Siemens SIMOTION D4x5-2 User manual

SIMOCRANE
SC integrated STS, GSU
Operating Instructions
valid for:
SIMOCRANE SC integrated STS, GSU
V3.0
07/2019
A5E48271265B AA
Preface
Fundamental safety
instructions 1
System description 2
Overview of the software 3
Communication interface to
SIMATIC S7 4
Configuration 5
Sway Control function
description 6
TLS control function
description 7
SIMOCRANE CeCOMM
commissioning and
diagnostic program 8
Commissioning AddOn
Software 9
Alarm, error, and system
messages 10
Parameters 11
Appendix A

Legal information
Warning notice system
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damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be
used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property
damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified
personnel are those who, based on their training and experience, are capable of identifying risks and avoiding
potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended or
approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
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Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described.
Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this
publication is reviewed regularly and any necessary corrections are included in subsequent editions.
Siemens AG
Digital Industries
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E48271265B AA
Ⓟ 08/2019 Subject to change
Copyright © Siemens AG 2014 - 2019.
All rights reserved

Preface
Introduction
The document describes the electronic sway control system SIMOCRANE SC integrated STS,
GSU Version 3.0 and the application solutions "Sway Control" and "TLS Control" for cranes.
The description is based on SIMOCRANE Basic Technology.
Target group
The target readership for this document includes commissioning engineers, programmers,
users, and service and maintenance personnel.
Benefits
This manual provides the information, procedures, and operator actions required for
commissioning and use.
Prerequisite (scope of validity)
This manual is valid for use with the following product versions:
Hardware
● SIMOTION D4x5-2 DP/PN: Firmware V5.2 SP1 (V5.02.01.00) or higher
● SINAMICS: Firmware V5.1 HF1 (V5.10.23.2) or higher
● SIMOCRANE (optional): CenSOR V2.0 HF3 (V2.0.0.3)
Software
● SIMOCRANE Basic Technology Version V3.0
● SIMOTION SCOUT version V5.2 SP1 or higher
● Option package CFC V9.0 or Drive Control Chart (DCC) V3.1 SP1 (both part of the SCOUT
installation package)
● SIMOCRANE CeCOMM diagnostic program version V4.4.2.0 or higher
● SIMOCRANE SC integrated STS, GSU V3.0
● Microsoft Windows 7 or 10
● SIMATIC Manager V5.6 or higher
SC integrated STS, GSU
Operating Instructions, 07/2019, A5E48271265B AA 3

Additional Information
Siemens product support for SIMOCRANE
The following addresses provide support for your SIMOCRANE products:
● Internet:
– You will find the latest information on SIMOCRANE products, product support, and
FAQs on the Internet here (http://support.automation.siemens.com/WW/view/en/
10807397/130000).
– You will find continuously updated information on Crane Application Notes on the
Internet Application notes (https://support.industry.siemens.com/cs/ww/en/ps/20087/
ae).
● Support request on the Internet (Product → SIMOCRANE):
– Support request (http://support.automation.siemens.com)
● Hotline for Europe:
– Phone: [phone]
– Fax: [phone]
– Email: Support Europe (mailto:[email protected])
● Hotline for America:
– Phone: [phone]
– Fax: [phone]
– Email: Support America (mailto:[email protected])
● Hotline for Asia/Pacific
– Phone: [phone]
– Fax: [phone]
– Email: Support Asia/Pacific (mailto:[email protected])
Siemens product support for SIMOTION and SINAMICS
The latest information about SIMOTION products, product support, and FAQs can be found on
the Internet here (http://support.automation.siemens.com/WW/view/en/10805436/130000).
The latest information about SINAMICS products, product support, and FAQs can be found on
the Internet here (http://support.automation.siemens.com/WW/view/en/13305690/130000).
Copyright information
“MATLAB®. © 1984 - 2013 The MathWorks, Inc.”
Siemens confirmed that it has a valid license agreement with Mathworks.
Preface
SC integrated STS, GSU
4Operating Instructions, 07/2019, A5E48271265B AA

Table of contents
Preface .........................................................................................................................................................3
1 Fundamental safety instructions.................................................................................................................13
1.1 General safety instructions related to the hardware...............................................................13
1.2 General safety instructions related to software ......................................................................14
1.3 Warranty and liability for application projects.........................................................................14
1.4 Industrial security ...................................................................................................................15
1.5 Additional specific "security measures"..................................................................................16
2 System description .....................................................................................................................................17
2.1 Introduction ............................................................................................................................17
2.2 System overview ...................................................................................................................17
2.2.1 System requirements and design...........................................................................................17
2.2.2 Applications............................................................................................................................18
2.2.2.1 Grab ship unloader (GSU) without camera measuring system..............................................18
2.2.2.2 STS container cranes with camera measuring system ..........................................................19
2.2.3 Overview of operating modes, functions and required licenses.............................................20
2.2.4 Product structure....................................................................................................................22
2.3 Scope of supply......................................................................................................................22
3 Overview of the software ............................................................................................................................25
3.1 Application projects ................................................................................................................25
3.1.1 SCOUT project GSU ..............................................................................................................25
3.1.2 SCOUT project STS...............................................................................................................27
3.2 AddOn software structure ......................................................................................................28
3.2.1 Structure of the SCOUT part of the project ............................................................................28
3.2.2 Structure of the function module ............................................................................................30
3.2.3 Global variables - connection between the components........................................................33
3.2.3.1 Overview ................................................................................................................................33
3.2.3.2 Naming scheme for the unit-global variables .........................................................................35
3.2.3.3 AddOn technology – Basic Technology .................................................................................35
3.2.3.4 AddOn technology – technology objects ................................................................................36
3.2.3.5 Polarity of velocities and position values................................................................................37
3.3 Sway control function blocks..................................................................................................37
3.3.1 AddOn DCC library ................................................................................................................37
3.3.1.1 DCC_SCHOIST......................................................................................................................38
3.3.1.2 DCC_SCTROLLEY ................................................................................................................40
3.3.1.3 DCC_SCTARGETS................................................................................................................42
3.3.1.4 DCC_SCOBSTACLES ...........................................................................................................44
3.3.1.5 DCC_SCCAMERA .................................................................................................................46
3.3.1.6 DCC_SCTLS2 ........................................................................................................................48
3.3.1.7 DCC_SCINTPO......................................................................................................................52
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3.3.1.8 DCC_SCCOMMON................................................................................................................54
3.3.1.9 DCC_SCDIAG........................................................................................................................57
3.3.2 AddOn FB library....................................................................................................................58
3.3.2.1 FB_CommonPLCToAddOn....................................................................................................58
3.3.2.2 FB_CommonAddOnToPLC....................................................................................................60
3.3.2.3 FB_HoistPLCToAddOn ..........................................................................................................61
3.3.2.4 FB_HoistAddOnToPLC ..........................................................................................................62
3.3.2.5 FB_TrolleyPLCToAddOn........................................................................................................63
3.3.2.6 FB_TrolleyAddOnToPLC........................................................................................................65
3.3.2.7 FB_IntpoPLCToAddOn ..........................................................................................................66
3.3.2.8 FB_IntpoAddOnToPLC ..........................................................................................................67
3.3.2.9 FB_TLSPLCToAddOn............................................................................................................68
3.3.2.10 FB_TLSAddOnToPLC............................................................................................................69
3.3.2.11 FB_TargetsPLCToAddOn ......................................................................................................70
3.3.2.12 FB_TargetsAddOnToPLC ......................................................................................................71
3.3.2.13 FB_ObstaclePLCToAddOn ....................................................................................................73
3.3.2.14 FB_ObstacleAddOnToPLC ....................................................................................................74
3.3.2.15 FB_AddDataPLCToAddOn ....................................................................................................75
3.3.2.16 FB_AddDataAddOnToPLC ....................................................................................................77
3.3.2.17 FB_Receive_Analysis.............................................................................................................79
3.3.2.18 FB_Send_Preparation ............................................................................................................80
3.3.2.19 FB_ReadWrite_MV440...........................................................................................................81
4 Communication interface to SIMATIC S7...................................................................................................83
4.1 SIMATIC S7 → SIMOTION D for AddOn................................................................................83
4.1.1 Common.................................................................................................................................83
4.1.2 Hoist .......................................................................................................................................86
4.1.3 Trolley ....................................................................................................................................88
4.1.4 Intpo .......................................................................................................................................90
4.1.5 TLS.........................................................................................................................................90
4.1.6 Targets ...................................................................................................................................93
4.1.7 Obstacles ...............................................................................................................................95
4.1.8 AddData .................................................................................................................................96
4.2 SIMOTION D for AddOn → SIMATIC S7................................................................................97
4.2.1 Common.................................................................................................................................97
4.2.2 Hoist .....................................................................................................................................100
4.2.3 Trolley ..................................................................................................................................102
4.2.4 Intpo .....................................................................................................................................104
4.2.5 TLS.......................................................................................................................................104
4.2.6 Targets .................................................................................................................................106
4.2.7 Obstacles .............................................................................................................................107
4.2.8 AddData ...............................................................................................................................107
5 Configuration ...........................................................................................................................................109
5.1 Requirement.........................................................................................................................109
5.2 Overview of the configuring steps to be performed..............................................................110
5.3 Performing setup..................................................................................................................111
5.4 Importing the (SCOUT) application project of the AddOn technology..................................111
5.5 PROFINET configuration .....................................................................................................112
5.5.1 Configuring the connection ..................................................................................................112
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5.5.2 General information..............................................................................................................120
5.5.3 Defining the telegram ...........................................................................................................121
5.6 Copying the address list.......................................................................................................121
5.7 Copying the AddOn FB library .............................................................................................123
5.8 Copying MCC source files....................................................................................................126
5.9 Inserting DCC blocks ...........................................................................................................127
5.10 Establishing the connection between Basic Technology and AddOn ..................................131
5.11 Connection between skew damping technology object and DCC block TLS2.....................132
5.12 Execution system .................................................................................................................134
5.13 Saving, compiling and checking consistency .......................................................................134
5.14 Downloading the user project to the CF card.......................................................................135
5.15 Transferring language files, online help files, JAVA files and parameter files to the CF
card ......................................................................................................................................138
5.16 Creating the license key and downloading it to the CF card ................................................140
5.17 Communication tests for the STS application project ..........................................................141
6 Sway Control function description ............................................................................................................147
6.1 Activation of the AddOn technology "Sway Control" in the Basic Technology.....................147
6.2 Sway Control operating modes ............................................................................................148
6.2.1 Manual mode (MAN) ............................................................................................................149
6.2.1.1 Method of operation .............................................................................................................149
6.2.1.2 Activation..............................................................................................................................150
6.2.1.3 Control..................................................................................................................................150
6.2.2 Positioning (POS).................................................................................................................152
6.2.2.1 Method of operation .............................................................................................................152
6.2.2.2 Activation..............................................................................................................................152
6.2.2.3 Control..................................................................................................................................152
6.2.3 Semi-automatic mode (SAM) ...............................................................................................155
6.2.3.1 Method of operation .............................................................................................................155
6.2.3.2 Activation..............................................................................................................................155
6.2.3.3 Control..................................................................................................................................155
6.2.4 Sway neutralization load position (SNL) ..............................................................................158
6.2.4.1 Method of operation .............................................................................................................158
6.2.4.2 Activation..............................................................................................................................158
6.2.4.3 Control..................................................................................................................................158
6.2.5 Sway neutralization drive position (SND).............................................................................158
6.2.5.1 Functional principle ..............................................................................................................158
6.2.5.2 Activation..............................................................................................................................158
6.2.5.3 Control..................................................................................................................................159
6.3 Generating the TRAVEL control bit......................................................................................159
6.4 Activating/deactivating the "sway control" function ..............................................................160
6.4.1 Calculation of the pendulum deflection ................................................................................160
6.4.2 Activating the "sway control" function ..................................................................................162
6.4.3 Deactivating the "sway control" function ..............................................................................162
6.4.4 Braking distance correction (S_Corr) due to influence of sway control ...............................163
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6.5 Drive activation and brake control........................................................................................163
6.6 Controlled stop .....................................................................................................................164
6.7 Terminating a travel operation .............................................................................................164
6.8 Acceleration and deceleration behavior ...............................................................................165
6.9 Immersion point....................................................................................................................166
6.9.1 Internal immersion point.......................................................................................................166
6.9.2 External immersion point......................................................................................................169
6.10 Blocked regions....................................................................................................................170
6.10.1 Definition of terms ................................................................................................................170
6.10.2 Fixed blocked regions ..........................................................................................................174
6.10.3 External variable blocked regions ........................................................................................174
6.10.4 Internally learned variable blocked regions..........................................................................176
6.10.5 Defining the blocked regions................................................................................................177
6.10.6 Locking state of the spreader as a function of the spreader constellation ...........................178
6.10.6.1 Spreader constellations........................................................................................................178
6.10.6.2 Lock bits ...............................................................................................................................179
6.10.6.3 Forming blocked regions during the learning travel .............................................................180
6.10.6.4 Forming the immersion point during a learning travel ..........................................................183
6.11 Collision protection - soft approach......................................................................................185
6.11.1 Soft approach.......................................................................................................................185
6.11.2 Position-dependent monitoring functions of semi-automatic mode (SAM) / manual mode
(MAN)...................................................................................................................................189
6.11.3 Velocity-dependent monitoring functions before semi-automatic mode starts.....................192
6.12 Selection of the control method............................................................................................193
6.12.1 Selection ..............................................................................................................................193
6.12.2 Conventional control ............................................................................................................193
6.12.3 Time-optimized control.........................................................................................................194
6.12.3.1 General information..............................................................................................................194
6.12.3.2 Relaxation oscillations with GSU .........................................................................................194
6.13 Target generator ..................................................................................................................195
6.13.1 Requirement.........................................................................................................................195
6.13.2 Parameterization ..................................................................................................................196
6.13.3 Control..................................................................................................................................196
6.13.3.1 Initialization ..........................................................................................................................196
6.13.3.2 Loading or unloading the ship ..............................................................................................196
6.13.3.3 Specifying starting position and target position....................................................................196
6.13.3.4 End of a loading or unloading operation ..............................................................................199
6.13.4 Diagnostics...........................................................................................................................200
6.13.5 Automatic target specification ..............................................................................................201
6.13.6 Offset for the target position.................................................................................................203
6.14 Bay scanner .........................................................................................................................204
6.14.1 Using a bay scanner ............................................................................................................204
6.14.2 Conversion of the bay scanner values .................................................................................209
6.15 Calculation of 2D trajectory in semi-automatic mode (SAM)................................................213
6.16 Sway control only when stopping.........................................................................................217
6.17 Suppressing the opposite direction ......................................................................................217
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6.18 Approaching the waiting position .........................................................................................218
6.19 Starting SAM mode after a manual hoist operation .............................................................218
6.20 Slack rope ............................................................................................................................219
6.21 Override ...............................................................................................................................219
6.22 Influencing the lowering point in SAM travel from WS to LS................................................221
6.23 Hoist takeover ......................................................................................................................221
6.24 Minimum hoisting height ......................................................................................................224
6.25 Velocity for automatic lowering ............................................................................................226
6.26 Adjusting the trajectory during inclined travel in SAM ..........................................................227
6.27 Special aspects of GSU applications ...................................................................................228
6.27.1 Differences between STS and GSU.....................................................................................228
6.27.2 On-the-fly unloading.............................................................................................................229
6.27.2.1 Use.......................................................................................................................................229
6.27.2.2 Activating on-the-fly unloading .............................................................................................232
6.27.2.3 Influence of parameters P75/P76 and P158 on the trajectory .............................................233
6.27.3 Procedure for changing targets over the hopper..................................................................235
7 TLS control function description ...............................................................................................................237
7.1 Requirements.......................................................................................................................238
7.1.1 Mechanical requirements for TLS with a hydraulic system ..................................................238
7.1.2 Mechanical requirements for TLS with a hydraulic system and electric drive......................239
7.2 TLS modes and TLS functions.............................................................................................241
7.2.1 "Cylinder jogging" mode......................................................................................................241
7.2.2 "Go to zero positions" mode.................................................................................................243
7.2.3 "TLS jogging" mode .............................................................................................................247
7.2.4 "TLS positioning" mode........................................................................................................250
7.2.4.1 Versions of "TLS positioning" mode.....................................................................................250
7.2.4.2 V1: Move to internally stored trim, list and skew positions...................................................252
7.2.4.3 V2: Move to externally defined skew position and internally stored trim and list positions....254
7.2.5 "Skew damping for damping skew oscillation" function .......................................................255
7.2.5.1 "Skew damping via electric drive" function...........................................................................255
7.2.5.2 "Skew damping via cylinders" function.................................................................................258
7.3 Control of a cylinder movement ...........................................................................................259
7.4 Controlling movement of the electric drive ...........................................................................259
7.5 Control of the modes and the skew damping for the hydraulic system................................260
7.6 Controlling travel and skew damping with electric drive.......................................................261
8 SIMOCRANE CeCOMM commissioning and diagnostic program ...........................................................263
8.1 Installing ...............................................................................................................................263
8.2 Design and operation ...........................................................................................................264
8.3 Establishing a connection to the device ...............................................................................266
8.4 Menu bar ..............................................................................................................................267
8.5 Monitor (tab).........................................................................................................................271
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8.5.1 Sway Control monitors .........................................................................................................275
8.5.2 TLS monitors........................................................................................................................277
8.5.3 Editing AddOn parameters...................................................................................................283
8.5.3.1 Overview ..............................................................................................................................283
8.5.3.2 Call and navigation in the parameter menus........................................................................284
8.5.3.3 Activating a parameter set ...................................................................................................284
8.5.3.4 Editing a parameter set ........................................................................................................285
8.5.3.5 Changing a parameter .........................................................................................................285
8.5.3.6 Copying a parameter set......................................................................................................286
8.5.3.7 Loading the saved parameter sets.......................................................................................286
8.5.3.8 Saving all sets of parameters...............................................................................................286
8.5.3.9 Switching over parameter sets.............................................................................................286
8.5.3.10 Setting default values...........................................................................................................287
8.5.3.11 More functions......................................................................................................................287
8.6 File manager ........................................................................................................................288
8.7 Diagram - trace function.......................................................................................................289
8.7.1 Procedure for recording diagrams........................................................................................290
8.7.2 Elements and functionality of the diagram user interface ....................................................293
8.7.3 x/y diagram...........................................................................................................................304
8.7.4 TLS trace..............................................................................................................................306
8.8 Effective pendulum length....................................................................................................307
8.9 Logger ..................................................................................................................................309
8.9.1 Introduction ..........................................................................................................................309
8.9.2 Data retention and storage...................................................................................................309
8.9.3 Method of operation .............................................................................................................311
8.9.4 Special situations .................................................................................................................313
8.9.5 Handling the “Logger” function in SIMOCRANE CeCOMM .................................................313
8.9.6 Display of blocked regions ...................................................................................................317
9 Commissioning AddOn Software..............................................................................................................319
9.1 Requirements.......................................................................................................................319
9.2 Communication of the camera measuring system via Ethernet...........................................319
9.3 Commissioning requirements for AddOn software...............................................................320
9.3.1 General requirements ..........................................................................................................320
9.3.2 Preparing the PLC program .................................................................................................322
9.3.3 Preparing the converters......................................................................................................322
9.3.4 Setting the access code .......................................................................................................323
9.3.5 Setting the language ............................................................................................................323
9.3.6 Checking of the communication between PLC and SIMOTION...........................................324
9.3.7 Setting up FTP file access ...................................................................................................325
9.4 Sway control commissioning................................................................................................328
9.4.1 Method of operation of sway control ....................................................................................328
9.4.2 Commissioning the sway control system .............................................................................331
9.4.2.1 Commissioning steps in the commissioning menu ..............................................................331
9.4.2.2 Selection of the control method............................................................................................337
9.4.2.3 Effective pendulum length correction ...................................................................................337
9.4.2.4 Setting the permissible residual sway ..................................................................................339
9.4.2.5 Settings to monitor the oscillation state................................................................................339
9.4.2.6 Setting the damping factor ...................................................................................................339
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9.4.2.7 Defining the activation velocity and ON delay......................................................................340
9.4.2.8 Setting the time constants for trolley (P153) and hoist (P154).............................................340
9.4.3 Commissioning positioning mode (POS) .............................................................................342
9.4.3.1 Selecting external and internal targets.................................................................................342
9.4.3.2 Changing the coordinate system..........................................................................................343
9.4.3.3 Position controller setting .....................................................................................................345
9.4.3.4 Other settings.......................................................................................................................346
9.4.4 Commissioning semi-automatic (SAM) mode ......................................................................347
9.4.5 On-the-fly unloading, GSU only ...........................................................................................349
9.5 Commissioning TLS (hydraulic system)...............................................................................350
9.5.1 System requirements ...........................................................................................................350
9.5.2 Activating the TLS functions.................................................................................................351
9.5.3 Parameterization of the actual positions ..............................................................................351
9.5.4 Parameterizing "cylinder jogging" mode ..............................................................................352
9.5.5 Parameterization of the central positions of the cylinders....................................................354
9.5.6 TLS inching and go to zero positions ...................................................................................356
9.5.7 Conversion of cylinder positions, angle of rotation...............................................................357
9.5.8 Calculating the effective pendulum length for the skew oscillation ......................................357
9.5.9 Monitoring the camera measuring system ...........................................................................360
9.5.10 Parameterization of observer ...............................................................................................361
9.5.11 Activates the "skew damping" function ................................................................................361
9.5.12 Optional adaptations ............................................................................................................361
9.6 Commissioning TLS (hydraulic system with electric drive) ..................................................362
9.6.1 System requirements ...........................................................................................................362
9.6.2 Commissioning cylinders .....................................................................................................363
9.6.3 Evaluation of the current position of the skew drive spindle ................................................363
9.6.4 Position controller setting (P328) .........................................................................................364
9.6.5 Setting the limit for set position P324...................................................................................365
9.6.6 Kinematic transformation of skew drive position, angle of rotation ......................................365
9.6.7 Parameterization of skew damping ......................................................................................366
9.7 Commissioning TLS (skew damping with electric drive only) .............................................367
9.7.1 System requirements ...........................................................................................................367
9.7.2 Activation of TLS function and skew drive ...........................................................................368
9.7.3 Commissioning cylinders and electric drive .........................................................................368
10 Alarm, error, and system messages.........................................................................................................369
10.1 Following error monitoring....................................................................................................369
10.2 Velocity monitoring...............................................................................................................370
10.3 Monitoring of start of sway control .......................................................................................371
10.4 Monitoring the oscillation state.............................................................................................371
10.4.1 Monitoring of excessive oscillations .....................................................................................372
10.4.2 Monitoring of the sway control system .................................................................................372
10.5 Error messages....................................................................................................................373
10.5.1 General information..............................................................................................................373
10.5.2 SIMOCRANE CenSOR error list ..........................................................................................373
10.5.3 Error list AddOn....................................................................................................................374
10.5.3.1 Overview ..............................................................................................................................374
10.5.3.2 Brief description ...................................................................................................................374
10.5.3.3 General and severe errors ...................................................................................................376
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10.5.3.4 Error in the limit or prelimit switch area ................................................................................379
10.5.3.5 Error in semi-automatic mode ..............................................................................................380
10.5.3.6 Other errors 1.......................................................................................................................384
10.5.3.7 Other errors 2.......................................................................................................................385
10.5.3.8 SIMOCRANE CeCOMM diagnostic program.......................................................................387
10.5.3.9 Troubleshooting/FAQs .........................................................................................................387
10.5.4 Error list TLS ........................................................................................................................387
11 Parameters ...............................................................................................................................................393
11.1 Overview of the parameter list .............................................................................................393
11.2 Trolley ..................................................................................................................................393
11.3 Hoist .....................................................................................................................................400
11.4 Sway control system ............................................................................................................407
11.5 General ................................................................................................................................408
11.6 Camera measuring system/reflector ....................................................................................412
11.7 Travel characteristic .............................................................................................................413
11.8 Controlled variables .............................................................................................................418
11.9 TLS.......................................................................................................................................420
A Appendix...................................................................................................................................................435
A.1 Service and maintenance.....................................................................................................435
A.2 References...........................................................................................................................435
A.3 List of abbreviations .............................................................................................................436
A.4 Assignment of signal names ................................................................................................437
A.5 Variable signals....................................................................................................................437
Glossary ...................................................................................................................................................443
Table of contents
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12 Operating Instructions, 07/2019, A5E48271265B AA

Fundamental safety instructions 1
1.1 General safety instructions related to the hardware
The Sway Control technology package is used in areas where electrical systems are being
operated. This area may contain high voltages, moving machine parts, hydraulic and
pneumatic systems. Consequently, follow the following general safety instructions.
WARNING
Electric shock and danger to life due to other energy sources
Touching live components can result in death or severe injury.
● Only work on electrical devices when you are qualified for this job.
● Always observe the country-specific safety rules.
Generally, the following six steps apply when establishing safety:
1. Prepare for disconnection. Notify all those who will be affected by the procedure.
2. Isolate the drive system from the power supply and take measures to prevent it being
switched back on again.
3. Wait until the discharge time specified on the warning labels has elapsed.
4. Check that there is no voltage between any of the power connections, and between any of
the power connections and the protective conductor connection.
5. Check whether the existing auxiliary supply circuits are de-energized.
6. Ensure that the motors cannot move.
7. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or
water. Switch the energy sources to a safe state.
8. Check that the correct drive system is completely locked.
After you have completed the work, restore the operational readiness in the inverse sequence.
WARNING
Electric shock due to connection to an unsuitable power supply
When equipment is connected to an unsuitable power supply, exposed components may
carry a hazardous voltage. Contact with hazardous voltage can result in severe injury or death.
● Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV-
(Protective Extra Low Voltage) output voltages for all connections and terminals of the
electronics modules.
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Operating Instructions, 07/2019, A5E48271265B AA 13

WARNING
Electric shock due to equipment damage
Improper handling may cause damage to equipment. For damaged devices, hazardous
voltages can be present at the enclosure or at exposed components; if touched, this can result
in death or severe injury.
● Ensure compliance with the limit values specified in the technical data during transport,
storage and operation.
● Do not use any damaged devices.
1.2 General safety instructions related to software
WARNING
Danger to life if the safety instructions and residual risks are not observed
If the safety instructions and residual risks in the associated hardware documentation are not
observed, accidents involving severe injuries or death can occur.
● Observe the safety instructions given in the hardware documentation.
● Consider the residual risks for the risk evaluation.
WARNING
Malfunctions of the machine as a result of incorrect or changed parameter settings
As a result of incorrect or changed parameterization, machines can malfunction, which in turn
can lead to injuries or death.
● Protect the parameterization against unauthorized access.
● Handle possible malfunctions by taking suitable measures, e.g. emergency stop or
emergency off.
1.3 Warranty and liability for application projects
Application projects are not binding and do not claim to be complete regarding configuration,
equipment or any eventuality which may arise. Application projects do not represent customer-
specific solutions; they are only intended to provide assistance with typical tasks.
As the user you yourself are responsible for ensuring that the products described are operated
correctly. Application projects do not relieve you of your responsibility for safe handling when
using, installing, operating and maintaining the equipment.
Fundamental safety instructions
1.3 Warranty and liability for application projects
SC integrated STS, GSU
14 Operating Instructions, 07/2019, A5E48271265B AA

1.4 Industrial security
Note
Industrial security
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, systems, machines and networks.
In order to protect plants, systems, machines and networks against cyber threats, it is
necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial
security concept. Siemens’ products and solutions constitute one element of such a concept.
Customers are responsible for preventing unauthorized access to their plants, systems,
machines and networks. Systems, machines and components should only be connected to an
enterprise network or the Internet if and to the extent that such a connection is necessary and
only when appropriate security measures (e.g. firewalls and/or network segmentation) are in
place.
Recommendations from Siemens regarding appropriate security measures should also be
taken into account. You will find more information about industrial security at:
Industrial Security (http://www.siemens.com/industrialsecurity)
Siemens’ products and solutions undergo continuous development to make them more secure.
Siemens strongly recommends that product updates are applied as soon as they are available
and that the latest product versions are used. Using versions that are either out-of-date or no
longer supported can increase the risk of cyber threats.
To stay informed about product updates, subscribe to the Siemens Industrial Security RSS
Feed at:
Industrial Security (http://www.siemens.com/industrialsecurity)
Further information is provided on the Internet:
Industrial Security Configuration Manual (https://support.industry.siemens.com/cs/document/
109751848/sinamics-industrial-security?lc=en-WW)
WARNING
Unsafe operating states resulting from software manipulation
Software manipulations (e.g. viruses, trojans, malware or worms) can cause unsafe operating
states in your system that may lead to death, serious injury, and property damage.
● Keep the software up to date.
● Incorporate the automation and drive components into a holistic, state-of-the-art industrial
security concept for the installation or machine.
● Make sure that you include all installed products in the holistic industrial security concept.
● Protect files stored on exchangeable storage media from malicious software using suitable
protection measures, e.g. virus scanners.
● Protect the drive against unauthorized changes by activating the "know-how protection"
drive function.
Fundamental safety instructions
1.4 Industrial security
SC integrated STS, GSU
Operating Instructions, 07/2019, A5E48271265B AA 15

1.5 Additional specific "security measures"
The customer is responsible for preventing unauthorized access to its plants, systems,
machines and networks, see also safety instruction Industrial security (Page 15).
In order to protect plants, systems, machines and networks against cyber attack, Siemens
Industrial Security functions can be incorporated into a customized industrial security concept.
For more information about the Industrial Security functions of SIMATIC/SIMOTION/
SINAMICS, please go to:
● SIMOTION/SINAMICS (https://support.industry.siemens.com/cs/ww/en/view/108862708)
● SIMATIC (https://support.industry.siemens.com/cs/ww/en/view/90885010).
Fundamental safety instructions
1.5 Additional specific "security measures"
SC integrated STS, GSU
16 Operating Instructions, 07/2019, A5E48271265B AA

System description 2
2.1 Introduction
Every movement of the trolley causes the load to sway. This makes positioning more difficult,
and it takes correspondingly longer. The main task of the sway control system is to eliminate
sway motion and to perform positioning operations automatically. This reduces the crane
driver's workload and increases productivity.
The sector solution SIMOCRANE Basic Technology has been available in the Siemens Cranes
business area since the middle of 2007. The platform is based on a SIMATIC S7 - SIMOTION -
SINAMICS hardware configuration and covers the motion control of all the main drives of a
crane. The modular design makes it possible to customize the system to each individual crane.
SIMOCRANE Basic Technology also permits the systematic use of Advanced Technology,
such as Sway Control. The TLS function is also available for STS cranes.
The sway control system described in these operating instructions is an AddOn for extending
the existing sector solution SIMOCRANE Basic Technology based on SIMOTION D4x5-2 DP/
PN.
The sway control system can be configured for a variety of applications. More detailed
information can be found in Chapter Applications (Page 18).
2.2 System overview
2.2.1 System requirements and design
The AddOn Sway Control with TLS Control is designed for the expansion of SIMOCRANE
Basic Technology. The following requirements must be fulfilled:
● Use of a crane control system (PLC) with PROFIBUS or PROFINET interface
Note
The sway control system described in this document can be linked to the crane control
system by means of both PROFIBUS and PROFINET.
The description in this document refers solely to communication based on PROFINET.
● SIMOTION D4x5 - 2 DP/PN as target hardware
● Closed-loop controlled drives
● Position encoder for the hoist and the trolley
● Hydraulic cylinders and/or electric axis for TLS
● SIMOCRANE CenSOR camera measuring system
The AddOn Sway Control with TLS Control is integrated into an existing SCOUT application
project of the crane application.
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Operating Instructions, 07/2019, A5E48271265B AA 17

The following diagram shows an example of communication paths between the individual
components.
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Figure 2-1 Communication paths between the components
The AddOn contains a DCC library and an FB library. The functions for sway control, TLS
control and CeCOMM are stored in the DCC library with the associated blocks. Communication
with the DCC blocks and the higher-level control system takes place via the FB library and the
associated functions. The FB library was programmed in "Structured Text" (ST).
The supplied application project already contains a complete sequential control system and the
necessary interconnections between Basic Technology and AddOn technology.
2.2.2 Applications
2.2.2.1 Grab ship unloader (GSU) without camera measuring system
As a general rule, GSU cranes are not equipped with a camera measuring system. This is due
to the design of the crane and the extreme application conditions of these crane types, such as
high temperatures or extremely dusty atmospheres.
The sway control system ascertains the oscillation states using a mathematical calculation
model. A sway control system without camera measuring system is capable of eliminating most
oscillations that are caused by crane motion. However, it is not capable of suppressing
oscillations caused by external forces such as diagonal pull or wind.
A detailed description of the GSU functions can be found in Chapter Special aspects of GSU
applications (Page 228).
System description
2.2 System overview
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18 Operating Instructions, 07/2019, A5E48271265B AA

2.2.2.2 STS container cranes with camera measuring system
When the camera measuring system is used, sway motion or rotation of the spreader caused
by external factors (e.g. wind or diagonal pull) can also be detected. This measuring system
uses optical non-contact measurement to determine the distance between camera and
reflector, pendulum deflection and rotation of the spreader. The closed-loop control system can
eliminate the swaying motion and rotation based on the measured values.
If the measuring signal of the camera measuring system fails, only the mathematical calculation
model is used.
Note
For additional information, please refer to the operating instructions for the SIMOCRANE
CenSOR camera measuring system [Ref. 1].
A target generator which specifies the targets semi-automatically during loading and unloading
is also available. Targets for the semi-automatic mode (SAM) can be input either by the target
generator or via the PLC interface.
A detailed description of the STS functions can be found in Chapter Sway Control function
description (Page 147).
3/&DQG6,027,21&DPHUD5HIOHFWRU
Figure 2-2 Schematic representation of a container crane with sway control components including a camera measuring
system
TLS system
STS cranes can be equipped with a TLS system. This system makes it possible to rotate the
spreader around all three axes (Trim, List, Skew). These rotations are implemented by four
hydraulic cylinders in most cases. An additional electric system can be used for skew damping.
You will find detailed information in Chapter TLS control function description (Page 237).
System description
2.2 System overview
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Operating Instructions, 07/2019, A5E48271265B AA 19

Laser measuring system
STS cranes can be equipped with a laser measuring system for measuring the container stack.
You will find detailed information in Chapter Using a bay scanner (Page 204).
Alternatively, a complete ship profile measured by a 2D/3D laser system can be transferred
from the higher-level control system to the sway control system for both STS and GSU
applications. The values are transferred to the sway control system via external variable
blocked regions. You will find more information in Chapter External variable blocked regions
(Page 174).
2.2.3 Overview of operating modes, functions and required licenses
This chapter provides an overview of the functions in the different operating modes and
explains which licenses are required for the individual operating modes.
Operating modes and functions
You will find detailed information on the operating modes and functions in the following
chapters:
● For sway control, see Chapter Sway Control function description (Page 147)
● For TLS control, see Chapter TLS control function description (Page 237)
Table 2-1 Overview of operating modes - sway control functions (STS, GSU)
Operating mode Functions
Manual mode (MAN) ● Specification of the velocity setpoint by the higher-level control system
● Operation with and without sway control (trolley)
● Single or combined operation of hoist and trolley
● Generation of internally learned variable blocked regions
● Soft approach: Consideration of blocked regions with different responses
depending on whether blocked regions are fixed or variable (can be activated/
deactivated)
Positioning mode (POS) ● Specification of a target position by the higher-level control system
● Operation with and without sway control (trolley)
● Single or combined operation of hoist and trolley
● Move to the target position on the shortest path without taking blocked regions into
account
● On-the-fly unloading without taking blocked regions into account (GSU only)
Sway neutralization load position
(SNL)
● Specification of the internally calculated load position as a target position
● Sway-controlled travel of the trolley
● Not for the hoist and not when GSU is selected
● Move to the target position on the shortest path without taking blocked regions into
account
System description
2.2 System overview
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20 Operating Instructions, 07/2019, A5E48271265B AA