Application example Single-axis application. SIMOCRANE Drive-Based Sway Control V1.0 SP2. Siemens Industry Online Support

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1 Application example Single-axis application SIMOCRANE Drive-Based Sway Control V1.0 SP2 Siemens Industry Online Support

2 Legal information Legal information Use of application examples Application examples illustrate the solution of automation tasks through an interaction of several components in the form of text, graphics and/or software modules. The application examples are a free service by Siemens AG and/or a subsidiary of Siemens AG ( Siemens ). They are nonbinding and make no claim to completeness or functionality regarding configuration and equipment. The application examples merely offer help with typical tasks; they do not constitute customer-specific solutions. You yourself are responsible for the proper and safe operation of the products in accordance with applicable regulations and must also check the function of the respective application example and customize it for your system. Siemens grants you the non-exclusive, non-sublicensable and non-transferable right to have the application examples used by technically trained personnel. Any change to the application examples is your responsibility. Sharing the application examples with third parties or copying the application examples or excerpts thereof is permitted only in combination with your own products. The application examples are not required to undergo the customary tests and quality inspections of a chargeable product; they may have functional and performance defects as well as errors. It is your responsibility to use them in such a manner that any malfunctions that may occur do not result in property damage or injury to persons. Disclaimer of liability Siemens shall not assume any liability, for any legal reason whatsoever, including, without limitation, liability for the usability, availability, completeness and freedom from defects of the application examples as well as for related information, configuration and performance data and any damage caused thereby. This shall not apply in cases of mandatory liability, for example under the German Product Liability Act, or in cases of intent, gross negligence, or culpable loss of life, bodily injury or damage to health, non-compliance with a guarantee, fraudulent non-disclosure of a defect, or culpable breach of material contractual obligations. Claims for damages arising from a breach of material contractual obligations shall however be limited to the foreseeable damage typical of the type of agreement, unless liability arises from intent or gross negligence or is based on loss of life, bodily injury or damage to health. The foregoing provisions do not imply any change in the burden of proof to your detriment. You shall indemnify Siemens against existing or future claims of third parties in this connection except where Siemens is mandatorily liable. By using the application examples you acknowledge that Siemens cannot be held liable for any damage beyond the liability provisions described. Other information Siemens reserves the right to make changes to the application examples at any time without notice. In case of discrepancies between the suggestions in the application examples and other Siemens publications such as catalogs, the content of the other documentation shall have precedence. The Siemens terms of use ( shall also apply. Security information Siemens provides products and solutions with industrial security functions that support the secure operation of plants, systems, machines and networks. In order to protect plants, systems, machines and networks against cyber threats, it is necessary to implement and continuously maintain a holistic, state-of-the-art industrial security concept. Siemens products and solutions constitute one element of such a concept. Customers are responsible for preventing unauthorized access to their plants, systems, machines and networks. Such systems, machines and components should only be connected to an enterprise network or the Internet if and to the extent such a connection is necessary and only when appropriate security measures (e.g. firewalls and/or network segmentation) are in place. For additional information on industrial security measures that may be implemented, please visit Siemens products and solutions undergo continuous development to make them more secure. Siemens strongly recommends that product updates are applied as soon as they are available and that the latest product versions are used. Use of product versions that are no longer supported, and failure to apply the latest updates may increase customer s exposure to cyber threats. To stay informed about product updates, subscribe to the Siemens Industrial Security RSS Feed at: Entry-ID: , V1.0, 09/2018 2

3 Table of contents Table of contents Legal information Introduction Overview Single-Axis with PLC interface Single-Axis with on-board IO interface (with DBT) Hardware and Software components Single-Axis application with PLC STEP7-SINAMICS interface Pre-requisites Address and Telegram configuration Interface STEP7 SINAMICS Interface SINAMICS STEP STEP7 program structure Control of Axis from STEP STEP7 control for operation in Manual mode STEP7 control for operation in positioning mode Single-Axis application with on-board IO interface Engineering Preconditions Engineering steps Import project in STARTER Configure Drive Object Activate technology package Execute script Parameterization in SINAMICS Integration of STEP7 application Save and compile project Commissioning Download project to SINAMICS Commissioning of SINAMICS Commissioning DBSC Effective pendulum length Manual mode Positioning mode Load dependent correction of effective pendulum length Implementation Commissioning Appendix Service and support Application support Related literature and links Revision history Entry-ID: , V1.0, 09/2018 3

4 1 Introduction 1 Introduction The scope of this application description is to explain the application project for SINAMICS S120 Single-Axis controller, delivered along with SIMOCRANE Drive- Based Sway Control V1.0 SP2. This application description covers the engineering and commissioning of the application projects. For detailed information on SIMOCRANE Drive-Based Sway Control product, please refer to Ref [5] SIMOCRANE Drive-Based Sway Control Operation instructions in section 7.3 Related literature and links. One of the two application projects is made without considering PLC. This application project makes use of SIMOCRANE Drive-Based Technology for basic crane logic (like master-switch, pre-limit etc.). However, this document does not describe anything about SIMOCRANE Drive-Based Technology. For engineering and commissioning information on SIMOCRANE Drive-Based Technology, please refer to Ref [4] SIMOCRANE Drive-Based Technology - Operation instructions in section 7.3 Related literature and links. The basic engineering and commissioning of SINAMICS is not part of this document. For basic engineering and commissioning information on SINAMICS, please refer to Ref [3] SINAMICS S120 Getting started for STARTER Commissioning tool in section 7.3 Related literature and links. For understanding of this document, basic engineering and commissioning knowledge of SINAMICS and STEP 7 is necessary. 1.1 Overview There are two single axis application projects delivered along with SIMOCRANE ; Single-Axis application with PLC interface Single-Axis application with onboard IO interface The application projects can be downloaded under following link: The application project needs to be adapted in order to match the actual crane configuration Single-Axis with PLC interface Application project DBSC_SingleAxis_PLC is based on SINAMICS CU310-2PN and PM240-2 along with STEP7 300 CPU. However, it can be adapted for any other combination of hardware as described in table 1-1: Hardware platform. The overall structure of this application is as shown below; Entry-ID: , V1.0, 09/2018 4

5 1 Introduction Figure 1-1: Single-Axis configuration with PLC In this application, the command interface for SINAMICS as well as SIMOCRANE Drive-Based Sway Control is considered in STEP7 whereas the sway controller and position controller of SIMOCANE Drive-Based Sway Control always remains a part of SINAMICS Drive Axis. The STEP7 part of application contains a pre-configured PROFIBUS/PROFINET interface, function block for handling command interface to SINAMICS and SIMOCRANE Drive-Based Sway Control and function block for handling load dependent correction of effective pendulum length. The User program needs to be merged with STEP7 application. The STARTER part of application has a script under SINAMICS Power Module, which upon execution does all interconnections between STEP7 and SINAMICS. With this application, a crane axis can be driven with sway control in manual as well as positioning mode Single-Axis with on-board IO interface (with DBT) This application is configured without considering PLC. The entire command interface is configured over on-board IOs of CU310-2 over which crane axis can be driven with sway control only in manual mode. Positioning mode is not considered for this application. The application project DBSC_SingleAxis_IO is based only on SINAMICS CU310-2PN and PM However, it can be adapted for any other combination of hardware as described in table 1-1: Hardware platform (without STEP7). The overall structure of this application is as shown below; Figure 1-2: Single-Axis configuration without PLC Entry-ID: , V1.0, 09/2018 5

6 1 Introduction Along with SIMOCRANE Drive-Based Sway Control, this application also uses SIMOCRANE Drive-Based Technology. This application contains two DCC charts. The DCC chart UserDCC present under Control Unit has entire command interface and crane specific logic. Another DCC chart CraneDCC under Drive Unit is for SIMOCRANE Drive-Based Technology. The application is provided with a script which upon execution configures all interconnections between SINAMICS onboard IOs, two DCC chards, SIMOCRANE Drive-Based Sway Control and SINAMICS setpoint channel. 1.2 Hardware and Software components The Single-Axis application supports the following combination of hardware; Table 1-1: Hardware platform STEP 7 S7 300 S7 400 Control Unit CU310-2 PN CU310-2 DP SINAMICS Power Module PM340 PM240 PM240-2 To use this application, it is necessary to have following software installed on PG/PC; Table 1-2: Software platform STARTER Software SIMOCRANE Drive-based Sway Control Technology package SINAMICS DCC Editor STEP7 Version V V V V5.5 SP4 Entry-ID: , V1.0, 09/2018 6

7 2 Single-Axis application with PLC 2 Single-Axis application with PLC The Single-Axis application with PLC offers the operation in both manual as well as positioning mode. Figure below illustrates the overview of Single-Axis application with PLC; Figure 2-1: Overview of Single-Axis application with PLC The STEP7 part of application project (with PLC) contains; Interface between STEP7 and SINAMICS Function block ControlAxisDBSC (FB90) to control the DBSC axis in all operation modes Function block PendulumCalcDBSC (FB190) to handle load dependent correction of effective pendulum length. The user program needs to be merged with STEP7 application. In SINAMICS, a script is provided which does all interconnections between S7 interface, SIMOCRANE Drive-Based Sway Control and SINAMICS setpoint channel. For further information on script, refer to section Execute script. There is no control logic (implemented using free function blocks or DCC) in SINAMICS. 2.1 STEP7-SINAMICS interface The drive can be controlled via PROFIBUS or PROFINET interface. For PROFIBUS / PROFINET interface between the higher-level SIMATIC STEP 7 controller and drive, protocols of maximum 16 process data is provided for both send and receive direction separately. See Figure 2-1: Overview of single axis application with PLC. All interconnections between SINAMICS drive object and SIMATIC STEP 7 controller is configured automatically by a script DBSC_SingleAxis which needs to be executed within the drive offline. Entry-ID: , V1.0, 09/2018 7

8 2 Single-Axis application with PLC NOTE The standard application is delivered considering PROFINET interface between STEP 7 and SINAMICS. For using PROFIBUS interface, all the necessary adaptations in hardware configuration need to be carried out by the user. However the same program blocks mentioned above can be used for both (PROFINET/PROFIBUS) interfaces Pre-requisites In order to establish the consistent communication between STEP7 and SINAMICS, the reference data in both parties must be identically configured. The reference data should be normalized to the maximum values. The following parameters in SINAMICS are required to be set for normalization; p2000 = r2700 = reference speed ( p1082 = maximum speed) p2001 = r2701 = reference voltage p2002 = r2702 = reference current ( p640 = Maximum current) p2003 = r2703 = reference torque ( p1520 = Maximum torque in positive direction) NOTE All reference data must be normalized to their maximum value: I max = I reference = 100% = I rated + I overload (maximum current = reference current = rated current + overload current) M max = M reference = 100% = M rated + M overload (maximum torque = reference torque = rated torque + overload torque) The definition for the relationship between the percentage value and hexadecimal value is shown in the following table and in the following diagram. If only positive values are used in the process data, then the value range is doubled; this means that the range starts at 0 and can be increased up to 65,535 (UINT, 0 to FFFF). Figure 2-2: Representing the value range of a word Entry-ID: , V1.0, 09/2018 8

9 2 Single-Axis application with PLC Table 2-1: Word range Percentage value Hexadecimal value 0 16# # ,994 16#7FFF # #C000 0,006 16# Address and Telegram configuration The network parameters (IP address, type and baud rate) of PROFINET communication between SIMATIC and SINAMICS are configured in STEP 7 HW- Configuration. The communication between SIMATIC and SINAMICS is implemented using a free telegram (999) with 16 process data in send and receive direction separately. The address range used for communication between STEP 7 and SINAMICS is as shown in table below. These addresses can be adapted in HW- Configuration. Table 2-2: Address range of DriveAxis Drive Interface STEP7 SINAMICS Address ranges, I/O (peripherals) in bytes DriveAxis_ Table 2-3: Process data from STEP7 to SINAMICS PZD Signal name Description 1 SINAMICS Control word_1 See below, Table 2-4: SINAMICS Control word_1. 2 Speed setpoint The speed setpoint is specified as a normalized value of percentage (%) hex = dec = 100 % 3 SINAMICS Control word_2 4 Free Free 5 Free Free 6 DBSC Control word In SINAMICS, this PZD (r2050[1]) is connected to parameter p39010 DBSC Main speed setpoint. See below, Table 2-5: SINAMICS Control word_2 See below, Table 2-6: DBSC Control word. In SINAMICS, this PZD (r2050[5]) is connected to p2099[0] Connector-binector converter signal source in order to demultiplex the control bits. 7+8 Hoist position The value connected here must be proportional to the actual hoist position in Double Integer format. In SINAMICS, these two combined PZDs (r2060[6]) are connected to parameter p39020 DBSC Hoist position Target position The target position in mm should be connected to the Entry-ID: , V1.0, 09/2018 9

10 2 Single-Axis application with PLC PZD Signal name Description combined two PZDs as Double Integer. In SINAMICS, these two combined PZDs (r2060[8]) are connected to parameter p39062 DBSC Target position Actual position The actual position of axis in mm should be connected to the combined two PZDs as Double Integer. In SINAMIS, these two combined PZDs (r2060[10]) are connected to parameter p39060 DBSC Actual position. 13 Damping factor Damping factor from STEP7 can be sent over this PZD. The normalization of this signal is as follows; Free Free 4666h 110% damping factor 1.1 (Max value) 4000h 100% damping factor h 30% damping factor 0.3 (Min value) 0h 0% damping factor from p39030 is used If the value any other than 0 is sent over this PZD, then the value set in parameter p39030 is ignored. If value at this signal is 0, then value set in p39030 becomes effective. In SINAMICS, this PZD (r2050[12] )is connected to parameter p DBSC Damping factor (BICO). Table 2-4: SINAMICS Control word_1 Bit Signal name Description 0 OFF1 A drive is switched-on and switched-off with OFF1. In SINAMICS, this signal (r2090[0]) is connected to p840[0] ON / OFF (OFF1) 1 OFF2 When this bit is reset, the inverter firing pulses are instantly withdrawn and drive is switched-off and motor coasts down. In this state, motor brakes must be instantly applied. Furthermore Sway Control must be disabled. For switching On the drive, this bit must be set. In SINAMICS, this signal (r2090[1]) is connected to parameter p844[0] OFF2 Signal source 1. 2 OFF3 When this bit is reset (when OFF1 and OFF2 are still set), the motor is stopped with the configured OFF3 ramp down time (p1135) and is then switched off. Furthermore Sway Control must be disabled. In SINAMICS, this signal (r2090[2]) is connected to parameter p848[0] OFF3 Signal source 1. 3 Pulse enable When this input is set, the IGBT firing pulses are enabled The setpoint is accepted and the travel command is executed only when the pulse enable input is set. 4 Ramp Function Generator (RFG) enable 5 Free Free In SINAMICS, this signal (r2090[3]) is connected to parameter p852[0] Operation Enable. The ramp-function generator is enabled by setting this bit. When this bit is reset, Ramp-function generator output gets disconnected with Speed controller resulting in zero setpoint to speed controller. In SINAMICS, this signal (r2090[4]) is connected to parameter p1140[0] Ramp-function generator enable. 6 Enable setpoint The speed setpoint sent from STEP 7 gets connected to input of Ramp-function generator when this bit is set. In SINAMICS, this signal (r2090[6]) is connected to parameter p1142[0] Speed Setpoint enable. Entry-ID: , V1.0, 09/

11 2 Single-Axis application with PLC Bit Signal name Description For operation with SIMOCRANE Drive-Based Sway Control, it is necessary to set this bit throughout operation with/without sway control. 7 Acknowledge fault Any fault present in SINAMICS can be acknowledged by setting this bit, only after the cause of the fault has been removed. In SINAMICS, this signal (r2090[7]) is connected to parameter p2103[0] Acknowledge faults. 8 Enable speed controller 9 Free Free 10 Master control by the PLC 11 Free Free 12 Select, closedloop speed / torque controlled operation 13 Free Free 14 Free Free 15 Free Free The speed controller is enabled by setting this bit. The speed control is inhibited with a low signal and as a consequence, a travel command cannot be executed, however the motor remains magnetized (when other enables are still set). In SINAMICS, this signal (r2090[8]) is connected to parameter p0856[0] Speed controller enable. This bit must be set in order to take the control of drive over PROFIBUS/PROFINET. If this bit is reset, no commands will be accepted by SINAMICS over PROFIBUS/PROFINET. In SINAMICS, this signal (r2090[10]) is connected to parameter p0854[0] Master control by PLC. This bit is used for the changeover between closed-loop speed and torque control. In SINAMICS, this signal (r2090[12]) is connected to parameter p1501[0] Changeover between closed-loop speed/torque control. When this bit is low, the torque setpoint from output of its own speed controller gets connected to input of its torque controller. When this bit is set, the torque controller input gets disconnected to speed controller output and gets connected to external source of torque setpoint (p1503[0]). This bit can be used in case of Master-slave configuration but the connection of torque setpoint from master to external torque setpoint source (p1503[0]) in slave has to be configured by user. Table 2-5: SINAMICS Control word_2 Bit Signal name Description 0 Select drive data set DDS bit 0 1 Select drive data set DDS bit Free Free With these two drive data set selection input bits, it is possible to toggle between four different drive data sets. In SINAMICS, the Select drive data set DDS bit0 signal (r2092[0]) is connected to parameter p0820[0] Drive Data Set selection DDS bit 0 and the signal Select drive data set DDS bit1 (r2092[1]) is connected to parameter p0821[0] Drive Data Set selection DDS bit 1. Do not change the data sets when axis is in operation. Entry-ID: , V1.0, 09/

12 2 Single-Axis application with PLC Table 2-6: DBSC Control word Bit Signal name Description 0 Enable Sway Control This bit enables / disables the sway controller. In SINAMICS, this signal (r2094[0]) is connected to parameter p39001[0] Switch on sway control. 1 End limit switch This bit activates end limit switch function in SIMOCRANE Drive-Based Sway Control. When this bit is reset, output of SIMOCRANE Drive-Based Sway Control ramps down to 0 without sway control. In SINAMICS, this signal (r2094[1]) is connected to parameter p39001[1] Not in limit switch range. 2 Operation mode This bit selects mode of operation in SIMOCRANE Drive- Based Sway Control. With this signal, selection of mode of operation can be done as; 3-15 Free Free False Manual mode True Positioning mode In SINAMICS, this signal (r2094[2]) is connected to parameter p39001[2] Select operating mode Interface SINAMICS STEP7 Table 2-7: Process data from SINAMICS to SIMATIC PZD Signal name Description 1 SINAMICS Status word_1 2 Speed actual value 3 SINAMICS Status word_2 4 Free Free 5 Free Free Refer to Table 2-8: SINAMICS Status word_1 In SINAMICS, signal r2089[0] Send binector-connector converter status word, Status word_1 is connected with parameter p2051[0] IF1 Profidrive send PZD1. The speed actual value, normalized to the reference value is received. The reference value should be the maximum value. n max = n reference = n rated + n FW = 100 % 4000 hex = dec = 100 % In SINAMICS, signal r0063[0] Actual speed value, unsmoothed is to parameter p2051[1] IF1 Profidrive send PZD2. Refer to Table 2-9: SINAMICS Status word_2 In SINAMICS, signal r2089[1] Send binector-connector converter status word, Status word_2 is connected to parameter p2051[2] IF1 Profidrive send PZD3. 6 Fault number The fault number of currently active fault is sent. In SINAMICS, signal r2131 Actual fault code is connected to parameter p2051[5] IF1 Profidrive send PZD6. 7 Alarm number The alarm number of currently active alarm is received. In SINAMICS, signal r2132 Actual alarm code is connected to parameter p2051[6] IF1 Profidrive send PZD7. 8 Smoothed total current actual value The smoothed actual current value, normalized to the reference value is received. The reference value should be the maximum value. Entry-ID: , V1.0, 09/

13 2 Single-Axis application with PLC PZD Signal name Description 9 Smoothed torque actual value 10 Speed setpoint before speed controller 11 DBSC Status word I max = I reference = I rated + I Overload = 100 % 4000 hex = dec = 100 % Signal r0068[1] Absolute current actual value is connected to parameter p2051[7] IF1 Profidrive send PZD8. The smoothed actual torque value, normalized to reference value is received. The reference value should be the maximum value. M max = M reference = M rated + M Overload = 100 % 4000 hex = dec = 100 % In SINAMICS, signal r0080[1] Torque actual value is connected to parameter p2051[8] IF1 Profidrive send PZD9. The total Speed setpoint before speed controller is received. In SINAMICS, signal r1438 Speed controller speed setpoint is connected to parameter p2051[9] IF1 Profidrive send PZD10. Refer to Table 2-10: DBSC Status word. In SINAMICS, signal r2089[2] Send binector-connector converter status word, Free status word_3 is connected to parameter p2051[10] IF1 Profidrive send PZD DBSC Fault word Refer to Table 2-11: DBSC Fault word. In SINAMICS, signal r2089[3] Send binector-connector converter status word, Free status word_4 is connected to parameter p2051[11] IF1 Profidrive send PZD DBSC Alarm word Refer to Table 2-12: DBSC Fault word Free Free Table 2-8: SINAMICS Status word_1 In SINAMICS, signal r2089[4] Send binector-connector converter status word, Free status word_5 is connected to parameter p2051[12] IF1 Profidrive send PZD13. Bit Signal name Description 0 Ready to be switched on A high signal at this bit means that the power supply is switched on, electronics has been initialized and SINAMICS can be switched on. In SINAMICS, signal r899.0 Ready for switch on is connected to parameter p2080[0] - Binector connector converter status word 1 Bit 0. 1 Ready A high signal at this bit means that DC link has been charged and SINAMICS is ready for operation enable. In SINAMICS, signal r899.1 Ready is connected to parameter p2080[1] Binector connector converter status word 1 Bit 1. 2 Operation enabled A high signal at this bit means that the inverter firing pulses have been enabled and torque is built in motor. From this stage, the brakes can be released before start of motion. In SINAMICS, signal r899.2 Operation enabled is connected to parameter p2080[2] Binector connector converter status word 1 Bit 2. 3 Fault active A high signal at this bit indicates that the drive has a fault and is therefore in switch-on-inhibit condition. With fault acknowledgment, after removal of cause behind the fault, the drive can be brought back in ready-to-switch-on state and Fault active signal will become low. Entry-ID: , V1.0, 09/

14 2 Single-Axis application with PLC Bit Signal name Description 4 Coasting down active (OFF2) 5 Quick stop active (OFF3) In SINAMICS, signal r Fault present is connected to parameter p2080[3] Binector connector converter status word 1 Bit 3. A high signal at this bit signifies that no OFF2 is active. In SINAMICS, signal r899.4 No coasting active is connected to parameter p2080[4] Binector connector converter status word 1 Bit 4. A high signal at this bit signifies that no OFF3 is active. In SINAMICS, signal r No quick stop active is connected to parameter p2080[5] Binector connector converter status word 1 Bit 5. 6 Switch on inhibit A high signal at this bit signifies that drive cannot be switched on in the current condition. The cause of switchon-inhibit state can be a fault or OFF2 or OFF3. The drive can come out of switch-on-inhibit condition only after removal of cause (Acknowledgement is required if the cause is fault). The signal r899.6 Switching-on inhibited active is connected to parameter p2080[6] Binector connector converter status word 1 Bit 6. 7 Alarm active A high signal at this bit means that the alarm is active in drive. In this condition also, drive can remain in operation. Once the cause of alarm is removed, this bit will become low without any acknowledgement. In SINAMICS, signal r Alarm present is connected with to parameter p2080[7] Binector connector converter status word 1 Bit 7. 8 Speed setpointactual value deviation within the tolerance range 9 Control request to PLC A high signal at this bit signifies that the actual speed value is within the tolerance range of deviation from setpoint (after RFG). The signal r Speed setpoint actual val deviation in tolerance t_off is connected to parameter p2080[8] Binector connector converter status word 1 Bit 8. A high signal at this bit means that the control of SINAMICS has been released to PLC. In SINAMICS, signal r899.9 Control request is connected with to parameter p2080[9] Binector connector converter status word 1 Bit Drive stationary A high signal at this bit means that SINAMICS is in stationary speed state. 11 I, M or P limit reached or exceeded 12 Holding brake open 13 No motor overtemperature alarm While stopping the axis, all enable signals to SINAMICS must be latched till this signal becomes high in STEP7. In SINAMICS, the signal r Brake threshold undershot is connected to parameter p2080[10] Binector connector converter status word 1 Bit 10. A high signal at this bit means that the I, M or P limit has been reached or exceeded. In SINAMICS, signal r Torque limit reached is connected to parameter p2080[11] Binector connector converter status word 1 Bit 11. A high signal at this bit means that the holding brake release command is activated. In SINAMICS, signal r Holding brake open is connected to parameter p2080[12] Binector connector converter status word 1 Bit 12. A high signal at this bit indicates that there is no alarm due to over-temperature of the motor. A low signal at this bit is an alarm of thermal overload on motor. In SINAMICS, signal r Alarm motor Entry-ID: , V1.0, 09/

15 2 Single-Axis application with PLC Bit Signal name Description overtemperature is connected to parameter p2080[13] Binector connector converter status word 1 Bit n_act >= 0 A high signal at this bit means that the actual speed 0 i.e. motor is running. In SINAMICS, signal r n_act >=0 is connected to parameter p2080[14] Binector connector converter status word 1 Bit No alarm, thermal power unit overload A high signal at this bit indicates that there is no alarm due to thermal overload of the drive converter. A low signal is an alarm of thermal overload of power unit. In SINAMICS, signal r Alarm power unit terminal overload is connected to parameter p2080[15] Binector connector converter status word 1 Bit 15. Table 2-9: SINAMICS Status word_2 Bit Signal name Description 0 Drive data set DDS active, bit 0 1 Drive data set DDS active, bit Free 10 Upper torque limit active 11 Lower torque limit active Free Free The active drive data set is signalled back over the combination of Drive data set DDS active, bit 0 and Drive data set DDS active, bit1. In SINAMICS, the signals r51.0 Drive Data Set DDS effective, bit 0 and r51.1 Drive Data Set DDS effective, bit 1 are connected to parameters p2081[0] Binector connector converter status word 2 Bit 0 and p2081[1] Binector connector converter status word 2 Bit 1. The activation of upper torque limit is signalled back using the high signal on this bit. In SINAMICS, signal r Upper torque limit active is connected to p2081[10] Binector connector converter status word 2 Bit 10. The activation of lower torque limit is signalled back using the high signal on this bit. In SINAMICS, signal r Lower torque limit active is connected to parameter p2081[11] Binector connector converter status word 2 Bit 11. Table 2-10: DBSC Status word Bit Signal name Description 0 Sway control active 1 Free 2 Active operation mode 3 Free Free This bit indicates that the Sway Control is enabled & the resultant motion will be with sway control. In SINAMICS, signal r Sway controller activated is connected to parameter p2082[0] - Binector connector converter status word 3 Bit 0. The active operation mode is signalled back at this bit. False Manual mode is active True Positioning mode is active In SINAMICS, signal r Active operating mode is connected to parameter p2082[2] - Binector connector converter status word 3 Bit 2. 4 Fault active A high signal at this bit indicates that the fault is active in SIMOCRANE Drive-Based Sway Control system and Entry-ID: , V1.0, 09/

16 2 Single-Axis application with PLC Bit Signal name Description operation is not possible till fault is withdrawn. After withdrawal of the cause of fault, to continue operation with SIMOCRANE Drive-based Sway Control, a fault acknowledgement is necessary at SINAMICS Control word_1 bit 7. In SINAMICS, signal r DBSC Fault active is connected to parameter p2082[4] - Binector connector converter status word 3 Bit 4. 5 Alarm active A high signal at this bit indicates that the alarm is active in SIMOCRANE Drive-Based Sway Control system Free Free 8 Target position reached Free Free In SINAMICS, signal r DBSC Alarm active is connected to parameter p2082[5] - Binector connector converter status word 3 Bit 5. A high signal at this bit indicates that actual position is within the tolerance (defined in p39060) of target position. In SINAMICS, signal r DBSC Target position reached is connected to parameter p2082[8] - Binector connector converter status word 3 Bit 8. Table 2-11: DBSC Fault word Bit Signal name Description 0..2 Free Free 3 Illegal withdrawal of SINAMICS enables This fault bit is set when any of the SINAMICS enable signals is withdrawn during movement (i.e. before status Drive stationary is reached). In SINAMICS, signal r DBSC Fault word: SINAMICS enables withdrawn during motion is connected to parameter p2083[3] - Binector connector converter status word 4 Bit 3. 4 Instability detected This fault bit is set when sway can no more be controlled by system and system is at the verge of instability Free Free 8 Illegal changeover of operation mode 9 Position following error 10 Actual position outside positioning limits In SINAMICS, signal r DBSC Fault word: Increased oscillations detected is connected to parameter p2083[4] - Binector connector converter status word 4 Bit 4. In event of illegal changeover of operation mode, this fault bit is set. In SINAMICS, signal r DBSC Fault word: Invalid operation mode changeover is connected to parameter p2083[8] - Binector connector converter status word 4 Bit 8. In event of position following error, this fault bit is set. In SINAMICS, signal r DBSC Fault word: Following error out of tolerance is connected to parameter p2083[9] - Binector connector converter status word 4 Bit 9. This fault bit is set when actual position is outside positioning limits. In SINAMICS, signal r DBSC Fault word: Actual position outside positioning range is connected to parameter p2083[10] - Binector connector converter status Entry-ID: , V1.0, 09/

17 2 Single-Axis application with PLC Bit Signal name Description 11 Target position outside positioning limits Free Free 15 End limit switch reached during positioning word 4 Bit 10. This fault bit is set when target position is outside positioning limits. In SINAMICS, signal r DBSC Fault word: Target position outside positioning range is connected to parameter p2083[11] - Binector connector converter status word 4 Bit 11. This fault bit is set when End limit switch is reached during positioning mode. In SINAMICS, signal r DBSC fault word: Limit switch range during positioning reached is connected to parameter p2083[15] - Binector connector converter status word 4 Bit 15. Table 2-12: DBSC Alarm word Bit Signal name Description 0 Free Free 1 Too many DBSC instances active 2 Manual license missing 3 Basic license missing 4 Basic RFG not active 5 Ramp-up time and Ramp-down time unequal This alarm bit is set when SIMOCRANE Drive-Based Sway Control technology package is activated in more than two drives on one control unit. This alarm bit is relevant only for multi-axis application. In SINAMICS, signal r DBSC Alarm word: DBSC is activated in more than two drives is connected to parameter p2084[1] - Binector connector converter status word 5 Bit 1. This alarm bit is set when manual license is missing. In this case, manual operation is not possible with sway control In SINAMICS, signal r DBSC Alarm word: Manual operation is not possible with SC is connected to parameter p2084[2] - Binector connector converter status word 5 Bit 2. This alarm bit is set when basic license is missing. In this case, positioning operation mode is not possible. In SINAMICS, signal r DBSC Alarm word: Positioning not possible is connected to parameter p2084[3] - Binector connector converter status word 5 Bit 3. This alarm bit is set when extended RFG configuration is activated in SINAMICS. SIMOCRANE Drive-Based Sway Control cannot work with extended RFG, hence it is necessary to switch to basic RFG configuration. In SINAMICS, signal r DBSC Alarm word: Basic SINAMICS ramp-function generator is not active is connected to parameter p2084[4] - Binector connector converter status word 5 Bit 4. This alarm bit is set if ramp-up time and ramp-down time configured in SINAMICS ramp-function generator are not same. For SIMOCRANE Drive-Based Sway Control, it is necessary to configure same ramp-up and ramp-down times in SINAMICS ramp-function generator. In SINAMICS, signal r DBSC Alarm word: Unequal ramp-up and ramp-down time in SINAMICS rampfunct gen is connected to parameter p2084[5] - Binector connector converter status word 5 Bit 5. 6 Effective This alarm bit is set if in SINAMICS, parameter p39022 Entry-ID: , V1.0, 09/

18 2 Single-Axis application with PLC Bit Signal name Description pendulum length not parameterized 7 End limit switch reached 8 Invalid parameterization of positioning range Free Free Conversion factor pendulum length and/or p39023 Offset pendulum length are not parameterized in order to get an actual effective pendulum length. In SINAMICS, signal r DBSC Alarm word: Effective pendulum length not parameterized is connected to parameter p2084[6] - Binector connector converter status word 5 Bit 6. This alarm bit is set when end limit switch range is reached during manual operation. In SINAMICS, signal r DBSC Alarm word: End limit switch range reached is connected to parameter p2084[7] - Binector connector converter status word 5 Bit 7. This alarm bit is set if the positioning range parameterized in parameters p39070 Lower position limit for positioning and p39071 Upper position limit for positioning are not correct and positioning mode Is activated. In SINAMICS, signal r DBSC Alarm word: Invalid parameterization of positioning range is connected to parameter p2084[8] - Binector connector converter status word 5 Bit 8. Entry-ID: , V1.0, 09/

19 2 Single-Axis application with PLC 2.2 STEP7 program structure The overall structure of STEP7 program for one axis is as shown below; Figure 2-3: Program structure The data to be sent (16 PZDs) from STEP7 to SINAMICS is configured in an instance DB DB_Drive_1_SendSinamics of function block Drive_1_SendSinamics. The data from DB_Drive_1_SendSinamics is sent to SINAMICS using SFC15 DP_Write. The data to be received (16 PZDs) in STEP7 from SINAMICS is configured in an instance DB DB_Drive_1_ReceiveSinamics of function block Drive_1_ReceiveSinamics. The data from SINAMICS is read into DB_Drive_1_ReceiveSinamics using SFC14 DP_Read. Function block ControlAxisDBSC, called in function block Drive_1_SendSinamics, drives the DBSC axis in all operation modes. Refer to section 2.3 Control of Axis from STEP7 for further details on function block ControlAxisDBSC. The interconnection between user program and all input pins of function block ControlAxisDBSC should be done in function block Drive_1_SendSinamics. Function block PendulumCalcDBSC can optionally be called if load dependent correction of effective pendulum length is required. For description on function block PendulumCalcDBSC, refer to section 6 - Load dependent correction of effective pendulum length. Entry-ID: , V1.0, 09/

20 2 Single-Axis application with PLC The data received from SINAMICS in DB_Drive_1_ReceiveSinamics can be interconnected into user program directly using variables of DB_Drive_1_ReceiveSinamics or in function block Drive_1_ReceiveSinamics. NOTE It is not necessary to follow same STEP7 program structure. User is free to write his own STEP7 program. However, for better performance in all modes, the use of function block (FB90) ControlAxisDBSC is highly recommended. Entry-ID: , V1.0, 09/

21 2 Single-Axis application with PLC 2.3 Control of Axis from STEP7 Figure 2-4: DBSC axis control from STEP7 Entry-ID: , V1.0, 09/

22 2 Single-Axis application with PLC Table 2-13: FB_ControlAxisDBSC (FB90) Variable name Type Data type Description ms_null IN BOOL Masterswitch null (zero) position ms_dirpositive IN BOOL Masterswitch positive direction command. This command generates positive speed setpoint at output outspeed_normalized. ms_dirnegative IN BOOL Masterswitch negative direction command. This command generates negative speed setpoint at output outspeed_normalized. ms_speedsetpercent IN REAL Absolute value of speed setpoint from masterswitch in percentage. Range: (%) Note: Do not give negative value for negative direction command of masterswitch. enableswaycontrol IN BOOL Sway controller enable command. This bit activates sway controller for manual mode. This signal should remain TRUE as long as operation with sway control is required. enablepositioningmode IN BOOL This signal is an interlock for activation of position mode whereas positioning mode gets activated with a positive edge at input startpositioning. When this signal is FALSE, only manual mode motion is possible. When this signal is TRUE, manual as well as positioning mode motion is possible. startpositioning IN BOOL Command (pulse) to start the positioning cycle. With (first) positive edge of this signal, the positioning mode gets activated & positioning motion starts. When positioning operation is already active, the (second) positive edge of this signal deactivates positioning mode and positioning motion stops. This input should be connected with positioning cycle start push button or foot pedal. allmasterswitchnull IN BOOL A combined signal of null position of masterswitches of all motions of crane. As depicted above, for a crane with Hoist, Trolley and Gantry axes, connect the AND output of all masterswitch Null signals. This signal is an interlock for activation of positioning mode. Upon activation of positioning mode via input startpositioning, signal at input allmasterswitchnull should become Entry-ID: , V1.0, 09/

23 2 Single-Axis application with PLC Variable name Type Data type Description TRUE within 2 seconds, otherwise positioning mode gets cancelled. prels_dirpositive IN BOOL Pre-limit switch in positive direction. In manual mode, when this signal is FALSE, the velocity in positive direction gets restricted to the pre-limit speed defined at input prelimit_velocity. When this signal is TRUE, the output speed setpoint in positive direction is same as percentage speed setpoint at input ms_speedsetpercent. This signal has no effect in positioning mode. prels_dirnegative IN BOOL Pre-limit switch in negative direction. In manual mode, when this signal is FALSE, the velocity in negative direction gets restricted to the pre-limit speed defined at input prelimit_velocity. When this signal is TRUE, the output speed setpoint in negative direction is same as percentage speed setpoint at input ms_speedsetpercent. This signal has no effect in positioning mode. prelimit_velocity IN REAL Modulus value of pre-limit velocity in percentage. Range: (%) endls_dirpositive IN BOOL End-limit switch in positive direction. In When this signal is low, the motion in positive direction is stopped, only in negative direction permitted. When this signal is FALSE, positioning mode is not possible. endls_dirnegative IN BOOL End-limit switch in negative direction. In manual mode, when this signal is FALSE, the motion in negative direction is stopped, only in positive direction permitted. When this signal is FALSE, positioning mode is not possible. externalinterlockoff1 IN BOOL External interlock which can cause controlled stop (ramp down to zero) of an axis. For operation in manual mode, this signal should be TRUE. When this signal is FALSE, positioning operation mode is not possible. statussin_stationary IN BOOL SINAMICS Status signal - Axis is stationary. The SINAMICS signal r Brake threshold undershot should be connected to this input. statussin_readyswitchon IN BOOL SINAMICS Status signal Axis is in ready to switch-on state. The SINAMICS signal r899.0 Ready for switching on should be connected to this Entry-ID: , V1.0, 09/

24 2 Single-Axis application with PLC Variable name Type Data type Description input. statussin_operationenabled IN BOOL SINAMICS Status signal Axis is in operation enabled state. The SINAMICS signal r899.2 Operation enabled should be connected to this input. statusdbsc_scactive IN BOOL DBSC Status signal sway control is active The DBSC signal in SINAMICS r Sway control activated should be connected to this input. statusdbsc_mode IN BOOL DBSC Status signal active operation mode The DBSC signal in SINAMICS r Active operating mode should be connected to this input. statusdbsc_fault IN BOOL DBSC Status signal fault is active The DBSC signal in SINAMICS r Fault active should be connected to this input. statusdbsc_targetreachd IN BOOL DBSC Status signal target position is reached The DBSC signal in SINAMICS r Target position reached should be connected to this input. sinamicscw_b0_off1 OUT BOOL Off1 command to SINAMICS. This signal should be connected to p840 ON/OFF (Off1) in SINAMICS. dbsccw_b0_scenable OUT BOOL Sway control enable command to DBSC in SINAMICS. This signal should be connected to p Swatch on sway control in DBSC in SINAMICS. dbsccw_b1_endlimit OUT BOOL End limit switch command to DBSC in SINAMICS. This signal should be connected to p Not in limit switch range in DBSC in SINAMICS. dbsccw_b2_operationmode OUT BOOL Operation mode command to DBSC in SINAMICS. This signal should be connected to p Select operation mode in DBSC in SINAMICS. dbsc_stationarystate OUT BOOL The status signal indicating stationary state of drive to DBSC in SINAMICS. This signal should be connected to p39011 DBSC Stationary state identified in DBSC in SINAMICS. outspeed_normalized OUT INT Normalized speed setpoint to DBSC in SINAMICS. This signal should be connected to p39010 DBSC Main speed setpoint in DBSC in SINAMICS. outspeed_percentage OUT REAL Speed setpoint in percentage. Entry-ID: , V1.0, 09/

25 2 Single-Axis application with PLC STEP7 control for operation in Manual mode Preconditions to start the motion in manual mode are; SINAMICS status signal r899.0 Ready for switching on at input statussin_readyswitchon should be TRUE. DBSC status signal r Fault active at input DBSC_fault should be FALSE. When the master-switch is deflected in positive direction and end-limit switch status at input endls_dirpositive is TRUE, the positive speed setpoint is set at the output outspeed_normalized. If the status of pre-limit switch at input prels_dirpositive is FALSE, the output speed (only) in positive direction gets restricted to prelimit velocity defined at input prelimit_velocity in percentage. When the master-switch is deflected in negative direction and end limit switch status at input endls_dirnegative is TRUE, the negative speed setpoint is set at the output outspeed_normalized. If the status of pre limit switch at input prels_dirnegative is FALSE, the output speed (only) in negative direction gets restricted to prelimit velocity defined at input prelimit_velocity in percentage STEP7 control for operation in positioning mode Preconditions: Preconditions to activate positioning mode are; End limit switches in both direction should be healthy i.e. signals endls_dirpositive and endls_dirnegative should be TRUE. Signal at input externalinterlockoff1 should be TRUE SINAMICS status signal r899.0 Ready for switching on at input statussin_readyswitchon should be TRUE. DBSC status signal r Fault active at input DBSC_fault should be FALSE. Target position received at p39062 DBSC Target position (which is stated at STEP7 SINAMICS send PZD (9+10)) is not equal to actual position received at p39060 DBSC Actual position (which is stated at STEP7 SINAMICS send PZD (11+12)) and the status of signal r Target position reached received at input statusdbsc_targetreachd is FALSE. Start of positioning operation: Once the above preconditions are met, positioning operation can be started in two conditions; Condition 1: Axis is stationary When axis is stationary (i.e status of signal r Brake threshold undershot at input statussin_stationary is TRUE) and master-switch is not deflected (i.e. signal ms_null is TRUE and ms_dirpositive and ms_dirnegative are FALSE), then irrespective of the status of signal at enableswaycontrol, positioning operation can be activated. With the (first) positive edge at input startpositioning, the positioning mode gets activated and then Off1 command is set in SINAMICS which in turn starts the positioning motion. Entry-ID: , V1.0, 09/

26 2 Single-Axis application with PLC Condition 2: Axis is moving in manual mode with sway control active When axis is moving in manual mode with sway control, it is still possible to switch to positioning mode & start positioning operation on fly. This dynamic changeover from manual to positioning mode is not possible if sway control is not active during manual movement. To start positioning cycle, release the deflected master-switch and apply positive edge at signal startpositioning which activates the positioning mode which in turn starts positioning motion. The overlap time of 2 seconds is permitted between the positive edge of command startpositioning and the master-switch (after release) brought back to null position (i.e. signal ms_null is TRUE and ms_dirpositive and ms_dirnegative are FALSE). If masterswitch is not brought back to null position within 2 seconds, the positioning mode gets deactivated and speed setpoint from master-switch is followed in manual mode. End of positioning operation: The positioning operation is stopped in three conditions; Condition 1: Upon reaching the target position When the status of signal r Target position reached received at input statusdbsc_targetreachd is FALSE and signal r Brake threshold undershot received at input statussin_stationary is TRUE, the positioning mode gets deactivated and Off1 command is withdrawn which in turn switches off the drive. Condition 2: Upon deflection of master-switch during positioning motion If the master-switch is deflected during positioning operation, the positioning mode gets deactivated and speed setpoint from master-switch is followed in manual mode. Condition 3: Upon (Second) positive edge at startpositioning during positioning motion If a positive edge is received at input startpositioning, the position mode gets deactivated and further operation in manual mode is seamlessly possible by deflecting master-switch. Entry-ID: , V1.0, 09/

27 3 Single-Axis application with on-board IO interface 3 Single-Axis application with on-board IO interface Single-Axis application with on-board IO command interface is designed for driving a crane axis in manual mode with sway control. No PLC has been considered for this application project. The overview of this application is as shown in figure below; Figure 3-1: Application overview Single-Axis with on-board IO interface In this application, along with SIMOCRANE Drive-Based Sway Control, SIMOCRANE Drive-Based Technology is considered in Drive Axis for handling prelimit function. The DCC chart CraneDCC of SIMOCRANE Drive-Based Technology is present under Drive Axis. Under Control Unit, there is one more DCC chart, which has entire command interface for SINAMICS and SIMOCRANE Drive-Based Sway Control as, digital masterswitch logic and all crane specific logic. No free function blocks are considered for any logic. The figure below shows the control structure of application Single-Axis application with on-board IO interface ; Entry-ID: , V1.0, 09/

28 3 Single-Axis application with on-board IO interface Figure 3-2: Axis control Single-Axis with on-board IO interface Entry-ID: , V1.0, 09/

29 3 Single-Axis application with on-board IO interface Under SINAMICS power unit, a script is provided which upon execution configures all interconnections between Sinamics onboard IOs, UserDCC chart in Control unit, CraneDCC chart (for SIMOCRANE Drive-Based Technology), SIMOCRANE Drive- Based Sway Control and SINAMICS setpoint channel, as shown in figure 3.1 Application overview Single axis with on-board IO interface. UserDCC chart is open for user for further extension/adaptation to existing logic. The command interface to UserDCC is as follows; Table 3-1: Command interface Signal Type Parameter / Signal Masterswitch_dir(+) IN p22500 (CU) Masterswitch_dir(-) IN p22501 (CU) Masterswitch_lim2 IN p22502 (CU) Masterswitch_lim3 IN p22503 (CU) Masterswitch_lim4 IN p22504 (CU) SpeedLimit1 IN p22505 (CU) SpeedLimit2 IN p22506 (CU) SpeedLimit3 IN p22507 (CU) SpeedLimit4 IN p22508 (CU) PreLS_dir(+) IN p22511 (CU) PreLS_dir(-) IN p22512 (CU) Description Masterswitch positive direction command Default connection: DI_0 (CU r722.0) Masterswitch negative direction command Default connection: DI_1 (CU r722.1) Masterswitch command bit 2 Default connection: DI_2 (CU r722.2) Masterswitch command bit 3 Default connection: DI_3 (CU r722.3) Masterswitch command bit 4 Default connection: DI_8 (CU r722.8) Masterswitch step one speed setpoint in percentage. Default value: 10% Masterswitch step two speed setpoint in percentage. Default value: 30% Masterswitch step three speed setpoint in percentage. Default value: 60% Masterswitch step four speed setpoint in percentage. Default value: 100% Pre-limit switch in positive direction. When this signal is FALSE, the speed in positive direction gets restricted to the speed limit defined in parameter p PreLimitSwitch_rLimit4 in Drive Axis. This signal has no influence over speed in negative direction. Default connection: DI_20 (CU r722.20) Pre-limit switch in negative direction. When this signal is FALSE, the speed in negative direction gets restricted to the speed limit defined in parameter p PreLimitSwitch_rLimit4 in Drive Axis. This signal has no influence over speed in positive direction. Default connection: DI_21 (CU r722.21) Entry-ID: , V1.0, 09/

30 3 Single-Axis application with on-board IO interface Signal Type Parameter / Signal PreLimitSwitch_rLimit4 IN p22057 (DriveAxis) EndLS_dir(+) IN p22509 (CU) EndLS_dir(-) IN p22510 (CU) Off1_interlock IN p22513 (CU) Off2_intelock IN p22514 (CU) Fault_ack IN p22516 (CU) SC_enable IN p22515 (CU) System fault OUT r22615 (CU) Brake release OUT r (DriveAxis) Description Pre-limit speed in percentage. Default value: 5% End-limit switch in positive direction. When this signal is FALSE, the motion in positive direction is blocked. This signal has no influence over motion in negative direction. Default connection: DI_16 (CU r722.16) End-limit switch in negative direction. When this signal is FALSE, the motion in negative direction is blocked. This signal has no influence over motion in positive direction. Default connection: DI_17 (CU r722.17) External interlock which can cause controlled stop (ramp down to zero) of an axis. This signal should be TRUE for enabling the axis. When this signal is FALSE, axis ramps down to zero speed and System fault is set. Default connection: DI_9 (CU r722.9) External interlock which withdraws Off2 signal to SINAMICS and inverter firing pulses are instantly withdrawn. Default connection: DI_10 (CU r722.10) Fault acknowledge signal. Default connection: DI_11 (CU r722.11) Sway controller enable signal. For operation with sway controller, this signal should remain TRUE throughout the operation. Default connection: DI_18 (CU r722.18) The system fault signal which is set in below conditions; Fault is active in SINAMICS Fault is active in SIMOCRANE Drive-Based Sway Control technology software Off1 interlock is FALSE Off2 interlock is FALSE When system fault is set, no operation is possible. Upon withdrawal of cause of system fault, it has to be acknowledged by a pulse at input Fault_ack before further operation is possible. Default connection: DO_14 (CU p744.0) Brake release command from SINAMICS brake logic. Default connection: DO_15 (CU p745.0) Entry-ID: , V1.0, 09/

31 4 Engineering 4 Engineering The scope of this chapter is to explain the necessary steps for engineering of this application. For detailed engineering information of SIMOCRANE Drive-Based Sway Control refer to Ref [5] SIMOCRANE Drive-Based Sway Control Operating instructions in section 7-3: Related literature and links. WARNING Incorrect wiring / parameterization / interconnections can cause damage to machinery 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). It is necessary to have supporting safety circuit for handling the emergency events. The following points should be taken care of while engineering of SIMOCRANE Drive-Based Sway Control application; Sway control function depends on the actual pendulum length of hoist which is internally calculated from actual hoist position input. The actual hoist position is not necessarily the absolute position in mm rather it can be any linearly progressing count. But absolute height in mm is always recommended Sudden changes in progression of hoist position can make sway control system unstable. It is very important to ensure the smooth progression of hoist position value proportional to actual progression of hoist. To eliminate high frequency noise in hoist position value, a smoothing time can be parameterized by p39025 DBSC Smoothing time effective pendulum length. For proper stopping of axis with sway control, it is necessary to keep SINAMICS in operation enabled state (i.e. Status, operation enabled - r899.2 = 1) till stationary speed is reached (i.e. Status, Brake threshold undershot - r = 1) and in case of positioning mode target position is also reached (i.e. Status, Target position reached r = 1). In case of application project with PLC, this is ensured by function block ControlAxisDBSC (FB90) in STEP7. In case of application project without PLC, this logic is configured in UserDCC. The residual sway after stopping of motion is largely influenced by the standstill detection of axis and the timing of brake closure. It is necessary to ensure that brakes are applied only after motion is standstill. This can be ensured by properly adjusting the parameters p1226 Threshold for zero speed detection and p1228 Pulse suppression delay time. The script DBSC_SingleAxis sets the parameter p1226 (Threshold for zero speed detection) to 10RPM and p1228 (Pulse suppression delay time) to 2.0Sec. The standstill detection should be verified with these values and if required, should be adjusted. It is necessary to keep Basic RFG configuration (i.e.p1115 Ramp-function generator selection = 0 (Basic)) in SINAMICS. Also, ramp-up time (p1120) and ramp-down time (p1121) should be same for proper working of sway control. Entry-ID: , V1.0, 09/

32 4 Engineering 4.1 Preconditions To start with the engineering of Single Axis application it is necessary to ensure that correct version of all software mentioned in table 1-2: Software platform are installed on PG/PC. 4.2 Engineering steps Follow the engineering steps in same order as listed below Import project in STARTER Import the application project into STARTER using XML import. This step has to be done regardless of the type of application project (i.e. with PLC / without PLC) Configure Drive Object Adapt the standard application according to the actual crane configuration. The configuration of the Drive data set (DDS) should be done according to the actual hardware. For details, refer to Ref. [3] SINAMICS S120 Getting Started for the STARTER Commissioning Tool in section 7.3 Related literature and links. During configuration of DDS, it is necessary to ensure below points; The brake control can be selected from one of the four configurations as shown in figure below; Figure 4-1: Permissible brake configurations Entry-ID: , V1.0, 09/

33 4 Engineering Set PROFIdrive telegram to free with 16 words in both directions Figure 4-2: PROFIDRIVE frame Adapt Drive CLiQ topology as per the actual topology on crane Activate technology package The SIMOCRANE Drive-Based Sway Control technology package needs to be activated in drive. Entry-ID: , V1.0, 09/

34 4 Engineering Figure 4-3: Activation of Technology package In both Single-Axis application projects, the technology package DB_SC is already activated Execute script The Script DBSC_SingleAxis is provided in SCRIPTS folder under DriveAxis. Based on the choice of project (with PLC / without PLC) this script does all interconnections in SINAMICS. It also sets some important parameters from the point of view of crane application. NOTE The script is a supporting tool for the application. When required, this script can be extended by user, and no guarantee for a complete match can be given. In case of pre-engineered STARTER / STEP7 project, do not use this Script as it will change entire STEP7 interface as well as interconnections within SINAMICS. The script DBSC_SingleAxis must be executed within the drive object and must be executed offline. For execution, right click on the script and select Accept and execute Entry-ID: , V1.0, 09/

35 4 Engineering Figure 4-4: Execution of Script under DriveAxis After the start of script execution, the mask shown below appears on display on which the necessary selections are required to be done; Figure 4-5: Script interface 1 Confirmation on DBSC pre-conditions 2 Choice of control interface 1. Confirmation on DBSC preconditions: Here it is absolutely mandatory to confirm both pre-conditions in the project. Without confirming these pre-conditions, script does not begin the execution. Make sure that these preconditions are met in drive object configuration because if any one of them is actually missing in drive object, the script will give error during execution. Entry-ID: , V1.0, 09/