but Motor = not ready
- K4/Power ON after precharging additionally: Main CB, Infeed = ON (running)
- K5/Exc. Breaker ON additionally: Exciter CB = ON
- K6/Excit. ON additionally: Exciter, Motor = ON (pulses still blocked)
- n.set via [ /\ ] or [ \/ ] additionally: Motor = ON (running at defined speed value) and feedback on K7/ENAOP
As this switching-on sequence shows, the standard routine requires the Main CB and the Infeed to be switched on
before the Excitation CB and the Excitation can be switched on. In consequence, the next steps to be carried out will
concern the preconditions required to switch on the Main CB and the Infeed.
In the fault free condition an interlocking sequence is predefined for Local Control.
PLEASE NOTE: DONT FOLLOW THESE STEPS AS YET
good number of measurements, settings and tests still need to be done before the drive can be switched on in full.
- Auxiliaries = ready
- K3/AUX ON
- K4/Power ON
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2.21 Controlling the drives operation via OP177
f the Auxiliaries are switched on, the operating state shown on the OP177 indicates ready to switch on for the main
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Files required to stamp the Power Stack Adapters
files required to stamp the VECTOR-PSA
\ADDON\SINAMICS\DATA\HW_DESC\13
DESC0000.acx DESC0004.acx ident_00.bin
files required to stamp the INFEED-PSA
\ADDON\SINAMICS\DATA\15\HW_DESC\40
files required to stamp the INFEED-PSAs
1 Infeed ?
Infeed ?
2 Infeeds ?
3 Infeeds ?
Yes No
No
No Yes
Yes
Yes
The PROFIBUS-address of the CX32 is automatically
assigned via the DRIVE-CLiQ port used for its connection:
port X105 address 15
X104 14
X103 13
X102 X100 12 10
DR-SM150
page 116
2.22 Stamping the Power Stack Adapters (PSA)
As a general rule, the PSAs are stamped correctly when leaving the factory as part of the Infeed or the Motor Module.
As a hardware spare part, however, a PSA is stamped as Motor Module GM150 and can be used in a SM150 Infeed
or Motor Module after the respective assignments of data only.
This stamping has to be be carried out in two steps:
- downloading the PSA-Identfiles to specify the particular function of the PSA as Infeed_SM150 respectively
as Motor Module_SM150
- downloading the acx-data to specify power unit data (voltage, current, ) and to define actual value channels.
After switching off the electronics power supply, remove the CFC from the D445, put it into the card reader and delete
the correct PSA data for the Motor Module: CFC, directory ADDON > SINAMICS > DATA > HW_DESC > 013
(delete files DESC0000.acx, DESC0004.acx and ident_00.bin).
On the CFC in file 0_Training you find a file CFC_GM_8MF which contains the PSA-data of a GM150; copy the
three GM-files to your CFC in the a.m. directory (you are now prepared to stamp the Vector-PSA with GM150-data).
Put the CFC back into the D445 and switch on the electronics power supply. After initialization the D445 displays fault
messages regarding PSA and Power Unit.
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This stamping has to be be carried out in two steps:
- downloading the PSA-Identfiles to specify the particular function of the PSA as Infeed_SM150 respectively
as Motor Module_SM150
- downloading the acx-data to specify power unit data (voltage, current, ) and to define actual value channels.
After switching off the electronics power supply, remove the CFC from the D445, put it into the card reader and delete
the correct PSA data for the Motor Module: CFC, directory ADDON > SINAMICS > DATA > HW_DESC > 013
(delete files DESC0000.acx, DESC0004.acx and ident_00.bin).
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2.22 Stamping the Power Stack Adapters (PSA)
s a general rule, the PSAs are stamped correctly when leaving the factory as part of the Infeed or the Motor Module.
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Stamping the Power Stack Adapters
establish the online connection
open the expert list of the drive device
INFEEFD or VECTOR, object CU
set access level 4 (service);
password 52190
identify the component number of the PSA
(topology view or configuration > version )
set p7814[0] to the value of the component
number of the PSA identified above
set p7814[1] to 0
Infeed ?
Yes No
Vector ?
Yes
p7815 = 0
activate the download: p7816 = 2
p7816 = 0 ?
Yes No
copy RAM to ROM
switch off the electronics power supply
download finished wait
wait 10 seconds
p7815 = 10
DR-SM150
page 118
Now perform the stamping of the VECTOR-PSA (with the GM150 data from file CFC_GM_8MF) following the
appropriate section of the flowchart above.
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page 117
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Now perform the stamping of the VECTOR-PSA (with the
appropriate section of the flowchart above.
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copy RAM to ROM
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switch off the electronics power supply
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download finished
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0 < no. < 10 ?
Yes No
check the component number of the PSA
(listing or topology view)
switch on the electronics power supply
Infeed ?
Yes No
Vector ?
Yes
open the expert list
of object VECTOR
of object INFEED
password 52190
Verify that the PSA-data on the
CFC match the type of converter
(SM150, GM, ) and application
(Line Infeed or Motor Module).
If so, then delete the user data
on the CFC, switch the electronics
supply off and on again and
download the SCOUT-project
DR-SM150
page 120
After the download and the power-on reset the online connection to the Infeed fails (at the given progress of stamping
this fact must be ignored) and two warnings signal problems regarding the power unit.
If you check the component number of the PSA, it will read 20<component no.> (instead of <component no.>; the
20x signals acyclic communication of a component). For this situation, the flow chart suggests incorrect PSA-data
or corrupted user files.
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or corrupted user files.
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After the download and the power-on reset the online connection to the Infeed fails (at the given progress of stamping
this fact must be ignored) and two warnings signal problems regarding the power unit.
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of object INFEED
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password 52190
set p6541 to the value of the component
number of the PSA to be stamped
activate the download: p6540 = 2
p6540 = 0 ?
Yes No
download finished
wait
(up to 5 minutes)
copy RAM to ROM
switch off the electronics power
supply and wait 10 seconds
switch on the
electronics power supply
if necessary, carry out a
firmware update of the PSA
DR-SM150
page 122
Again remove the CFC from the D445, put it into the card reader and delete the GM150 PSA data for the Motor
Module from the CFC. Then copy the correct SM150 data from your file Cardcopy in directory SCOUT C:\
Temp_Trainee to the assigned location of the CFC.
Put the CFC back into the D445 and switch on the electronics power supply. As before, ignore the fact that the online-
connection to the Infeed fails; the D445 displays warnings regarding the Power Unit as before.
Once more perform the stamping of the VECTOR-PSA (now with the correct SM150 data) following the appropriate
sections of the flowchart (page 114ff).
Please note that the component number has to be assigned to parameter p7814.0 as it has been identified upstream
in the flowchart (e.g. 205).
Stamping the INFEED will be omitted, as it is correct already.
After the power-on reset and the initialization the D445 displays ready state and run condition; on request, an
online-connection is now established to all three drive devices.
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connection to the Infeed fails; the D445 displays warnings regarding the Power Unit as before.
Once more perform the stamping of the VECTOR-PSA (now with the correct SM150 data) following the appropriate
sections of the flowchart (page 114ff).
Please note that the component number has to be assigned to parameter p7814.0 as it has been identified upstream
in the flowchart (e.g. 205).
Stamping the INFEED will be omitted, as it is correct already.
After the power-on reset and the initialization the D445 displays ready state and run condition; on request, an
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Again remove the CFC from the D445, put it into the card reader and delete the GM150 PSA data for the Motor
Module from the CFC. Then copy the correct SM150 data from your file Cardcopy in directory SCOUT C:\
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supply and wait 10 seconds
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switch on the
electronics power supply
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if necessary, carry out a
firmware update of the PSA

14 Common Syn0 S

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14 Common Syn0 S

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Commissioning Common Functions

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