Siemens SINAMICS G120X User manual

SINAMICS G120X
commissioning guide
for permanent
magnet motors PMSM
SINAMICS G120X
https://support.industry.siemens.com/cs/ww/en/view/109780815
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G120X commissioning guide for permanent magnet motors PMSM
Entry-ID: 109780815, V1.0, 07/2020
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©Siemens 2020 All rights reserved
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Table of content
1Introduction .............................................................................................................................3
1.1 Document purpose ....................................................................................................3
1.2 Reference list of commissioned PM motors..............................................................3
1.3 Related documents....................................................................................................4
1.4 Support contacts........................................................................................................4
2General conditions of operation............................................................................................5
2.1 Supported permanent magnet motor designs...........................................................5
2.2 Application restrictions...............................................................................................5
2.3 General requirements on using 3rd party PMSM motors with SINAMICS drives ......6
2.4 Motor run-up..............................................................................................................6
2.5 Explanation on inductances Ld, Lq............................................................................6
2.6 Motor data required for commissioning.....................................................................7
2.7 Sizing of G120X with a PMSM motor........................................................................7
2.8 Operation with a sine-wave filter ...............................................................................8
3Commissioning using IOP-2..................................................................................................9
3.1 Preconditions.............................................................................................................9
3.2 Procedure..................................................................................................................9
3.3 Common issues and possible solutions ..................................................................15
3.3.1 Speed controller optimization ..................................................................................15
3.3.2 Troubleshooting.......................................................................................................16
4Appendix 1: Guidance on commissioning LSPM –Line Started Permanent
Magnet motors ......................................................................................................................17

1 Introduction
G120X commissioning guide for permanent magnet motors PMSM
Entry-ID: 109780815, V1.0, 07/2020
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©Siemens AG 2020 All rights reserved
1 Introduction
1.1 Document purpose
It provides guidance for commissioning permanent magnet synchronous motors (PMSM) with
SINAMICS G120X drives using the IOP-2 interface. Despite the fact the PMSM motors are not
standardized and the optimal performance with G120X drive cannot be always guaranteed most
3rd party PMSM motors that meet the criteria described in this guide can be successfully
commissioned.
1.2 Reference list of commissioned PM motors
This document contains information based on several successful tests with PMSM motors.
So far the biggest power rating of the motor that was tested with G120X inverter is
18.5kW/400V. For that reason the information provided in this guide is currently
restricted to applications of up to 18.5kW.
Table 1-1
Make
Type
Design
kW
rpm
V
Hz
Poles
Lq/Ld
Note
Hanning
P3S120-040P0110-
030-003-HS0-029
IPM
1.1
3000
310
150
6
1.3
Lq, Ld set
according to data
sheet
VEM
IE5-PS2R 90 S 4 H
TMP140
SMPM
1.5
3000
310
100
4
1
Lq, Ld set
according to data
sheet
VOLT
Pro
IE5 - 80
IPM
1.5
3000
300
250
10
1.1
ID run ok. Tested
up to 200Hz.
KSB
UMA-S 150E 7/42
Submersible
borehole motor
IPM
4
3000
400
100
4
1.7
Nominal voltage
corrected to
331V. Lq, Ld set
according to data
sheet values.
Tested with sine-
wave filter.
KSB
UMA-S 150E 18/42
Submersible
borehole motor
IPM
18.5
3000
400
100
4
1.6
Nominal voltage
corrected to
366V. Lq, Ld set
according to data
sheet values.
Tested with
du/dt+VPL and
sine-wave filter.

1 Introduction
G120X commissioning guide for permanent magnet motors PMSM
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©Siemens AG 2020 All rights reserved
1.3 Related documents
SINAMICS G120X Operating instructions
https://support.industry.siemens.com/cs/ww/en/view/109769350
SINAMICS IOP-2 Operating instructions
https://support.industry.siemens.com/cs/ww/en/view/109767180
General system requirements for S120 drives regarding 3rd party motors (in most aspects
applicable to all SINAMICS drives including G120X)
https://support.industry.siemens.com/cs/ww/en/view/109760445
1.4 Support contacts
Competence center in Prague
gmc.tech.team.infrastructure-[email protected]
Drive System Enhancement in Congleton
sinamics.solutions.mot[email protected]om

2 General conditions of operation
G120X commissioning guide for permanent magnet motors PMSM
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©Siemens AG 2020 All rights reserved
2 General conditions of operation
2.1 Supported permanent magnet motor designs
Supported designs:
•Surface mounted permanent magnet motors SMPM (preferred)
•Internal permanent magnet motors IPM
•Line started permanent magnet motors LSPM
(see Appendix 1 for instructions on commissioning this type of motor)
Not supported designs:
•Brushless DC motors BLDC
•Permanent magnet assisted synchronous reluctance motors PMASynRM
2.2 Application restrictions
•G120X only supports Encoderless operation with PMSM (p1300 = 20). It is required to
set Application class p96 = 2: Dynamic Drive Control.
•Deragging function is currently not supported with PMSM.
•High-dynamic applications are not suitable for PMSM operated from G120X.
•Flying start is not possible with PMSM. Motor must be standstill before each start.
•Regenerative applications are not released with PMSM.
•DC braking in not effective and must not be activated.
•PMSM rated voltage should be ideally ≤0.9 x inverter supply voltage.
Note: Some motor manufactures provide rated power grid voltage instead of the real
motor rated voltage at nominal speed and load.
If the motor nameplate shows nominal mains voltage values like 380V, 400V, 480V etc.
then see the Commissioning chapter on how to calculate motor rated voltage in such a
case.
•PMSM Multimotor applications are not allowed
•All applications requiring continues operation below 15% of motor nominal speed are
not allowed
•Operation is only allowed in range up to motor nominal speed –no operation in the field
weakening range is allowed
•Long cable + sinus wave filter systems are not generally supported (exceptions require
a customer specific test to be done)
•Maximum operating frequency is 200Hz (exceptionally up to 240Hz)
•The load inertia should not be less than 20% of the motor inertia. See p341 and p342

2 General conditions of operation
G120X commissioning guide for permanent magnet motors PMSM
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2.3 General requirements on using 3rd party PMSM motors with
SINAMICS drives
General requirements on 3rd party motors and their operations are described in the document
SINAMICS S120 Requirements placed on third-party motors:
https://support.industry.siemens.com/cs/ww/en/view/109760445
Most important are:
•Motor insulation system –check requirements regarding voltage stress. If needed use
dv/dt filter.
•BEMF waveform –must be sinusoidal ideally up to 2% THD.
•Low cogging torque –up to 4% peak-peak value compared to rated torque.
•Rated motor voltage –this should be ideally ≤0.9 x inverter supply voltage otherwise
derating may apply.
•Pulse frequency –depending on frame size and/or voltage rating the standard pulse
frequency of G120X inverters is either 4kHz or 2kHz. The motor must be of a suitable
design for this.
2.4 Motor run-up
During operation the rotor position is derived from known motor parameters and measured
quantities (voltage and current).
1. At every drive enable the initial rotor position is measured indirectly. This is called Pole
Position Identification (PolID). As default a sequence of voltage pulses is sent to the
motor phases, this results in a current increase which is evaluated to determine the pole
positions. This results in a short delay of approx. 200ms during which a “humming”
noise can be heard from motor.
2. The acceleration phase then follows with an injected current 10% more according to the
maximum expected load.
3. Once the speed reaches the value defined by p1755 (Motor model changeover speed
encoderless operation) the inverter operation switches to closed-loop mode providing
highly efficient motor control.
Note that motor operation in the open-loop phase is utilized only for transient conditions i.e. start
of acceleration or end of deceleration. The motor minimum operating speed (p1080) must
always be greater than Motor model changeover speed!
2.5 Explanation on inductances Ld, Lq
Ld –direct inductance and Lq –quadrature inductance. These motor parameters represent the
motor inductance when the rotor is positioned either in direct or in quadrature axis.
Direct axis is where the rotor magnetic axis is aligned with stator magnetic axis.
Quadrature axis is where the rotor magnetic axis is at an angle = (90°/pole-pair number) with
respect to the stator magnetic axis. That means 90° electrical.
Non equality between Ld and Lq indicates that a reluctance torque may be present in the motor.
This must be taken into account in the motor control to optimize efficient operation –MTPC
(Maximum Torque Per Current)
User experience shows the best results can be expected when the Ld, Lq difference is less than
20% like in case of SMPM.

2 General conditions of operation
G120X commissioning guide for permanent magnet motors PMSM
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2.6 Motor data required for commissioning
For correct automatic setting of motor model and control loop parameters some important data
must be entered into the inverter during commissioning. They can usually be found either on the
motor nameplate or in the datasheet provided by the motor supplier:
Table 2-1
Parameter name
Parameter number
Unit
Rated motor current
p305
Arms
Rated motor power
p307
kW
Rated motor speed
p311
rpm
Maximum motor speed
p322
rpm
Minimum speed
p1080
rpm
Rated motor voltage
p304
V
Rated motor frequency
p310
Hz
Maximum motor current/ current limit
p640
Arms
Motor temperature sensor type1
p601
-
Other motor parameters that are recommended and preferred to know for commissioning:
Table 2-2
Parameter name
Parameter number
Unit
Motor moment of inertia
p341
kg.m2
Ratio between the total and motor
moment of inertia 2
p342
-
Motor stator resistance cold
p350
Ohm
Cable resistance (if length exceeds 5m)
p352
Ohm
Motor stator inductance q axis3
p356
mH
Motor stator inductance d axis
p357
mH
2.7 Sizing of G120X with a PMSM motor
Always check the motor rated current and preferably use an inverter with at least 5% greater
rated current after considering all derating factors like altitude, ambient temperature, sine-wave
filter, number of starts per hour, overload requirements, increased pulse frequency requirements
etc.
This is important because there are usually some production tolerances in the properties of
permanent magnets and they also tend to decrease slightly in strength during the service life of
the motor.
1
It is strongly recommended to use temperature sensor for motor thermal protection particularly when using
a non-standardized motor.
2
(JLoad + JMotor) / JMotor
3
With some motors the inductance becomes significantly smaller at higher currents (saturation effect) than
given in the name plate, hence the current controller has to be adapted. IOP-2 displayed name may be Motor
stator leakage inductance.

2 General conditions of operation
G120X commissioning guide for permanent magnet motors PMSM
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2.8 Operation with a sine-wave filter
Currently only G120X FSA-G support sine-wave filters.
Basically a sine-wave filter with a PMSM motor can be used however the operation with long
cables may lead to instability and without making a customer specific test the operation cannot
be guaranteed.
Table 2-3
Important sine wave filter application notes
Always activate the sine-wave filter option in the Startup menu to protect the filter from
possible damage. Advanced Startup → Hardware Options → Output filter. Enter filter
inductance and capacitance.
Ensure p1901[1] is set at default (0).
Set p1980 = 10 and perform Save RAM to ROM.4
If using a 3rd party sine-wave filter check for suitability regarding maximum operating
frequency, minimum pulse frequency and current rating.
Consider the volt-drop due to the filter impedance (usually 10-15%) and the naturally lower
drive output voltage due to inhibition of Pulse Edge Modulation (approx. 0.92* Drive input
voltage). This can result in a significant derating.
Enter motor inductances Ld, Lq manually. Before performing the stationary ID run set
p1909[15] = 1.
4
Ensure rotor is unloaded before every start. Repeat after every motor ID run.

3 Commissioning using IOP-2
G120X commissioning guide for permanent magnet motors PMSM
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3 Commissioning using IOP-2
3.1 Preconditions
•Mounting, wiring and safety requirements are done in accordance to G120X Operating
instructions
•G120X drive and IOP-2 are both in factory setting
•User has fundamental skills with drive commissioning
Note: If not explicitly mentioned in the following procedure the inverter setting or parameter
value is to remain in factory setting.
3.2 Procedure
Table 3-1
Step
Description
Instructions
1
From initial screen go to Setup menu and
use Advanced Startup when
commissioning PM motor
2
If the inverter is not in factory setting do it
now: Factory Reset → Drive factory reset

3 Commissioning using IOP-2
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3
If you are using any type of output choke
or filter go to Hardware Options and
Output filter and select the right option:
Motor Reactor –enter its inductance and
number of reactors connected in series
Dv/dt filter –just select this option to
activate filter protection
Sinus Filter Siemens or 3rd party –enter
its inductance and capacitance values
from filter nameplate or data sheet. If
Siemens filter is selected the values are
pre-filled already and should equal
nameplate data.
4
In Control Type option select Dynamic
Drive Control
5
Go to Motor Data and enter the
parameters as shown in the table below.
Table 3-2
Motor data
Standard
Depending on power units to be used for commissioning enter
either IEC (50Hz, SI) or NEMA (60Hz, SI) for values in kW or NEMA
(60Hz, US) for values in HP.
Motor Type
2:Sync
Current
Enter Motor Rated Current
Power
Enter Motor Rated Power (mechanical)
Speed
Enter Motor Rated Speed
Voltage
Enter Motor Rated Voltage (refer to NOTE)
Frequency
Enter Motor Rated Frequency

3 Commissioning using IOP-2
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Temp Sensor
Select correct type of sensor if used
NOTE
Sometimes the motor manufacturers provide the nominal voltage of the supply grid the inverter
is connected to rather than actual motor rated voltage. If the motor nameplate shows nominal
mains voltage like 380V, 400V, 480V etc. then in most cases you can calculate correct value
provided other nameplate data is consistent:
󰇟󰇠 󰇟󰇠
󰇟󰇠
Some other PMSM motor manufacturers provide nameplate data containing PWM content –
i.e. actual values measured at the end of temperature rise tests with motors supplied from a
reference inverter. This could cause issues during commissioning as this data differs from the
required fundamental (1st harmonics) values normally used in motor model. Commonly it
shows rated voltage higher and power factor smaller. Using this data may lead to nuisance
overcurrent or ground faults during commissioning. See chapter 3.3.2 Troubleshooting how to
deal with this issue.
Some incomplete motor nameplate data can be calculated using following equations:
Motor rated power: Pn=Mn* 2 * π * Nn/60 [W]
Mn–rated torque [Nm]
Nn - rated speed [rpm]
Approximate motor rated voltage (if efficiency and power factor unknown):
󰇛󰇜
 

fn–motor rated frequency [Hz]
In–motor rated current [A]
Lq –motor quadrature inductance phase-starpoint [H]

3 Commissioning using IOP-2
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6
Go to Limit Settings and enter the
parameters as shown in the table below.
Table 3-3
Limit settings
Supply Voltage
If it differs from factory default value. Note that proportional derating
may apply if the inverter supply voltage is lower than nominal value.
Min. Freq.
Enter minimum frequency required by motor or application and
ensure it is greater than 15% of nominal frequency.
Max. Freq.
Insert maximum frequency used in the fan/pump or other
application. This maximum frequency should not be higher than
motor rated frequency in order to avoid field weakening and
possible overloading!
Ramp-up/ Ramp-down
Time5
In most applications the factory setting of 10s is adequate and
should not be reduced before the first start up. Longer ramp times
are required for high inertia loads like fans and centrifuges.
Max. Current
Change this only if the motor max. current is lower than inverter
default value.
7
Next go to I/O setup and based on the
actual application and I/O wiring Select
Macro and/or manually adjust
configuration of Inputs/Outputs.
For details see Operation Instructions
manual.
5
Exception: some special types of PM motors such as submersible borehole motors require fast ramp
setting to reach min. speed quickly. In this case set the required ramp as per motor supplier requirements.
Activation of Dual ramp function is recommended in this case.

3 Commissioning using IOP-2
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8
If the drive is connected to fieldbus go to
Fieldbus Setup and set appropriate
communication parameters if necessary.
9
Skip from the Advanced Startup menu by
pressing Ok or ESC key for 2s and
confirm Save Settings.
10
Go to Parameters menu
11
In the Parameter Filter select option
Expert
12
Then go to Search by number and type
00352 confirmed by OK to display
parameter p352. Enter correct motor
cable resistance.

3 Commissioning using IOP-2
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
The motor cable resistance can be measured:
Figure 3-1
p352 = Ω
p352 = Ω /2
NOTE
Always correct for measuring lead resistance (by subtracting it from the measured value) if not
using precise m-Ohm meter with Kelvin leads (4-wire measurement).
If measurement is not possible use calculated value based on cable length L [m], conductor
cross area A [mm2] and resistivity ρ [Ω.mm2/m]:
p352 = ρ * L/A ;for copper conductor use value ρ = 0.0171 Ω.mm2/m
13
KTY84
Temperature switch
PTC
Pt1000
Pt100 (evaluated via
a converter analog
input)
If you are using a temperature sensor set
up related parameters as per the sensor
type and level of protection. Follow
Operation instructions G120X Chapter
6.8.3.
14
Enable drive and wait several seconds
until the stationary Motor Identification is
finished. Rotor may slightly move during
this test.
15
Once the stationary ID run is done re-
enable the drive and let the motor
accelerate to min. speed (greater than
p1755 value) while observing the motor
current value on IOP-2 status display. In
applications with variable torque
(centrifugal pumps/fans) after
acceleration is finished the current should
be significantly lower than motor rated
value.



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NOTE
If fault 7969 Drv: PolID incorrect appears try the remedy detailed in the Operating instruction
manual in chapter: Warnings, faults and system messages.
If the problem persists, try changing the PolID method in p1980. Possible values for PMSM
motors are 1, 4 or 10. Value 4 is most suitable for IPM motors. Value 10 can be used only
when the application allows for motor shaft to freely move before start (i.e. ventilators,
centrifugal pumps etc.).
When you later re-run Motor identification test the value in p1980 will be automatically
reset to 1. You must change it manually to the desired value and perform Save RAM to
ROM afterwards.
16
Increase the speed to maximum and check the current at worst case load (usually open
valve/flap in system). The drawn motor current shouldn’t be greater than rated motor
current even if it runs for a longer time.
17
Stop the drive and save parameters by
going into the Extras menu, selecting
"Parameters settings" and finally "Save
RAM to ROM".
3.3 Common issues and possible solutions
3.3.1 Speed controller optimization
In order to avoid issues with drive stability or speed overshoots it is recommended to perform an
automatic speed controller optimization. To do it you will need to know motor and load moments
of inertia. If you don’t know them exactly you can make a good estimation by using known data
of similar motor/load of the same rating.
Update parameters:
p341 –Motor moment of inertia: JMotor
p342 –Total moment of inertia / Motor moment of inertia: (JLoad + JMotor) / JMotor
Then update speed controller gains p340 = 4.
If you still experience speed overshoot increase p342 gradually (not more than in 20% steps)
each time followed with p340 = 4.
Other information including mastering of critical applications can be found in G120X Operating
instructions in chapter: 6.7.3.2 Optimizing the speed controller.

3 Commissioning using IOP-2
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3.3.2 Troubleshooting
Table 3-4
Issue
Possible reason
Remedy
Nuisance Overcurrent
or Ground Fault during
PolID or stationary ID
test.
[F07807: Short
cct/grnd F]
Due to the reasons
described in chapter 3.2
Step 5, the value of
rated voltage is too high.
First check the motor wiring and
insulation resistance to confirm nuisance
tripping. Calculate the new motor rated
voltage using one of formulas in chapter
3.2 Step 5. Provided it’s lower than the
original one use the new value (in
Advanced Startup menu) and re-run
stationary motor ID test (Advanced
Startup →Optimisation →Motor
Identification →MotID only standst).
You can also repeatedly reduce original
value in 5 to 10V steps followed every
time with stationary ID test until the
nuisance trip is not occurring any more.
Note: If you directly change motor rated
voltage in p304 (p10=3), then after each
change re-calculate motor model p340=1
and only then re-run stationary ID test
p1900 = 2.
Motor current
increases significantly
when operating at low
speeds continually
despite no mechanical
issues being present.
The motor is operated
below the minimum
allowed speed defined
by p1755 Motor model
changeover speed
encoderless operation.
Ensure the motor is always operated
above the p1755 value and never below
15% of rated speed.
Set the Minimum speed p1080 > p1755.
Drive faults with the
message PolID
incorrect
Motor has significant
pole saliency
Change PolID technique p1980 to value 4
or 10.
Pole position
identification current is
too high
Reduce value in p329. Do it in about 10%
steps as too low a value leads to
inaccuracy in motor control.
Motor stalls or
struggles to run-up
Not enough starting
torque generated by
drive
Increase p1610 or/and p1611 value.
Before any attempt to re-run the motor
allow it to cool down.
Motor magnetic circuit
oversaturated
Check setting p1610 and p1611 and
reduce them by 10% steps gradually to
see the effect.
Motor oscillates or
tends to oscillate
Transition between open
loop to closed loop
phase during
acceleration is not
stable
Gradually increase p1755 in approx. 10%
steps until the transition is smooth and
stable.
Closed loop controller
gains inappropriate
Perform speed controller optimization,
chapter 3.3.1.
Motor overspeed fault
Speed overshoot at the
end of fast acceleration
Increase p1120 Ramp up time or
increase p1131 Final rounding 1. Perform
speed controller optimization, chapter
3.3.1.

4 Appendix 1: Guidance on commissioning LSPM (Line Started Permanent Magnet motors)
G120X commissioning guide for permanent magnet motors PMSM
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©Siemens AG 2020 All rights reserved
4 Appendix 1: Guidance on commissioning LSPM
(Line Started Permanent Magnet motors)
LSPM are special kind of PM motors comprising also the rotor cage.
It allows to connect this motors D.O.L. (direct on line) similarly to asynchronous motors.
Once the motor speed is close to synchronous speed the rotor magnets cause locking into
synchronism and successive operation as synchronous motor.
If the supplier of LSPM motor allows operation from frequency inverter then you can
commission the drive using V/F mode for PM motors.
Recommended procedure:
P10 = 1 (Quick commissioning)
P96 = [IEC/NEMA Standard]
P300 = 2 (Synchronous motor)
P304 = [nominal voltage]
P305 = [nominal current]
P307 = [nominal power]
P308 = 0 (you do not need to enter power factor if P300=2)
P310 = [nominal frequency]
P311 = [synchronous speed; 60 * nominal frequency/number of pole-pairs]
P611 = [Here should be put motor winding thermal time constant if known from motor
supplier or the overtemperature protection should be based on temperature sensor.
It his case change setting p601]
P3900 = 3 (end of Quick commissioning with motor parametrization)
Starting performance:
If the motor tends to stall at starting adjust the starting voltage boost using P1310, P1311,
P1312.
NOTE
If there are problems with current or speed oscillations during motor acceleration then adjust
P1338, P1339, P1349. Usually you need to set P1349 to about 95% of nominal motor
frequency.