Siemens SINAMICS S120 Parts list manual

Function Manual
Drive functions
Edition www.siemens.com/drives 06/2019
S120
SINAMICS

SINAMICS
S120
Drive functions
Function Manual
Valid as of:
Firmware version 5.2
06/2019
6SL3097-5AB00-0BP2
Introduction 1
Fundamental safety
instructions 2
Infeed 3
Extended setpoint channel 4
Servo control 5
Vector control 6
U/f control (vector control) 7
Basic functions 8
Function modules 9
Monitoring functions and
protective functions 10
Safety Integrated Basic
Functions 11
Applications 12
Web server 13
Basic information about the
drive system 14
Appendix A

Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be
used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property
damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified
personnel are those who, based on their training and experience, are capable of identifying risks and avoiding
potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended or
approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described.
Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this
publication is reviewed regularly and any necessary corrections are included in subsequent editions.
Siemens AG
Digital Industries
Postfach 48 48
90026 NÜRNBERG
GERMANY
Document order number: 6SL3097-5AB00-0BP2
Ⓟ 07/2019 Subject to change
Copyright © Siemens AG 2004 - 2019.
All rights reserved

Table of contents
1 Introduction.................................................................................................................................................17
1.1 The SINAMICS converter family ............................................................................................17
1.2 General information about SINAMICS documentation...........................................................18
1.3 Usage phases and their documents/tools (as an example) ..................................................20
1.4 Where can the various topics be found?................................................................................21
1.5 Training and support ..............................................................................................................22
1.6 Using OpenSSL .....................................................................................................................23
1.7 General Data Protection Regulation ......................................................................................24
2 Fundamental safety instructions.................................................................................................................25
2.1 General safety instructions.....................................................................................................25
2.2 Warranty and liability for application examples ......................................................................26
2.3 Industrial security ...................................................................................................................27
3 Infeed..........................................................................................................................................................29
3.1 Active Infeed ..........................................................................................................................30
3.1.1 Active Infeed closed-loop control booksize ............................................................................31
3.1.2 Active Infeed closed-loop control chassis ..............................................................................33
3.1.3 Line supply and DC link identification ....................................................................................35
3.1.4 Active Infeed open-loop control..............................................................................................36
3.1.5 Reactive current control .........................................................................................................39
3.1.6 Harmonics controller ..............................................................................................................39
3.1.7 Parameterizable bandstop filters for Active Infeed Controls in chassis format ......................40
3.1.8 Function diagrams and parameters .......................................................................................41
3.2 Basic Infeed ...........................................................................................................................43
3.2.1 Basic Infeed open-loop control...............................................................................................45
3.2.2 Function diagrams and parameters .......................................................................................47
3.3 Smart Infeed...........................................................................................................................49
3.3.1 Line supply and DC link identification routine for Smart Infeed Booksize ..............................51
3.3.2 Extended Smart Mode ...........................................................................................................52
3.3.3 Smart Infeed open-loop control..............................................................................................52
3.3.4 Function diagrams and parameters .......................................................................................55
3.4 Line contactor control.............................................................................................................56
3.5 Pre-charging and bypass contactor Chassis and Chassis-2..................................................58
4 Extended setpoint channel .........................................................................................................................59
4.1 Motorized potentiometer ........................................................................................................62
4.2 Fixed setpoints .......................................................................................................................64
4.3 Speed setpoint .......................................................................................................................65
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4.3.1 Main/supplementary setpoint and setpoint scaling ................................................................65
4.3.2 Jogging...................................................................................................................................66
4.3.3 Direction of rotation limiting and direction reversal ................................................................70
4.4 Speed limiting.........................................................................................................................71
4.5 Ramp-function generator .......................................................................................................73
4.5.1 Ramp-function generator tracking..........................................................................................76
4.5.2 Signal overview, function diagrams and important parameters ............................................78
5 Servo control ..............................................................................................................................................81
5.1 Comparison between servo control and vector control ..........................................................82
5.2 Influencing calculation of the open-loop control and closed-loop control parameters............86
5.3 Setpoint addition ....................................................................................................................87
5.4 Speed setpoint filter ...............................................................................................................89
5.5 Speed controller .....................................................................................................................91
5.5.1 Speed controller adaptation ...................................................................................................91
5.5.2 Torque-controlled operation ...................................................................................................93
5.6 Torque setpoint limitation .......................................................................................................96
5.7 Current setpoint filter............................................................................................................100
5.8 Current controller .................................................................................................................107
5.9 Autotuning ............................................................................................................................109
5.9.1 One Button Tuning ...............................................................................................................109
5.9.2 Online tuning ........................................................................................................................114
5.9.2.1 "Drive-based" online tuning..................................................................................................114
5.9.2.2 Adaptation of the control parameters ...................................................................................118
5.9.2.3 Problem handling .................................................................................................................119
5.9.3 Current setpoint filter adaptation ..........................................................................................120
5.9.3.1 Stability of the speed control loop ........................................................................................124
5.9.3.2 Lower and upper limit frequencies .......................................................................................124
5.9.3.3 Remedy for insufficient adaptation.......................................................................................125
5.9.4 Function diagrams and parameters .....................................................................................125
5.10 Notes about the electronic motor model ..............................................................................127
5.11 Increased stall power at the voltage limit .............................................................................128
5.12 U/f control.............................................................................................................................131
5.13 Optimizing the current and speed controller ........................................................................135
5.14 Encoderless operation .........................................................................................................137
5.15 Motor data identification .......................................................................................................142
5.15.1 Motor data identification for induction motors ......................................................................145
5.15.2 Motor data identification for synchronous motors ................................................................147
5.16 Pole position identification....................................................................................................150
5.16.1 Supplementary conditions....................................................................................................151
5.16.2 Important parameters (process-dependent).........................................................................155
5.16.3 Setting of the elasticity-based pole position identification ....................................................156
5.16.4 Commutation angle offset commissioning support (p1990) .................................................165
5.16.5 Overview of important parameters (see SINAMICS S120/S150 List Manual) .....................165
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5.17 Vdc control ...........................................................................................................................167
5.18 Dynamic Servo Control (DSC) .............................................................................................171
5.19 Travel to fixed stop...............................................................................................................176
5.20 Vertical axes.........................................................................................................................181
5.21 Variable signaling function ...................................................................................................182
5.22 Central probe evaluation ......................................................................................................184
5.22.1 Examples .............................................................................................................................190
5.22.2 Function diagrams and parameters .....................................................................................191
5.23 Voltage precontrol ................................................................................................................193
5.23.1 Function diagrams and parameters .....................................................................................201
6 Vector control ...........................................................................................................................................203
6.1 Technology application (application) (p0500) ......................................................................208
6.2 Vector control without encoder (SLVC)................................................................................209
6.2.1 Three-phase induction motor ...............................................................................................209
6.2.2 Permanent-magnet synchronous motors .............................................................................213
6.2.3 Synchronous reluctance motors...........................................................................................215
6.3 Vector control with encoder..................................................................................................218
6.4 Speed controller ...................................................................................................................219
6.4.1 Speed controller adaptation .................................................................................................221
6.4.2 Speed controller precontrol and reference model ................................................................224
6.5 Droop ...................................................................................................................................228
6.6 Open actual speed value .....................................................................................................230
6.7 Closed-loop torque control ...................................................................................................232
6.8 Torque limiting......................................................................................................................235
6.9 Vdc control ...........................................................................................................................237
6.9.1 Function diagrams and parameters .....................................................................................240
6.10 Current setpoint filter............................................................................................................241
6.11 Speed actual value filter.......................................................................................................242
6.12 Current controller adaptation................................................................................................243
6.13 Motor data identification and rotating measurement............................................................244
6.13.1 Overview ..............................................................................................................................244
6.13.2 Motor data identification .......................................................................................................245
6.13.3 Rotating measurement.........................................................................................................248
6.13.4 Shortened rotating measurement.........................................................................................250
6.13.5 Overview of important parameters .......................................................................................251
6.14 Pole position identification....................................................................................................253
6.14.1 Operation without an encoder ..............................................................................................253
6.14.2 Operation with encoder ........................................................................................................254
6.14.3 Messages and parameters...................................................................................................256
6.15 Efficiency optimization..........................................................................................................258
6.15.1 Efficiency optimization for induction motors .........................................................................258
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6.15.2 Efficiency optimization for reluctance motors.......................................................................260
6.15.3 Function diagrams and parameters .....................................................................................261
6.16 Fast magnetization for induction motors ..............................................................................262
6.17 Flying restart ........................................................................................................................266
6.17.1 Fast flying restart..................................................................................................................268
6.17.2 Flying restart for a synchronous reluctance motor ...............................................................270
6.17.3 Messages and parameters...................................................................................................271
6.18 Synchronization....................................................................................................................272
6.19 Voltage Sensing Module ......................................................................................................274
6.20 Simulation mode ..................................................................................................................276
6.21 Redundancy mode power units............................................................................................277
6.22 Bypass .................................................................................................................................278
6.22.1 Bypass with synchronization with overlap............................................................................280
6.22.2 Bypass with synchronization without overlap.......................................................................283
6.22.3 Bypass without synchronization ...........................................................................................284
6.22.4 Function diagrams and parameters .....................................................................................286
6.23 Asynchronous pulse frequency ............................................................................................288
7 U/f control (vector control) ........................................................................................................................291
7.1 Technology application (application) (p0500) ......................................................................295
7.2 Voltage boost .......................................................................................................................296
7.3 Slip compensation................................................................................................................300
7.4 Resonance damping ............................................................................................................301
7.5 Vdc control ...........................................................................................................................302
8 Basic functions .........................................................................................................................................307
8.1 Switching over units .............................................................................................................307
8.2 Reference parameters/scaling .............................................................................................309
8.3 Checking for a short-circuit/ground fault at a motor .............................................................313
8.4 Modular machine concept ....................................................................................................314
8.5 Sine-wave filter.....................................................................................................................317
8.6 Motor reactors ......................................................................................................................319
8.7 dv/dt filter plus Voltage Peak Limiter....................................................................................321
8.8 dv/dt filter compact plus Voltage Peak Limiter .....................................................................323
8.9 Pulse frequency wobbling ....................................................................................................325
8.10 Direction reversal without changing the setpoint..................................................................326
8.11 Automatic restart ..................................................................................................................328
8.12 Armature short-circuit...........................................................................................................331
8.12.1 Internal armature short-circuit braking .................................................................................332
8.12.2 External armature short-circuit braking ................................................................................333
8.12.3 Internal voltage protection....................................................................................................336
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8.12.4 Configuring a fault reaction ..................................................................................................337
8.12.5 Function diagrams and parameters .....................................................................................337
8.13 DC braking ...........................................................................................................................339
8.13.1 Configuring the function via parameters ..............................................................................339
8.13.2 Activating a function via fault reaction..................................................................................341
8.13.3 Activating a function via OFF fault responses......................................................................341
8.13.4 Configuring a function as a response to a speed threshold .................................................341
8.13.5 Internal voltage protection....................................................................................................342
8.13.6 Configuring a fault reaction ..................................................................................................343
8.13.7 Function diagrams and parameters .....................................................................................344
8.14 Motor Module as a Braking Module .....................................................................................345
8.14.1 Configuring resistors ............................................................................................................346
8.14.2 Activating the "Braking Module" function .............................................................................349
8.14.3 Protective equipment ...........................................................................................................352
8.14.4 Overview of the important parameters .................................................................................352
8.15 OFF3 torque limits................................................................................................................354
8.16 Technology function friction characteristic ...........................................................................355
8.17 Simple brake control ............................................................................................................357
8.18 System runtime / operating hours counter ...........................................................................360
8.19 Energy-saving display ..........................................................................................................362
8.20 Encoder diagnostics.............................................................................................................365
8.20.1 Datalogger............................................................................................................................365
8.20.2 Encoder dirty signal..............................................................................................................366
8.20.3 Early encoder failure detection.............................................................................................366
8.20.4 Function diagrams and parameters .....................................................................................367
8.21 Tolerant encoder monitoring ................................................................................................368
8.21.1 Encoder track monitoring .....................................................................................................369
8.21.2 Zero mark tolerance .............................................................................................................370
8.21.3 Freezing the speed raw value ..............................................................................................371
8.21.4 Adjustable hardware filter.....................................................................................................371
8.21.5 Edge evaluation of the zero mark ........................................................................................372
8.21.6 Pole position adaptation.......................................................................................................373
8.21.7 Pulse number correction for faults .......................................................................................374
8.21.8 "Tolerance band pulse number" monitoring .........................................................................375
8.21.9 Signal edge evaluation (1x, 4x)............................................................................................376
8.21.10 Setting the measuring time to evaluate speed "0" ...............................................................377
8.21.11 Sliding averaging of the speed actual value.........................................................................377
8.21.12 Troubleshooting ...................................................................................................................378
8.21.13 Tolerance window and correction ........................................................................................381
8.21.14 Dependencies ......................................................................................................................382
8.21.15 Overview of important parameters .......................................................................................384
8.22 Parking axis / parking encoder.............................................................................................385
8.23 Position tracking...................................................................................................................388
8.23.1 Position tracking with a measuring gearbox.........................................................................389
8.24 Encoder as drive object........................................................................................................393
8.25 Terminal Module 41 .............................................................................................................396
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8.25.1 SIMOTION mode .................................................................................................................396
8.25.2 SINAMICS mode..................................................................................................................397
8.25.3 Zero mark emulation (SINAMICS mode) .............................................................................399
8.25.4 Synchronization of the zero marks (SINAMICS mode) ........................................................402
8.25.5 Limit frequencies for TM41...................................................................................................403
8.25.6 Example in the SINAMICS mode .........................................................................................404
8.25.7 Function diagrams and parameters .....................................................................................405
8.26 Upgrade the firmware and project........................................................................................407
8.26.1 Updating the firmware and STARTER project data using the web server ...........................408
8.26.2 Downgrade lock ...................................................................................................................409
8.26.3 Protection against power failure while updating via the Web server....................................409
8.27 Essential service mode (ESM) for CU310-2 on Blocksize power units................................411
8.27.1 Configuring the essential service mode ...............................................................................414
8.27.2 Function diagrams and parameters .....................................................................................415
8.28 Pulse/direction interface.......................................................................................................416
8.29 Derating function for chassis units .......................................................................................418
8.30 Parallel connection of motors...............................................................................................419
9 Function modules .....................................................................................................................................423
9.1 Technology controller...........................................................................................................425
9.2 Extended monitoring functions.............................................................................................430
9.3 Extended Brake Control .......................................................................................................432
9.4 Braking Module external ......................................................................................................438
9.5 Cooling unit ..........................................................................................................................440
9.6 Extended torque control (kT estimator, servo) .....................................................................442
9.7 Position control.....................................................................................................................445
9.7.1 Position actual value conditioning ........................................................................................445
9.7.1.1 Indexed actual value acquisition ..........................................................................................449
9.7.1.2 Load gear position tracking ..................................................................................................450
9.7.1.3 Function diagrams and parameters .....................................................................................456
9.7.2 Position controller.................................................................................................................457
9.7.3 Monitoring functions .............................................................................................................458
9.7.4 Measuring probe evaluation and reference mark search.....................................................460
9.7.5 Commissioning the function .................................................................................................461
9.8 Basic positioner....................................................................................................................463
9.8.1 Mechanical system...............................................................................................................465
9.8.2 Limits....................................................................................................................................468
9.8.2.1 Maximum velocity.................................................................................................................468
9.8.2.2 Maximum acceleration/deceleration.....................................................................................468
9.8.2.3 Limit traversing range...........................................................................................................469
9.8.2.4 Jerk limitation .......................................................................................................................472
9.8.2.5 Starting against a closed brake............................................................................................473
9.8.2.6 Function diagrams and parameters .....................................................................................473
9.8.3 EPOS and safe setpoint velocity limitation...........................................................................474
9.8.4 Referencing..........................................................................................................................474
9.8.4.1 Reference point approach (incremental measuring system)................................................478
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