Application for Drive Technology - Siemens AG · Application for Drive Technology MICROMASTER 4...

Application for Drive Technology

MICROMASTER 4 Application description

Asynchronous Servomotors 1PH7 in combination with MICROMASTER MM440

Warranty, Liability and Support


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Warranty, Liability and Support

We do not accept any liability for the information contained in this docu-ment.

Any claims against us – based on whatever legal reason – resulting form the use of the examples, information, programs, engineering and perform-ance data etc., described in this document shall be excluded. Such an ex-clusion shall not apply in the case of mandatory liability, e.g. under the German Product Liability Act (“Produkthaftungsgesetz”), in case of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of a condi-tion which goes to the root of the contract (“wesentliche Vertragspflichten”). However, claims arising from a breach of a condition which goes to the root of the contract shall be limited to the foreseeable damage which is intrinsic to the contract, unless caused by intent or gross negligence or based on mandatory liability for injury of life, body or health. The above provisions does not imply a change in the burden of proof to your detriment.

The Application Examples are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. They do not represent customer-specific solutions. They are only intended to provide support for typical applications. You are responsible in ensuring that the described products are correctly used.

These Application Examples do not relieve you of the responsibility in safely and professionally using, installing, operating and servicing equip-ment. When using these Application Examples, you recognize that Sie-mens cannot be made liable for any damage/claims beyond the liability clause described above. We reserve the right to make changes to these Application Examples at any time without prior notice. If there are any de-viations between the recommendations provided in these Application Ex-amples and other Siemens publications – e.g. Catalogs – then the contents of the other documents have priority.

Copyright© 2005 Siemens A&D. It is not permissible to transfer or copy these Application Examples or excerpts of them without first having prior authorization from Siemens A&D in writing.

For questions about this document please use the following e-mail-address:

mailto:[email protected]

mailto:[email protected]

Definitions and Warnings


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Qualified personnel

In the sense of this documentation, qualified personnel are those who are knowledgeable and qualified to install, mount, commission, operate and service/maintain the MICROMASTER 4 and SINAMICS G110 products to be used. He or she must have the appropriate qualifications to carry-out these activities, for example:

Trained and authorized to energize and de-energize, ground and tag circuits and equipment according to applicable safety standards.

Trained or instructed according to the latest safety standards in the care and use of the appropriate safety equipment.

Trained in rendering first aid.

There is no explicit warning information in this documentation. However, reference will be made to warning information and instructions in the Operating Instructions for the particular product.

User group

The application software and the application example were developed to support Siemens personnel in the generation of user programs for machines or systems.

This is not intended to be directly passed-on or sold to persons/companies outside Siemens AG.

Application software may only be passed-on as part of a complete machine for plant software.

If passed-on to persons/companies outside Siemens AG who are not involved in a total project integrated application software, then the person or persons who transferred this information carry full responsibility for an liability or damage claims.

Only qualified personnel may use the application software and the application example.

If this is incorrectly used, this can result in the plant or system being destroyed and/or injury to personnel.

Exclusion of liability

The application examples are provided at no charge. They may be used under the clear understanding that the party using them does so at his own risk. They may only be passed-on to third parties, completely unchanged, maintaining all of the confidential property notices. These application examples may only be commercially passed-on after prior authorization in writing from Siemens Aktiengesellschaft.



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Siemens does not accept any liability for recommendations which are provided or implied by the following description. The following description does not represent any additional guarantee, warranty or liability which goes beyond Siemens general conditions for supply. Any other claims are completely excluded. The authors and owners are only liable for deliberate and gross negligence. It is especially important to note that the authors are not liable for possible defects and subsequent damage.

Information regarding trademarks SIMOVERT® is a Siemens registered trademark.

MICROMASTER ® is a Siemens registered trademark

Revisions/author

Version Datum/Änderung Verfasser 1.0 03/04, Erstausgabe Weissenfels


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1 Motor description

1.1 Features

Compact 1PH7 three-phase motors are force-ventilated squirrel-cage induction motors. The motors can only be fed from a frequency inverter. These motors cannot be directly connected to the line supply. Originally, 1PH7 motors were used for main spindle applications in the machine tool industry. Later, these were complemented by applications in general machinery construction. Existing DC drives can be replaced as a result of the type of construction (mechanical design) as well as the technical data.

These motors are especially suitable for the following requirements:

Wide speed control range

Speed down to zero without torque reduction

Low space requirement

Rotational accuracy, balance quality, low envelope dimensions as well as dynamic performance are some of the outstanding features.

Three-phase 1PH7 motors are available with rated powers from 3.7 kW to 385 kW at rated speeds from 400 RPM to 2900 RPM; in conjunction with MICROMASTER 440, the maximum power rating is limited to 200 kW.

Advantages of 1PH7 motor include:

Rugged, low-maintenance four-pole squirrel-cage induction motor

Compact design (low overall envelope dimensions)

Low moment of inertia

Full torque is continually available even at standstill thanks to the separately-driven fan

Excellent rotational accuracy - even at low speeds

High speeds in the field-weakening range

Motor temperature is monitored using KTY

Bearing design for high cantilever forces for belt out-drives

High stability against vibration

IP54 degree of protection - optionally IP55


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1.2 Design

1PH7 compact induction motors have no separate enclosure. The essential components of the stator include the drive-end bearing endshield, stator core, non-drive end bearing endshield as well as the modules/assemblies for the fans and terminal boxes. Contrary to force-ventilated standard induction motors, the cooling air is not blown across the cooling ribs, but through ducts in the stator core.

View of frame sizes 100, 132, 160

Figure 1-1: 1PH7 motor, frame sizes 100, 132, 160

View of the frame sizes 180, 225, 280

Figure 1-2: 1PH7 motor, frame sizes 180, 225, 280


1.3 Motor design

Winding design 1PH7 motors are exclusively four-pole motors. The winding is used to adapt the motor speed.

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Speed n

Frequency inverteroutput voltage

Maximum frequency inverteroutput voltage reached

400 1000 1500 25002000 Figure 1-3: Winding design for 1PH7 motors

The interrelationship between the rated speed and rated frequency is shown in the following table.

Rated speed in RPM

Rated frequency in Hz

400 Approx. 14.3

1000 Approx. 35.6

1500 Approx. 51.6

2000 Approx. 68.9

2500 Approx. 84.1

Table 1-1: Interrelationship between the rated speed / rated frequency


Winding and frequency inverter

Speed n

Frequency inverteroutput voltage

Maximum frequency inverteroutput voltage

nN1 nN2

MICROMASTER 4403-ph. 400 V AC

MICROMASTER 4403-ph. 480 V AC

Figure 1-4: Rated speed of 1PH7 motors

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1PH7 motors were originally developed and adapted for the SIMODRIVE and MASTERDRIVES frequency inverter systems. However they can also be used with the MICROMASTER MM440 frequency inverters. For line supply voltages of 400 V and 480 V, data is specified in the selection tables in Section 3. It has been taken into account that the MICROMASTER MM440 with closed-loop Vector control can only provide approx. 91% of the output voltage. No motor calculations have been made for 1PH7 motors fed from MICROMASTER MM440 drive inverters. This is the reason that the MASTERDRIVES MC power – speed characteristics have been used. The motors have the same winding for a specific speed range independent of the line supply voltage. This is the reason that different rated speeds are obtained for the various line supply voltages.

Power (torque) diagram The speed-power diagram is shown in the overview.

Field weakening range

P

n

Constanttorque range

Constant power rangePn

Stall limit at the maximum frequencyinverter output voltage and input voltage

V = V line, rated

S1

S6 40%

S6 25%

S6 60%30% power

margin

~ 1/n

Figure 1-5: Speed-power diagram


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Constant torque is available from standstill up to the rated operating point. The field and therefore the torque in the motor remain constant over this base speed range. The power increases linearly with the speed. This is then followed by a constant-power range that is characterized by the field weakening. The field-weakening range is limited by the stall limit. Operation should remain approximately 30% below the stall limit for safety reasons (fluctuations in the line supply and motor parameters). At a speed n1 there is only a margin of 30% to the stall limit. In addition to the S1 characteristic (continuous duty), the characteristics for S6 duty (intermittent duty) for the different relative power-on durations (60%, 40%, 25%) are also shown in the characteristics. The motors are utilized in accordance with Class F.


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2 Engineering

2.1 Drives with a constant torque characteristic

The selection table in Section 3 shows, for each listed 1PH7 motor, the associated frequency inverter. However, this association only applies if the motor is operated with a constant torque that is less than/equal to the rated torque and the frequency inverter overload capability is adequate (200% for 3 seconds, 150% for 60 seconds for a 300 second cycle time). This allows occasional acceleration operations.

2.2 Drives with a changing torque characteristic

A drive with a fixed load duty cycle, several accelerating/braking phases as well as constant-torque phases is shown in the following.

Speedn

n1

n2

Load torqueML

M1

M2

Motor torqueMM

M1

M2

MB1 MB2 MB3

tB1 tB2 tB3t1 t2T

MB1

Figure 2-1: Example of a drive with changing load conditions


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The torque Mmotor that the motor must provide comprises the frictional torque Mfriction, the load torque Mload as well as the accelerating torque Maccel.

accelloadfrictionmotor MMMM ++=

The accelerating torque Maccel is calculated as follows

accel

totalaccel t

nJM*55.9*Δ

=

Accelerating torque Maccel [Nm] Moment of inertia J [kgm2] Speed difference Δn [RPM] Accelerating time taccel [sec]

For the above example, the RMS torque MRMS and the maximum required torque Mmax can be calculated from the load cycle.

TtMtMtMtMtMM BBBBBB

RMS3

232

222

221

211

21 ***** ++++

=

),,,,max( 32211max BBB MMMMMM =

When dimensioning the motor, the RMS torque should be less than the rated motor torque; the maximum torque should be less than 200% of the rated motor torque.

The currents that the frequency inverter must supply are calculated as follows:

ratedmotorratedmotorratedmotor

RMSratedmotorratedinverterfrequency I

II

IM

MII,

2

2

,2

22

,,, )1(*)(* μμ +−≥

The maximum frequency inverter current required is calculated as follows:

ratedmotorratedmotorratedmotorratedmotorinverterfrequency I

II

IM

MII,

2

2

,2

22

,

max,max, )1(*)(* μμ +−≥

When dimensioning the frequency inverter for the maximum current, both the overload capability as well as the time must be taken into account.

0.12 kW to 75 kW Overload current = 150% rated current for 60 seconds for a load duty cycle of 300 seconds

Overload current = 200% rated current for 3 seconds for a load duty cycle of 300 seconds

90 kW to 200 kW Overload current = 136% rated current for 57 seconds for a load duty cycle of 300 seconds

Overload current = 160% rated current for 3 seconds for a load duty cycle of 300 seconds

If operating situations occur where the motor torque is greater than the rated torque and the time is longer than the permissible overload time, then the rated drive inverter current must be dimensioned for the increased motor torque.


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Even more complex torque characteristics can be calculated in a user-friendly fashion using the PATH and SIZER engineering programs.


3 Technical data

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Table 3-1: Selection data, 1PH7 motors for a 3-ph. 400 V AC line supply


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Table 3-2: Selection table, 1PH7 for a 3-ph. 480 V AC line supply


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4 Frequency inverter settings

The motor can be generally set using the motor data identification of the frequency inverter. It should be noted that 1PH7 compact induction motor data differs significantly from that of the standard induction motors. This is the reason that the setting values are listed in Table 4-1 and Table 4-2. From previous experience it can be stated that the mot ID of the equivalent circuit diagram data can be quite precisely determined. If control problems occur for a specific motor, then in addition, at first, the magnetizing current should be entered together with the mot ID. The determined equivalent circuit diagram data can be checked using Tables 4-3 and 4-4. It is also possible to directly enter the equivalent circuit diagram data using Tables 4-5 and 4-6. When directly entering the equivalent circuit diagram data, the following should be carefully noted: The value entered for the stator resistance P0350 also includes the

resistance of the feeder cable. For the motor data identification, the feeder cable resistance is set to 20% of the stator resistance. For short and also for long feeder cables, the value of the cable resistance should either be measured or calculated and entered into parameter P0352. The stator resistance in the motor model is corrected by this factor. This increases the accuracy of the Vector control.

For quick start-up, parameter P0340 is also indirectly initiated by setting parameter P3900 at the end. As long as this is at either 1 or 2, then the equivalent circuit diagram data of the standard motor saved in the drive-inverter is automatically entered and calculated. This means that the specific equivalent circuit diagram data must be directly entered after start-up, as otherwise the values will be again set to default values. The setting parameters for the Vector control are calculated, without overwriting the equivalent circuit diagram data, by subsequently setting parameter P0340=3.


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Table 4-1: Setting parameters, 1PH7 motors for a 3-ph. 400 V AC line supply


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Table 4-2: Setting parameters, 1PH7 motors for a 3-ph. 480 V AC line supply


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Table 4-3: Input and display values, equivalent circuit diagram, 3-ph. 400 V AC line supply voltage


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Table 4-4: Input and display values, equivalent circuit diagram, 3-ph. 480 V AC line supply voltage


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5 Ordering versions

In the standard version, 1PH7 compact induction motors are supplied with an integrated fan, pulse encoder as well as temperature monitoring using a KTY 84. Options and ordering versions of the motors are coded in the Order No. The options that are available as well as the associated key are listed in Catalog DA 65.3. It should be noted that when connecting the motors to MICROMASTER MM440, only the following encoder versions can be used - "Pulse encoder with 1024" or "Pulse encoder with 2048 pulses" per revolution. It is not possible to connect absolute value encoders, resolvers as well as sinusoidal/cosinusoidal encoders.


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6 Documentation

The following documentation is available for 1PH7 compact synchronous motors: Catalog DA65.3 - Servomotors Characteristics of 1PH7 motors when fed from MASTERDRIVES frequency inverters http://intra1.nbgm.siemens.de/mc/mediadb/c624e205-f66c-11d4-86b6-080006278927/view/Kennlinien_Asynchron_Servo_am_Masterdrives_V1_0.pdf Additional information is provided in the INTRANET under

http://intra1.nbgm.siemens.de/mc/mc-all/de/b5fa4d87-9180-4c82-8096-0d61aca38d8d/index.aspx

http://intra1.nbgm.siemens.de/mc/mediadb/c624e205-f66c-11d4-86b6-080006278927/view/Kennlinien_Asynchron_Servo_am_Masterdrives_V1_0.pdf

http://intra1.nbgm.siemens.de/mc/mediadb/c624e205-f66c-11d4-86b6-080006278927/view/Kennlinien_Asynchron_Servo_am_Masterdrives_V1_0.pdf



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