SIMOCRANE Drive-Based Sway Control

Transcription

1 Preface Fundamental safety instructions 1 SIMOCRANE Operating Instructions System description 2 Hardware interfaces 3 Function description 4 Installation/uninstallation 5 Commissioning 6 Parameters 7 Function diagram 8 Spare parts, accessories, and maintenance 9 Appendix A valid for: SIMOCRANE as of Version 1.0 SP1 11/2015

2 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: Trademarks 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. 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 Division Process Industries and Drives Postfach NÜRNBERG GERMANY P 12/2015 Subject to change Copyright Siemens AG All rights reserved

3 Preface This document describes the software-based sway control system SIMOCRANE Drive-Based Sway Control. The software is part of the SIMOCRANE Advanced Technology package for the mid-range market. Target group This document is for customers, commissioning engineers, service and maintenance personnel. Benefits This manual provides the information, procedures, and operator actions required for operation and commissioning. Prerequisite (scope of validity) This manual is valid for use with the following product versions: Hardware SINAMICS S120 CU310-2 DP CompactFlash card with Firmware V 4.7 HF11 CRANES Software STARTER as of V4.4 HF3 SIMOCRANE Drive-Based Technology V1.0 SP1 HF2 (Optional) 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 ( You will find continuously updated information on Crane Application Notes on the Internet here ( Support request on the Internet: Support request ( Operating Instructions, 11/2015 3

4 Preface Hotline for Europe: Phone: +49(0) Fax: +49 (0) Support Europe (mailto:support.automation@siemens.com) Hotline for America: Phone: Fax: Support America (mailto:support.america.automation@siemens.com) Hotline for Asia/Pacific Phone: Fax: Support Asia/Pacific (mailto:support.asia.automation@siemens.com) Siemens product support for SINAMICS You will find the latest information on SINAMICS products, product support, and FAQs on the Internet here ( Copyright information MATLAB The MathWorks, Inc. Siemens confirms that it has a valid license agreement with Mathworks. 4 Operating Instructions, 11/2015

5 Table of contents Preface Fundamental safety instructions General safety instructions Industrial security System description Introduction System overview Options for commissioning Requirements of the crane and crane axis Scope of delivery Hardware interfaces CompactFlash memory card of the CU310-2 DP Interfaces of the CU310-2 DP BOP20 Basic Operator Panel Function description Licensing State behavior of the technology package applicable to all functions Sway-controlled motion Switching sway control on and off Pre-limit switch function Damping factor "Ready-to-run" functions on the CompactFlash card Logic for switching the drive (OFF1) on and off Digital joystick switch Pre-limit switch function Activating the sway control function Installation/uninstallation Installation of the technology package Activating the technology package in the drive object Compile the project and load it into target device Uninstalling the technology package...32 Operating Instructions, 11/2015 5

6 Table of contents 6 Commissioning Commissioning with STARTER Requirements Requirements of the SINAMICS project Parameterizing the technology package Fundamentals of parameter assignment Interconnecting and activating the technology package (part 1) Parameterizing the pre-limit switch range Parameterizing functions of the technology package Interconnecting and activating the technology package (part 2) Example of setpoint curves Optional settings Commissioning with Basic Operator Panel BOP20 or Web browser Operation of the BOP Access to the parameter lists with a Web browser Requirements for commissioning Establish the operating state of the CU310-2 DP for commissioning Preparing the motor for commissioning Motor commissioning and motor data identification Adapting the brake control Configuration of the encoder (optional) Parameterizing Drive-Based Technology (optional) Parameterization of the analog input for the hoisting height Parameterizing the functions of the technology package Parameters Description of parameters List of parameters of the technology package Function diagram Spare parts, accessories, and maintenance...71 A Appendix...73 A.1 List of abbreviations...73 A.2 Glossary...74 A.3 List of references Operating Instructions, 11/2015

7 Fundamental safety instructions General safety instructions WARNING Risk of death if the safety instructions and remaining risks are not carefully observed If the safety instructions and residual risks are not observed in the associated hardware documentation, accidents involving severe injuries or death can occur. Observe the safety instructions given in the hardware documentation. Take into account residual risks when assessing risks. WARNING Danger to life or malfunctions of the machine as a result of incorrect or changed parameterization As a result of incorrect or changed parameterization, machines can malfunction, which in turn can lead to injuries or death. Protect the parameterization (parameter assignments) against unauthorized access. Respond to possible malfunctions by applying suitable measures (e.g. EMERGENCY STOP or EMERGENCY OFF). WARNING Danger to life posed by uncontrolled changeover between operating states Uncontrolled change of the operating state can cause malfunctions on machines that can result in injuries or death. Assess the effects of changeover between operating states in the risk analysis. Provide appropriate safety measures, e.g. EMERGENCY OFF. Operating Instructions, 11/2015 7

8 Fundamental safety instructions 1.2 Industrial security 1.2 Industrial security Note Industrial security Siemens provides products and solutions with industrial security functions that support the secure operation of plants, solutions, machines, equipment and/or networks. They are important components in a holistic industrial security concept. With this in mind, Siemens products and solutions undergo continuous development. Siemens recommends strongly that you regularly check for product updates. For the secure operation of Siemens products and solutions, it is necessary to take suitable preventive action (e.g. cell protection concept) and integrate each component into a holistic, state-of-the-art industrial security concept. Third-party products that may be in use should also be considered. For more information about industrial security, visit this address ( To stay informed about product updates as they occur, sign up for a product-specific newsletter. For more information, visit this address ( WARNING Danger as a result of unsafe operating states resulting from software manipulation Software manipulation (e.g. by viruses, Trojan horses, malware, worms) can cause unsafe operating states to develop in your installation which can result in death, severe injuries and/ or material damage. Keep the software up to date. You will find relevant information and newsletters at this address ( support.automation.siemens.com). Incorporate the automation and drive components into a holistic, state-of-the-art industrial security concept for the installation or machine. You will find further information at this address ( industrialsecurity). Make sure that you include all installed products into the holistic industrial security concept. 8 Operating Instructions, 11/2015

9 System description Introduction At the end of 2010, an industry solution based on the SINAMICS platform SIMOCRANE Drive- Based Technology was launched onto the market. It is used to serve the diversified midperformance market, which has developed very dynamically over the past few years. In accordance with increased productivity requirements, this market demands certain advanced technologies, e.g. a function for damping the load sway. Siemens Cranes is meeting the challenges of this market with SIMOCRANE. Every movement of the trolley of a crane causes the load to sway. This makes positioning more difficult, and it takes correspondingly longer, depending on the experience of the crane driver. The main purpose of the sway control system is to eliminate the sway motion so that manual movement by the crane driver is made easier. This can relieve the crane driver and increase the handling capacity. This new mid-performance crane solution will not take a market share from the existing SIMOCRANE Sway Control Systems. SIMOCRANE is rather a perfect addition to the SIMOCRANE product portfolio. SIMOCRANE can be used as a standalone system or with SIMOCRANE Drive-Based Technology. Both technologies together provide a compact solution within the SINAMICS world for most mid-performance crane applications. For further information on SIMOCRANE Drive-Based Technology, see Ref. [1]. The advantages of SIMOCRANE are: easy and quick commissioning, high flexibility with many possibilities for adaptation, load can be moved without sway. One highlight of Version 1.0 SP1 is a preconfigured project directly on the CompactFlash card. It offers the user additional possibilities for performing commissioning without engineering. A Basic Operator Panel BOP20 or a Web browser is used for these commissioning tasks. The preconfigured CompactFlash card combines SIMOCRANE Drive-Based Technology and SIMOCRANE and provides a complete solution both for the trolley and the gantry. 2.2 System overview The main function of is sway-controlled operation of a crane axis in manual operation. Operating Instructions, 11/2015 9

10 System description 2.3 Options for commissioning It therefore performs the following functions: Sway is damped during manual travel. For movements during manual travel, the velocity is specified, e.g. by a master controller. It is not possible to specify target positions or perform position-controlled travel. After the axis has stopped, little or no load sway remains. The technology package is an additional software for SINAMICS S120. With its interfaces, the technology package is integrated into the setpoint channel. Design Image 2-1 Integration of the technology package into the SINAMICS setpoint channel (without using Drive-Based Technology) The technology package intervenes between the ramp-function generator and the speed controller. The technology package reads the speed output of the ramp-function generator and outputs an additional speed value that is added to the value from the ramp-function generator. The summated result is the input value of the speed controller. 2.3 Options for commissioning can be commissioned in different ways: Integration of the technology package into an existing project with the STARTER commissioning software ("Upgrade Existing Project"). Configuration in the STARTER commissioning software based on the standard applications ("ready-to-apply" solution). Standard applications and application notes are provided in the application section on the product DVD. Commissioning via a Basic Operator Panel BOP20 or via a Web browser with the preconfigured CompactFlash card ("ready-to-run" solution). 10 Operating Instructions, 11/2015

11 System description 2.4 Requirements of the crane and crane axis The "ready-to-run" and the "ready-to-apply" solutions differ on account of the functions that can be used with them and that are configured in addition to the sway control methods. The following table provides an overview. Table 2-1 Functional scope Function Ready-to-run Ready-to-apply Upgrade Existing Project Drive-Based Technology Digital master switch Drive-Based Technology Analog master switch Drive-Based Technology Pre-limit switch Preconfigured Profibus interface Preconfigured I/O interface Operation with encoder on travel axis technology package Interconnectable damping factor customizable - customizable customizable - customizable customizable - - customizable - customizable 2.4 Requirements of the crane and crane axis For the correct operation of the SIMOCRANE, the following requirements must be met: The axes for the trolley and gantry must be orthogonal with respect to each other. The relationship between the speed of the crane drive and the velocity of the crane axis is linear. In crane operation, the speed actual value of the crane drive follows the speed setpoint sufficiently well. An increase in the deviation between the two values is a cause of the poor quality of the sway control. Note Encoder on the travel axis An encoder on the travel axis is not necessary but is recommended to improve performance. The hoist must be equipped with an encoder so that the pendulum length can be provided for sway control. Operating Instructions, 11/

12 System description 2.5 Scope of delivery The load sway must be roughly equivalent to a mathematical sway model. Above all, no mechanical sway control systems must be present (e.g. separate cable tensioning). Mechanical sway control systems can result in a large deviation between the internal sway model and the real load sway. In this case the sway control will not work correctly with Drive- Based Sway Control. SIMOCRANE works without a camera measuring system. For this reason, the following sway motion cannot be detected: Load sway before sway-controlled travel starts, Sway caused by a collision, wind, or asymmetrical load distribution, Sway caused by oblique hoisting of the load. To ensure sway control works as expected, the disturbances stated above must be avoided while the product is in use. If the SINAMICS drive is controlled via PROFIBUS, non-isochronous communication must be configured. The requirements for configuration and parameter assignment of the SINAMICS drive are described in section Requirements of the SINAMICS project (Page 34). Note SIMOCRANE requires the SINAMICS firmware for cranes and can only be used with vector control mode. 2.5 Scope of delivery The scope of delivery of the SIMOCRANE V1.0 SP1 package (6GA7280-1AA10-0AB0) includes: a preconfigured CompactFlash memory card with: Crane-specific firmware version SINAMICS FW V4.7 HF11 Cranes technology package Standard application ("ready-to-run") License key for technology package a DVD with: STARTER installation file of the technology package (oasp_db_sc_v1_1_oaif zip) Memory card image for recovery (DBSC_CF_card.zip) Product documentation Readme files Application examples and application notes ("ready-to-apply") a license certificate for the technology package 12 Operating Instructions, 11/2015

13 Hardware interfaces CompactFlash memory card of the CU310-2 DP The CompactFlash memory card contains the files in section Scope of delivery (Page 12). Note The CompactFlash memory card must only be inserted in the CU310-2 DP Control Unit when it is disconnected from the power supply. 3.2 Interfaces of the CU310-2 DP The CU310-2 DP Control Unit (PROFIBUS) is a control module for single-motor drives in which the open-loop and closed-loop control functions of the drive are implemented. The table shows an overview of the interfaces on the CU310-2 DP. Table 3-1 Overview of the interfaces on the CU310-2 DP Type Number Isolated digital inputs 11 Non-isolated digital inputs/outputs 8 Isolated digital output 1 Non-isolated analog input 1 DRIVE-CLiQ interface 1 PROFIBUS interface 1 Serial interface (RS232) 1 Encoder interface (HTL/TTL/SSI) 1 LAN (Ethernet) 1 Temperature sensor input 1 EP terminal 1 Test sockets 3 Operating Instructions, 11/

14 Hardware interfaces 3.2 Interfaces of the CU310-2 DP Image 3-1 CU310-2 DP interfaces The interface to the Power Module is located at the rear of the CU310-2 DP. Image 3-2 CU310-2 DP/PN_interface Power Module 14 Operating Instructions, 11/2015

15 Hardware interfaces 3.2 Interfaces of the CU310-2 DP Image 3-3 CU310-2 DP connection example For more information, see Ref. [3]. Operating Instructions, 11/

16 Hardware interfaces 3.3 BOP20 Basic Operator Panel 3.3 BOP20 Basic Operator Panel Image 3-4 BOP20 Basic Operator Panel The BOP20 Basic Operator Panel is a panel with six keys and a backlit display unit. It can be inserted in the SINAMICS CU310-2 DP Control Units or CU310-2 PN and operated there. Functional scope Entering parameters and activating functions Display of operating modes, parameters, alarms and faults Displays and keys RUN S P C FN P Image 3-5 BOP20 displays and keys Table 3-2 Display top left 2 positions RUN Displays Meaning The active drive object of the BOP is displayed here. The displays and key operations always refer to this drive object. It illuminates when the displayed drive is in the RUN state (in operation). 16 Operating Instructions, 11/2015

17 Hardware interfaces 3.3 BOP20 Basic Operator Panel Display top right 2 positions S P C Below, 6 digit Meaning The following is displayed in this field: More than 6 digits: characters that still exist but are not visible (e.g. "r2": two characters to the right are not visible, "L1": one character to the left is not visible) Faults: selects/displays other drives with faults Designation of BICO inputs (bi, ci) Designation of BICO outputs (bo, co) The source object of a BICO interconnection to a drive object differs from the active one It illuminates when at least one parameter was changed and the value was not transferred to the non-volatile memory. It illuminates when the value for a parameter becomes effective only after pressing the P key. It illuminates when at least one parameter was changed and the calculation for consistent data management has still not been initiated. Displays, e.g. parameters, indices, faults and alarms. Table 3-3 BOP20 keys 1) Key Name Effect ON 2) Power-up the drives for which the "ON/OFF1", "OFF2" or "OFF3" commands should come from the BOP. FN P OFF 2) Functions 3) Parameter Raise Lower Power-down the drives for which the "ON/OFF1", "OFF2" or "OFF3" commands should come from the BOP. The effect of this key depends on the current display. The effect of this key depends on the current display. These keys depend on the current display; use these keys to set the displayed values higher or lower. 1) The structure of the BOP control word corresponds to the structure of the PROFIBUS control word. 2) The effect of this key can be defined using the appropriate BICO parameterization (for example, you can use this key to control all axes concurrently). 3) The effect of this key to acknowledge faults can be defined using the appropriate BICO parameterization. Note You will find further information on the BOP20 in the "SINAMICS S120 Commissioning Manual," Ref. [4]. Operating Instructions, 11/

18 Hardware interfaces 3.3 BOP20 Basic Operator Panel 18 Operating Instructions, 11/2015

19 Function description 4 This chapter describes the functions of. 4.1 Licensing Use with license only The functions of the technology package can only be used if the relevant licenses are installed. The SINAMICS basic functions can be used without restriction even without a license. The license key is stored on the preconfigured CompactFlash card. You will find this in folder KEYS\SINAMICS in file KEYS.txt. The license certificate is also supplied with the. If the license is missing, the SINAMICS basic system generates the warning A13000 (insufficient licenses). The RDY LED on the Control Unit red/green also flashes at a frequency of 0.5 Hz. 4.2 State behavior of the technology package applicable to all functions The technology package works with the following two states internally: Standstill Motion These states are relevant to a number of functions and are therefore described as state behavior applying to multiple functions. Change to the standstill state If the input signal p39049 "DB_SC threshold value speed undershot" has changed from 0 to 1 and the setpoint output of the ramp-function generator (r1150) is equal to 0, the Drive-Based Sway Control technology package will change to standstill. Change to the motion state If parameter r1150 "Ramp-function generator speed setpoint at the output" is not equal to 0, the technology package will change from standstill to motion. Operating Instructions, 11/

20 Function description 4.4 Switching sway control on and off 4.3 Sway-controlled motion Range of hoist positions Sway-controlled motion with is only possible in a limited range of hoist positions. The limits are the hoist positions that correspond to effective pendulum lengths 200 mm or 200,000 mm. Internally, the effective pendulum length is limited to the range from 200 mm to 200,000 mm and indicated in parameter r The relationship between the hoist position and the effective pendulum length is described in chapter Parameterizing functions of the Drive-Based Sway Control technology package (Page 39). Traversing range of the crane axis While sway control is active, the path from initiation of stopping the crane axis to standstill will be longer. Rather than the fastest possible braking, an adapted velocity profile must be used while sway control is active, see also examples in Chapter Damping factor (Page 23). When braking with the sway control function active, the maximum load position in the direction of motion can be greater than when sway control is not active. WARNING System behavior with activated sway control To prevent damage to third parties, the system behavior must be taken into consideration when stopping the crane while sway control is active. 4.4 Switching sway control on and off Parameter 39001[1] "Switch on sway control" With the parameter (39001[1]) "Switch on sway control," you can switch the sway control function on and off. This input can be connected to the PROFIBUS interface of the SINAMICS Control Unit or to a digital input of the Control Unit. You will find detailed information in Chapter "Commissioning with STARTER (Page 34)." Functional principle The parameter r "Sway control function activated" indicates whether the sway control function in the technology package is switched on (r = 1) or switched off (r = 0). If the sway control function is switched off, the addition value for the setpoint channel (r39032) is equal to Operating Instructions, 11/2015

21 Function description 4.5 Pre-limit switch function The state of parameter p39001[1] = 1 does not always mean that the sway control function has been activated, for example see the figure in Section Activating the sway control function (Page 27). It is only possible to activate the sway control function while the axis is at standstill (see chapter State behavior of the technology package applicable to all functions (Page 19)). If the state of parameter p39001[1] changes from 0 to 1 during motion of the crane axis, the sway control function is not activated in the technology package and the value of parameter r remains 0. If the state of parameter p39001[1] is still equal to 1 when standstill is reached, the sway control function will be activated. A negative edge of the state of parameter p39001[1] always causes immediate deactivation of the sway control function. When the sway control function is switched off during axis motion, the Drive-Based Sway Control technology package sets the values of the ramp-function generator via parameters and r , see also Interconnecting and activating the technology package (part 2) (Page 40). This permits continuous speed curves at the input of the speed controller (r1170). Note The statuses of OFF1, OFF2, and OFF3 do not affect the behavior of the Drive-Based Sway Control technology package. However, if OFF1 = 0 or OFF3 = 0, the additional value of the technology package (r39032, interconnected to p1169) in the setpoint channel of the SINAMICS firmware is not considered (cf. [6], function diagram 3080). In this case, if OFF1 = 0 or OFF3 = 0, motion is performed without sway control. Note The speed setpoint of the speed controller (r1170) is not subject to jerk limitation while the sway control function is active, but only to speed and acceleration limitations. The following parameters are used as the limits in the technology package: p1082[0] for the maximum speed p1120[0] for the ramp-up and ramp-down time This applies both to the simple and to the extended ramp-function generator. 4.5 Pre-limit switch function Parameter p39001[2] Not in pre-limit switch range Parameter p39001[2] "Not in pre-limit switch range" signals to the technology package whether a pre-limit switch range has been reached. A set bit (p39001[2] = 1) means that the crane axis is outside the pre-limit switch range. The state of parameter p39001[2] = 0 means that the crane axis is within the pre-limit switch range. Operating Instructions, 11/

22 Function description 4.5 Pre-limit switch function The control bit is non-directional, i.e. different pre-limit switch ranges are not distinguished. If the pre-limit switch control bit is not set (value = 0), the technology package switches the sway control function off and the value to be added for the setpoint channel (r39032) becomes 0 [rpm]. Note Velocity in the pre-limit switch range. The technology package does not reduce the velocity of the drive to the value desired in this range in the pre-limit switch range. The reduction of the velocity must be implemented at a higher level, e.g. in the SINAMICS project or in a S7 controller. To traverse with active sway control function again, the crane axis must be moved out of the pre-limit switch range. As soon as the axis is out of the pre-limit switch range, the Drive-Based Sway Control technology package will behave exactly like the switch on/off sway control function: Once the load sway has settled, new, sway-controlled motion can start after the axis has reached standstill (see also Switching sway control on and off (Page 20)). Image 4-1 Behavior in the pre-limit switch range (example) 22 Operating Instructions, 11/2015

23 Function description 4.6 Damping factor 4.6 Damping factor Effect of the damping factor on the sway control function The damping factor determines the degree of sway control. The value can be passed to the technology package in parameter p39026 or via BICO connector p If the input signal is not equal to 0, the value of the BICO signal p39027 is used. If the input signal is not equal to 0, the value of parameter p39026 is used. The damping factor has a setting range of 0.3 to 1.1. A change of the damping factor during motion (see chapter State behavior of the Drive-Based Sway Control technology package applicable to all functions (Page 19)) only takes effect once the axis is at standstill again. The effect of the damping factor is illustrated in the following graph. Operating Instructions, 11/

24 Function description 4.6 Damping factor Image 4-2 Effect of the damping factor Different damping factors (0.4; 0.8; 1.0) are compared in the graph. In the "Speed" figure above, you can see that the r1170 speed curve deviates less from the speed curve of the ramp-function generator (r1150) as the damping factor becomes smaller. 24 Operating Instructions, 11/2015

25 Function description 4.7 "Ready-to-run" functions on the CompactFlash card Select a high damping factor, e.g. 0.8, the speed will be overshot less than with a smaller value. The load sway will then settle faster during motion with constant velocity (see lower graph "Load angle"). Note The choice of damping factor depends on the specific application scenario of the crane. If low residual sway is important, a higher damping factor is recommended. The damping factor must therefore be optimized during commissioning in accordance with the application. 4.7 "Ready-to-run" functions on the CompactFlash card The preconfigured CompactFlash card contains a configuration with which you can commission via the Basic Operator Panel BOP20 or via a Web browser. The STARTER commissioning tool is then no longer required. Some functions are already preconfigured in the configuration. These can be used directly after commissioning. The functions are described in the following sections Logic for switching the drive (OFF1) on and off On the preconfigured CompactFlash card, logic is implemented for switching the drive (OFF1) on and off. It is shown in the following figure. Image 4-3 Logic for setting OFF1 Operating Instructions, 11/

26 Function description 4.7 "Ready-to-run" functions on the CompactFlash card This logic activates the drive by setting a direction bit (DI0 or DI1). Note Resetting the direction bit (DI0 or DI1) does not immediately reset OFF1 (p0840[0]). OFF1 is only reset after standstill has been reached via r Digital joystick switch On the preconfigured CompactFlash card SIMOCRANE Drive-Based Technology uses digital joystick switch. You will find detailed information about the function in Ref. [1] (Section 7.1.1) Pre-limit switch function On the preconfigured CompactFlash card SIMOCRANE Drive-Based Technology uses the pre-limit switch function. The pre-limit switch is suitably interconnected as shown in the following figure. You will find detailed information about the function in Ref. [1] (Section 4.4). The following figure shows the interconnections of the digital inputs of the CU310-2 DP with the pre-limit switch function of Drive-Based Technology and with the technology package. Image 4-4 Interconnecting the pre-limit switch 26 Operating Instructions, 11/2015

27 Function description 4.7 "Ready-to-run" functions on the CompactFlash card Activating the sway control function The following figure shows interconnection of the input for activating the sway control function P39001[1] in the configuration. Image 4-5 Interconnection of the input for activating the sway control function Operating Instructions, 11/

28 Function description 4.7 "Ready-to-run" functions on the CompactFlash card 28 Operating Instructions, 11/2015

29 Installation/uninstallation 5 If you perform commissioning with the preconfigured CompactFlash card via a BOP20 or with a Web browser, this chapter is not relevant for you. Go straight to Chapter Commissioning with Basic Operator Panel BOP20 or Web browser. (Page 43). 5.1 Installation of the technology package Installation of the technology package in the STARTER commissioning tool is described below. Requirement The STARTER commissioning tool is open (offline mode). No projects are open. Operating Instructions, 11/

30 Installation/uninstallation 5.2 Activating the technology package in the drive object Procedure Proceed as follows: 1. Select the menu item "Options > Installation of libraries and technology packages...". Image Click the "Add..." button. Selecting and installing the technology package 3. Open the file "oasp_db_sc_v1_1_oaif zip." The technology package is added. 4. Click the "Close" button. 5.2 Activating the technology package in the drive object The technology package is assigned to a drive object as described below. Requirement A project matching the device is open (see chapter Requirements of the SINAMICS project (Page 34)). The corresponding drive axes have been created in the project. The STARTER commissioning tool is in OFFLINE mode. 30 Operating Instructions, 11/2015

31 Installation/uninstallation 5.2 Activating the technology package in the drive object Procedure Proceed as follows: 1. Open a project matching the device. 2. In the project navigator, select the drive object for which the technology package ("DB_SC") is required (e.g. DriveAxis). 3. Select "Properties" from the shortcut menu (right mouse button). 4. Go to the "Technology Packages" tab. 5. Select the "DB_SC" option. The technology package is activated. 6. Click "OK" to confirm your entries. Image 5-2 Object properties 7. Open the expert list of the drive object. The additional parameters of the installed technology package must now be visible in the expert list of the corresponding drive object. Please note that the parameters are not displayed in the expected sequence. Operating Instructions, 11/

32 Installation/uninstallation 5.4 Uninstalling the technology package 5.3 Compile the project and load it into target device Loading and compiling the project with the technology package is described below. Requirements The steps described in the preceding sections have been performed: The technology package has been installed in the STARTER The technology package has been installed in the drive object The STARTER commissioning tool is in OFFLINE mode. Procedure Proceed as follows: 1. Save and compile the drive unit in whose drive object you have activated the Drive-Based Sway Control technology package. 2. Establish an ONLINE connection to the target device. 3. Load the drive unit into the target device. 5.4 Uninstalling the technology package The technology package is uninstalled using the STARTER tool as described below. Uninstallation is performed in the reverse sequence to installation. Procedure Proceed as follows: 1. Deactivate the technology package in the drive object (see Chapter Activating the technology package in the drive object (Page 30)). 2. Uninstall the technology package in the STARTER (see Chapter Installation of the technology package (Page 29)). 32 Operating Instructions, 11/2015

33 Commissioning 6 You can commission in various ways: With the STARTER commissioning software (integration into an existing project or configuration based on the standard application). With the Basic Operator Panel BOP20 or via a Web browser. Notes on the safety concept for the crane WARNING Danger to life due to malfunctions of the machine resulting from failure of the hoist encoder or a loose contact in its wiring If the effective pendulum length changes suddenly (e.g. due to failure/loose contact of the hoist encoder or its wiring), this change can result in unpredictable movements of the crane axis. Protect the parameter assignments against unauthorized access. Respond to possible malfunctions by applying suitable measures (e.g. Emergency stop or Emergency switching off). Consider the following system characteristic in the safety concept for the crane application and always consider the following suggested ways of switching off. Sudden changes in the progression of the hoist position can result in the speed output (of the technology package) not going down to a constant 0 in the time that follows even if speed input p39050 (of the technology packages) equals 0. If the enables continue to apply, the crane axis will not stop in these situations. Ways of switching off when the preconfigured CompactFlash card is used: Resetting the input Enable Sway Control" (digital input DI18) can result in a speed setpoint of 0 at the input of the speed controller (r1170). Resetting OFF2 via the digital input DI10 (e.g. via the emergency off chain). Before traversing with the sway control function active again, the Enable Sway Control" input (digital input DI18) must briefly be reset. Method for switching off if the technology package is used in a userspecific configuration: Resetting OFF1 or OFF2 combined with resetting the input Enable Sway Control" (p39001[1]). Operating Instructions, 11/

34 Commissioning 6.1 Commissioning with STARTER 6.1 Commissioning with STARTER Requirements The following conditions must be met before the SIMOCRANE can be commissioned: The crane meets the technological requirements (see chapter Requirements of the crane and crane axis (Page 11)). The SINAMICS drive is configured in such a way that an axis can be moved (see the following section Requirements of the SINAMICS project (Page 34)). The STARTER commissioning tool as of Version V4.4 must be installed. Note In the description below, it is assumed that commissioning of the PLC (if there is one) and drive has been completed Requirements of the SINAMICS project The SINAMICS configuration already exists and must meet the following requirements: The STARTER commissioning tool has been installed. A STARTER project has been created, can be compiled, and loaded onto the SINAMICS Control Unit (CU310-2 DP). The drive, in particular the speed control and current control, has been commissioned and optimized. The ramp-function generator is used in the drive object. 34 Operating Instructions, 11/2015

35 Commissioning 6.1 Commissioning with STARTER If the crane axis does not have a brake or the brake is controlled via the BICO signal r1229.1, p1215=3 (motor holding brake like sequential control system, connection via BICO) must be set. If the existing brake of the crane axis is controlled via the drive-integrated brake connection, p1215=1 must be set. Extended brake control must be activated for the axis in the drive. You must set the parameters p1226[0] and p1228 correctly. These two parameters are relevant for bit r1229.7, which is used to detect standstill of the technology package. Only with this activation and parameterization will the state behavior in the Drive-Based Sway Control technology package operate as intended (see Chapter State behavior of the technology package applicable to all functions (Page 19)). For details of the extended brake control, see Ref. [5]. Note The extended brake control in the project must always be activated and parameterized (p1226[0], p1228). The activation and parameterization also apply if the brake of the axis is not controlled via SINAMICS or if there is no brake Parameterizing the technology package Fundamentals of parameter assignment The basics for parameterization of the technology package are described below. Parameter ranges The parameters of the technology package ("DB_SC") are in the number range Note Handling the parameters The parameters (interconnection, change, ) are handled like the other SINAMICS parameters, Ref. [6]. Operating Instructions, 11/

36 Commissioning 6.1 Commissioning with STARTER Before performing parameter assignment and interconnection of the Drive-Based Sway Control technology package, check the following settings in the STARTER project. Replace these if necessary. Before adaptation, the parameter p0112 must be set to "Expert." Select one of the five options from the following list to set parameters p115[3] and p115[1] of the axis (sampling times for internal control loops): p0115[3] = 8000, p0115[1] = 1000 p0115[3] = 4000, p0115[1] = 1000 p0115[3] = 2000, p0115[1] = 1000 p0115[3] = 2000, p0115[1] = 500 p0115[3] = 1000, p0115[1] = 500 Note To ensure proper functioning of the sway control function, one of the five ratios between p0115[1] and p0115[3] stated above must be set. Setting other ratios is not recommended and can result in malfunctions. The interpolators in the setpoint channel must be set as follows: p1189[0].0 = Yes p1189[0].1 = No The ramp-function generator ramp-up and ramp-down times (p1120[0] and p1121[0]) must be the same. does not require a particular setting for the open-loop/closedloop control mode (p1300). If there is no encoder in your hardware configuration, you can set both U/f (V/Hz) control (p1300=0..7) and encoderless speed control (p1300=20). If an encoder is available, speed control with an encoder (p1300=21) is recommended. The basic requirement for sway-controlled travel of the crane axis to function is that the actual speed value has to track the speed setpoint sufficiently closely (see Requirements of the crane and crane axis (Page 11) Interconnecting and activating the technology package (part 1) Interconnection of the technology package is described below. Interconnection with the SINAMICS setpoint channel 1. Interconnect the output of the ramp-function generator (r1150) with parameter p Activate the technology package via parameter p39001[0]. 36 Operating Instructions, 11/2015

37 Commissioning 6.1 Commissioning with STARTER Interconnection with the SINAMICS stationary monitoring Interconnect the parameter r with parameter p Interconnection of the hoisting height There are two ways of interconnecting the hoisting height: Either via SINAMICS-IO or via PROFIBUS as described below. Option 1: Interconnection of the hoisting height via SINAMICS-IO 1. If the hoist position is provided to the technology package via analog inputs of the Control Unit, interconnect r755[0] with parameter p Parameter r755[0] has the scaling PERCENT. After interconnection with parameter p39051, the absolute value is used in the technology package (i.e. 100 % corresponds to the integer value 1,073,741,824, etc.). Example: l eff = s_hoist Factor + Offset, where s_hoist is in the range -2,147,483,648 to 2,147,483,647. Note To ensure that no values are lost, proceed as follows when scaling the analog value: The absolute value of parameter r755[0] must be within the integer-32 value range (-2,147,483,648 to 2,147,483,647) of the input for the hoist position p With parameter r39052, you can verify the input value p39051 and check how the value is processed in the technology package. Option 2: Interconnection of the hoisting height via PROFIBUS 1. If the technology package provides the hoist position via a PROFIBUS interface, interconnect parameter p39051 (integer-32) with an appropriate PROFIBUS parameter. You can interconnect the following PROFIBUS parameters: Drive object: r2050[i], i = 0 31 Drive object: r2060[i], i = 0 30 Control Unit: r2050[i], i = With parameter r39052, you can verify the input value p39051 and check how the value is processed in the technology package. Interconnection of the input signal to activate the sway control function If you want to use the function for switching sway control on and off (see chapter Switching sway control on and off (Page 20)), you must interconnect the BICO connector p39001[1]. You have two options: Operating Instructions, 11/

38 Commissioning 6.1 Commissioning with STARTER Either via SINAMICS-IO or via PROFIBUS as described below. Note If the sway control function is always to remain active, it is not necessary to interconnect parameter p39001[1]. The BICO connector can be set constantly to 1. In this case, you can skip the following two sections describing options. Option 1: Interconnection of parameter p39001[1] via SINAMICS-IO 1. If the signal for switching the sway control function on and off is provided to the Drive-Based Sway Control technology package via a digital input of the Control Unit, interconnect the corresponding parameters, e.g. r722.0, with p39001[1]. Option 2: Interconnection of parameter p39001[1] via PROFIBUS 1. If the signal for switching the sway control function on and off is provided to the Drive-Based Sway Control technology package via PROFIBUS, interconnect the corresponding PROFIBUS parameter with p39001[1]. You can interconnect the following PROFIBUS parameters: Drive object/control Unit: r to r Drive object/control Unit: r to r Drive object/control Unit: r to r Drive object/control Unit: r to r Drive object/control Unit: r to r Drive object/control Unit: r to r Parameterizing the pre-limit switch range Interconnection of the technology package for use of the pre-limit switch function is described below. Interconnection with parameter Not in pre-limit switch range If the parameter setting is correct, the evaluation signal of the pre-limit switches are interconnected with the control bit for the pre-limit switch of the technology package. 1. Interconnect the signal of the pre-limit switches with the input parameter p39001[2]. Note The control bit for reaching a pre-limit switch range can be used for one or more pre-limit switch ranges. 38 Operating Instructions, 11/2015

39 Commissioning 6.1 Commissioning with STARTER Parameterizing functions of the technology package Conversion of speed to translatory velocity The translatory velocity of the crane axis is required for the sway control function. The Drive- Based Sway Control technology package therefore converts the speed input p39050 to a translatory velocity. This conversion is parameterized with p Set the parameter in such a way that the following applies: Translatory velocity of the crane axis [mm/s] = p39021 speed [rpm] The result of the conversion can be verified with parameter r39010[1]. Effective pendulum length The sway control function is based on an internal oscillation model. This model requires the current effective pendulum length, which is calculated by the following formula: Effective pendulum length (l eff ) [mm] = p39022 p p39023 Note: Parameters p39022 and p39023 have the unit millimeters (mm). The relationship between the effective pendulum length and oscillation frequency f is: f = (1/(2π)) (g/(l eff )) (g 9.81 m/s² (= gravitational acceleration)) To calculate parameters p39022 and p39023, proceed as follows: 1. Move the hoist into a lower position and note the value of parameter ((DB_SC hoist position internal) p39052 (= h1). 2. Move the crane axis to produce sway. 3. Count several oscillations (>5) and divide the elapsed time by the number of oscillations. This yields the period duration T1 of one oscillation. The oscillation frequency at this hoisting height is therefore f1 = 1 / T1 The effective pendulum length is l eff1 = 1000 g / (2π f1)² 4. Move the hoist into an upper position and note the current value of parameter p39052 (=h2). 5. In the same way as in step 3, calculate values T2, f2, and l eff2. 6. Define the parameters as follows: p39022 = (l eff1 l eff2 ) / (h1 h2) p39023 = l eff1 - p39022 h1 The setting can be verified with the two output parameters r39042 and r Parameter p39001[0] must be active for the verification. Smoothing of the effective pendulum length The resolution and possible noise of the signal of the hoist position influences for the effective pendulum length. Resolution and noise have an influence on the quality of the sway control function. The following always applies: The coarser the resolution and the more severe the noise, the worse the sway control function will work. Operating Instructions, 11/

40 Commissioning 6.1 Commissioning with STARTER In case of coarse resolution, you can smooth the signal. Set the amount of smoothing with parameter p If the analog input of the CU310-2 DP is used for the hoist position, the signal will be noisy. In this case, set p39028 to at least the value 50 ms Interconnecting and activating the technology package (part 2) Final interconnection of the technology package is described below. Interconnection with the SINAMICS setpoint channel If the parameterization is correct, outputs of the technology package must be interconnected with the SINAMICS setpoint channel. 1. Interconnect the speed addition setpoint r39032 with the input parameter (speed controller speed setpoint 2) p1160[0] of the SINAMICS setpoint channel 2. Interconnect the output parameter (ramp-function generator setting value) r39033 with parameter p1144[0]. 3. Interconnect the output parameter (apply ramp-function generator setting value) r with parameter p1143[0]. This completes commissioning and the crane will operate under sway control subject to the described conditions Example of setpoint curves The following diagrams show examples of setpoint curves after successful commissioning. The following conditions apply to the example: Effective pendulum length (r39042) is 10,000 mm. The SINAMICS ramp-function generator accelerates the speed setpoint (r1150) to 1000 revolutions per minute. In this example, that corresponds to a translatory velocity of 1000 mm/s because p39021 = 1. The following figure shows: the set speed from the ramp-function generator for sway control (r1150 interconnected with p39050, yellow), the setpoint speed resulting from the sway control function for speed control (r39012, light blue). 40 Operating Instructions, 11/2015

41 Commissioning 6.1 Commissioning with STARTER Image 6-1 Set speed / resulting setpoint speed The following figure shows the curve of the pendulum angle in the internal oscillation model in centidegrees (r39040, beige). Image 6-2 Curve of the pendulum angle Operating Instructions, 11/

42 Commissioning 6.1 Commissioning with STARTER The following figure shows the translatory values (r39010[1], green and r39010[0], blue) belonging to the first figure. Image 6-3 Translatory values Optional settings This chapter describes settings that are not mandatory for sway control. The parameters can be used optionally, depending on operational or individual requirements. Influencing the effect of sway control With the parameters for the damping factor p39026 or p39027, you can influence the effect of sway control. Chapter Damping factor (Page 23) explains how this works: You can parameterize the damping factor in two ways in the technology package: Option 1: Set the damping factor via parameter p Enter the desired value. Option 2: Set the damping factor via parameter p To do this, interconnect parameter p39027 via PROFIBUS. 42 Operating Instructions, 11/2015

43 Commissioning 6.2 Commissioning with Basic Operator Panel BOP20 or Web browser. 1. If the technology package provides the damping factor via a PROFIBUS interface, interconnect parameter p39027 (integer-16) with an appropriate PROFIBUS parameter. You can interconnect the following PROFIBUS parameters: Drive object: r2050[i], i = 0 31 Control Unit: r2050[i], i = 0 19 Note Pay attention to the effectiveness of the two different parameters. The damping factor is taken over from parameter p39026 as long as the BICO parameter p39027 is equal to 0. As soon as the BICO parameter p39027 is not equal to 0, this value will be used as the damping factor and p39026 will be ignored. 6.2 Commissioning with Basic Operator Panel BOP20 or Web browser. This section describes how you can commission the preconfigured CompactFlash card via the Basic Operator Panel BOP20 or via a Web browser. It is not necessary to use the STARTER commissioning software. In both cases, is commissioned by setting and reading out the same parameters of the CU310-2 DP. The parameters are uniquely identified by their numbers. The two possibilities for commissioning differ by the method of access. BOP20 In this version, parameter assignment is performed directly on site at the CU310-2 DP. The BOP20 is used as the input and display device. See Operation of the BOP20 (Page 44) and BOP20 Basic Operator Panel (Page 16). Web browser You require the following to perform commissioning with a Web browser: a programming device, notebook, PC, or tablet with an up-to-date browser network access to the CU310-2 DP Control Unit In this version, the Webserver functionality of the CU310-2 DP is used. The Web browser is used as the interface for parameter assignment. You will find a detailed description of the Webserver in the "SINAMICS S120 Function Manual" Ref. [5]. Note IP address of the CU310-2 DP In the delivered state, is set as the IP address and as the subnet mask for the CU310-2 DP. This IP address is needed to establish the connection via the Web browser. Operating Instructions, 11/

44 Commissioning 6.2 Commissioning with Basic Operator Panel BOP20 or Web browser. The drive is controlled exclusively via the analog and digital inputs of the CU310-2 DP. Below, the parameters stated in the commissioning steps must be parameterized via BOP or Web browser Operation of the BOP20 This section outlines operation of SINAMICS S120 via the Basic Operator Panel BOP20. You will find a detailed description of the BOP20 in the "SINAMICS S120 Function Manual" Ref. [5]. Changing between the operating display and parameter display After the Control Unit has been switched on and has started up, the display of the BOP20 switches to the operating display. Any pending errors are displayed there. 1. You can use the "arrow" keys to switch between error numbers. 2. Pressing key "P" switches to the parameter display. The upper left part of the parameter display shows the drive object number you just selected. 3. Pressing key "P" switches back to the operating display. Saving the parameter values (RAM to ROM) A small "S" in the center of the top half of the display indicates unsaved parameters. 1. Press the "P" key for around 3 seconds until the display flashes. After saving, the small "S" in the center of the top half of the display disappears. Acknowledging errors 1. Switch to the error or operating display (see above "Changing between the operating and parameter display"). 2. After pressing the "FN" key, acknowledge the pending errors. If errors are still shown, errors are still pending. Changing the active drive object 1. Switch to the parameter display (see "Changing between the operating and parameter display" above). 2. Hold the "FN" key down and press the "arrow up" key until the drive object number upper left flashes. 3. Select the required drive object using the "arrow" keys. 4. Confirm the selection with the "P" key. The selected drive object is shown in the upper left part of the display. 44 Operating Instructions, 11/2015

45 Commissioning 6.2 Commissioning with Basic Operator Panel BOP20 or Web browser. Displaying parameter values 1. Switch to the parameter display (see "Changing between the operating and parameter display" above). 2. Choose the desired parameter with the "arrow" keys. Note: With the "FN" key, you jump back to parameter r Pressing the "P" key displays the current parameter value. Note on value display Only six characters can be indicated on the display. If the parameter has more than six characters, this is stated in the upper right part of the display as follows: Bit arrays On the display, either bits 0 to 15 (r4 upper right in the display) or bits 16 to 31 (L4 upper right in the display) are displayed. Decimal numbers In the case of decimal numbers, it is displayed how many characters are visible to the right and left (e.g. "r2": 2 characters to the right are not visible,"l1": 1 character to the left is not visible) 4. Press the "P" key and an "arrow" key to switch between the bit areas. Changing a parameter value 1. Switch to the parameter display (see "Changing between the operating and parameter display" above). 2. Select the desired drive object (see above "Changing the active drive object"). 3. Choose the desired parameter with the "arrow" keys. 4. For parameters without an index: Press the "P" key. The current parameter value is displayed. For parameters with an index: Press the "P" key. An index value is displayed (e.g. in0000). Choose the desired index with the "arrow" keys and then press the "P" key. The current parameter value is displayed. 5. Press the "FN" key to select the correct position of the figure. The right-hand figure on the value display starts flashing. 6. Press the "arrow" keys to change the value. 7. Press the "FN" key again. The figures of a position further to the left start flashing. 8. Repeat this step depending on the number of positions. 9. Press the "arrow" keys to change the value. 10.Press the "P" key. The changes to the value have been completed. If the set value does not appear in the lower half of the display, it was not possible to take over the value. Note: Parameters for which SINAMICS automatically adapts the value again, e.g. p340, are exceptions to this. Operating Instructions, 11/

46 Commissioning 6.2 Commissioning with Basic Operator Panel BOP20 or Web browser Access to the parameter lists with a Web browser If you perform commissioning with a Web browser, observe the following steps Preparing for access to the parameter lists 1. Open the Web browser on your computer and enter the valid IP address of your CU310-2 DP in the address field. The preset IP address is Log on with the name "SINAMICS" in the user name field. No password is required. 3. Choose menu item "Parameters" from the left main menu. User-specific parameter list in the Web browser The parameter lists are stored on the preconfigured CompactFlash card. These contain the necessary parameters for the typical commissioning described here. If you want to adapt or view the parameters that are not contained in these lists, you can create user-specific lists. Proceed as follows: 1. Select menu item "Parameter". 2. Open the "Define" tab. 3. Create the user-specific parameter list with the "Add new list" button. Note Decimal places in the Web browser The parameter values are only displayed with two decimal places in the Web browser. However, the values are stored with a higher precision/accuracy in the CU310-2 DP. You can enter parameter values with a higher precision/accuracy at any time via the Web browser Requirements for commissioning The following conditions must be met before the SIMOCRANE can be commissioned with the preconfigured CompactFlash card via BOP20 or via a Web browser: The crane meets the technological requirements (see chapter Requirements of the crane and crane axis (Page 11)). The analog and digital inputs and the digital outputs of the CU310-2 DP are wired in accordance with the following figure. When commissioning via the Webserver, the "IO-Monitoring" parameter list can be used to verify the interconnections. The list shows the status of all inputs and outputs (see also Access to the parameter lists with a Web browser (Page 46)). 46 Operating Instructions, 11/2015

47 Commissioning 6.2 Commissioning with Basic Operator Panel BOP20 or Web browser. Commissioning with a Basic Operator Panel: BOP20 (not included in the scope of delivery) is plugged into the top of the CU310-2 DP. Commissioning with a Web browser: Programming device, notebook, PC, or tablet with a network connection with the CU310-2 DP and a Web browser. Default setting CU310-2 DP Image 6-4 Default setting CU310-2 DP with a preconfigured CompactFlash card Note If the 24 V supply is briefly interrupted, the digital outputs are deactivated during this time. This must be considered during commissioning if the brake is operated via a digital output. Operating Instructions, 11/