Siemens A5E33032452 GH180 Robicon Perfect Harmony NXGpro controller 12 cell 6SR0960-0CC12-0AD0
Siemens A5E33032452 GH180 Robicon Perfect Harmony NXGpro controller 12 cell 6SR0960-0CC12-0AD0
Siemens A5E33032452 GH180 Robicon Perfect Harmony NXGpro controller 12 cell 6SR0960-0CC12-0AD0 NXGpro DCR
Table of contents
1 Security information......................................................................................................................................9
2 Introduction.................................................................................................................................................11
2.1 Power Topology .....................................................................................................................12
2.2 Control Overview....................................................................................................................13
2.3 Protocol for Cell Communication............................................................................................14
3 Security Information....................................................................................................................................15
4 Safety notes................................................................................................................................................17
4.1 General Safety Information ....................................................................................................17
4.2 Safety Concept.......................................................................................................................18
4.3 Observing the Five Safety Rules............................................................................................19
4.4 Safety Information and Warnings...........................................................................................20
4.5 ESD-sensitive Components ...................................................................................................22
4.6 Electromagnetic Fields in Electrical Power Engineering Installations ...................................24
4.7 Security Information ...............................................................................................................25
5 NXGpro Control Description .......................................................................................................................27
5.1 Control System.......................................................................................................................28
5.1.1 Digital Control Rack (DCR) ....................................................................................................29
5.1.2 System Interface Board (SIB) ................................................................................................30
5.1.3 User I/O..................................................................................................................................31
5.1.4 Control System Power Supply ...............................................................................................31
5.2 Control Modes........................................................................................................................33
5.2.1 Open Loop Vector Control (OLVC) ........................................................................................36
5.2.2 Open Loop Test Mode (OLTM) ..............................................................................................36
5.2.3 Synchronous Motor Control (SMC) ........................................................................................37
5.2.4 Volts/Hertz Control (V/Hz)......................................................................................................39
5.2.5 Closed Loop Control (CLVC or CSMC)..................................................................................39
5.2.6 Permanent Magnet Motor Control (PMM) ..............................................................................39
5.2.7 PMM with Conveyor ...............................................................................................................44
5.2.8 Synchronous Motor with DC Brushless Exciter (SMDC)........................................................50
5.3 Watchdog Protections ............................................................................................................51
5.4 Control Loops.........................................................................................................................52
5.4.1 Current Loop ..........................................................................................................................52
5.4.2 Speed Loop............................................................................................................................52
5.4.3 Flux Loop ...............................................................................................................................53
6 Hardware Interface Description ..................................................................................................................55
6.1 Non-user Accessible Interfaces .............................................................................................56
NXGpro Control
Operating Manual, AJ, A5E33474566_EN 3
6.1.1 System Inputs and Outputs for Motor Control........................................................................56
6.1.2 Test Point Port .......................................................................................................................57
6.1.3 Control Power ........................................................................................................................58
6.1.4 Modulator and Fiber Optics....................................................................................................58
6.1.5 Bypass Control.......................................................................................................................59
6.2 User Accessible Interfaces.....................................................................................................60
6.2.1 Human Machine Interface ......................................................................................................60
6.2.2 Inhibit Input (Control Relay 3, CR3) .......................................................................................60
6.2.3 Encoder Interface...................................................................................................................61
6.2.4 User Inputs and Outputs ........................................................................................................62
6.2.4.1 User I/O Board .......................................................................................................................62
6.2.4.2 Discrete External I/O via WAGO System ...............................................................................66
6.2.4.3 Interface for External I/O ........................................................................................................66
6.2.5 I/O Configuration ....................................................................................................................68
6.2.6 Dedicated I/O .........................................................................................................................69
6.2.6.1 Dedicated I/O for Type 4 Pre-charge .....................................................................................69
6.2.6.2 Dedicated I/O for Type 5 and Type 6 Pre-charge ..................................................................70
6.2.6.3 Dedicated I/O for Input Protection (IP) ...................................................................................71
6.2.7 Network Connections .............................................................................................................73
7 Parameter Assignment / Addressing ..........................................................................................................77
7.1 Menu Descriptions .................................................................................................................77
7.2 Safety Notes for Parameter Changes ....................................................................................80
7.3 Options for Motor Menu (1) ....................................................................................................82
7.4 Options for Drive Menu (2).....................................................................................................92
7.5 Options for Stability Menu (3)...............................................................................................122
7.6 Options for Auto Menu (4)....................................................................................................134
7.7 Options for Main Menu (5) ...................................................................................................146
7.7.1 Options for Main Menu (5) ...................................................................................................146
7.7.2 Security Access Levels and Codes......................................................................................149
7.8 Options for Log Control Menu (6).........................................................................................150
7.9 Options for Drive Protect Menu (7) ......................................................................................153
7.10 Options for Meter Menu (8) ..................................................................................................156
7.11 Options for Communications Menu (9) ................................................................................161
7.12 Options for Multiple Configuration Files ...............................................................................164
8 Operating the Control ...............................................................................................................................169
8.1 Signal Frame of Reference for Motor...................................................................................170
8.2 Cell Bypass ..........................................................................................................................173
8.2.1 Fast Bypass (U11) ...............................................................................................................173
8.2.2 Forced Bypass - Non-faulted Cells ......................................................................................175
8.2.3 Mechanical Cell Bypass .......................................................................................................176
8.2.4 Neutral Point Shift during Bypass ........................................................................................177
8.3 Energy Saver .......................................................................................................................184
8.4 Power Monitoring .................................................................................................................185
Table of contents
4
NXGpro Control
Operating Manual, AJ, A5E33474566_EN
8.5 Motor Thermal Overload Protection .....................................................................................186
8.6 Thermal Over Temperature Rollback...................................................................................193
8.7 Input Side Monitoring and Protection ...................................................................................195
8.7.1 One Cycle Protection ...........................................................................................................196
8.7.2 Transformer Protection for Cell Single-Phasing...................................................................198
8.7.3 Protecting Transformer by Limiting Secondary Currents .....................................................199
8.7.4 Excessive Drive Losses Protection ......................................................................................201
8.7.5 System Arc Detection...........................................................................................................204
8.8 Drive Output Torque Limiting ...............................................................................................205
8.8.1 Input Under-Voltage Rollback ..............................................................................................205
8.8.2 Extended Undervoltage Ride-through..................................................................................206
8.8.3 Input Single-Phase Rollback ................................................................................................207
8.8.4 Transformer Thermal Rollback.............................................................................................208
8.8.5 Torque Limit Setting .............................................................................................................209
8.8.6 Field-Weakening Limit..........................................................................................................210
8.8.7 Cell Current Overload ..........................................................................................................210
8.8.8 Timers for Drive Operation in Cell or Transformer Over-temperarure .................................210
8.9 Command Generator ...........................................................................................................212
8.9.1 Analog Input Sources...........................................................................................................212
8.9.2 Proportional-Integral-Derivative (PID) Controller .................................................................213
8.9.3 Set Point Sources ................................................................................................................214
8.9.4 Speed Profile........................................................................................................................214
8.9.5 Critical Speed Avoidance .....................................................................................................215
8.9.6 Polarity Control.....................................................................................................................215
8.9.7 Speed Ramp ........................................................................................................................216
8.9.8 Speed Limits ........................................................................................................................216
8.10 Process Tolerant Protection Strategy ..................................................................................217
8.11 Drive Tuning.........................................................................................................................219
8.11.1 Auto-tuning...........................................................................................................................219
8.11.2 Spinning Load ......................................................................................................................221
8.12 Data Loggers........................................................................................................................223
8.12.1 Event Log .............................................................................................................................223
8.12.2 Alarm/Fault Log....................................................................................................................223
8.12.3 Historic Log ..........................................................................................................................224
8.13 Faults and Alarms ................................................................................................................225
9 Advanced Operating Functions ................................................................................................................227
9.1 Frequency (Speed) Regulator..............................................................................................228
9.2 Overmodulation....................................................................................................................229
9.3 Slip Compensation ...............................................................................................................230
9.4 Speed Droop ........................................................................................................................232
9.5 Flux Regulator......................................................................................................................233
9.6 Flux Feed-Forward...............................................................................................................234
9.7 External Flux Reference.......................................................................................................236
Table of contents
NXGpro Control
Operating Manual, AJ, A5E33474566_EN 5
9.8 Dual-Frequency Braking ......................................................................................................237
9.9 Regenerative Braking (six-step)...........................................................................................242
9.10 Dynamic Braking with External Resistors ...........................................................................244
9.11 Voltage Attenuator Resistors ...............................................................................................245
9.12 Torque Current Regulator ....................................................................................................246
9.13 Magnetizing Current Regulator ............................................................................................247
9.14 Phase Lock Loop .................................................................................................................248
9.15 Output Filters........................................................................................................................249
9.16 Synchronous Transfer..........................................................................................................250
9.16.1 Synchronous Transfer Operation Generator Options and Potential Fault Conditions .........251
9.16.2 Input/Output Signals for Synchronous Transfer (L29)..........................................................252
9.16.3 Synchronous Transfer without Output Reactor ....................................................................253
9.16.4 Synchronous Transfer Operation for Synchronous Motors..................................................257
9.16.5 Synchronous Transfer for Permanent Magnet Motors (PMM) .............................................259
9.16.6 Parameter Settings for Synchronous Transfer Operation ....................................................260
9.17 Pre-charge using SOP .........................................................................................................261
9.17.1 Electric Shock Hazard..........................................................................................................261
9.17.2 Limiting Function (applicable to all precharge types) ...........................................................261
9.17.3 Preconditions for Pre-charge Types 1 to 3...........................................................................261
9.17.4 Type 1 (Closed) Pre-charge ................................................................................................263
9.17.5 Type 2 (Open) Pre-charge ...................................................................................................265
9.17.6 Type 3 Pre-charge (Parallel Drives).....................................................................................267
9.18 Pre-charge using Dedicated I/O...........................................................................................270
9.18.1 Electric Shock Hazard..........................................................................................................270
9.18.2 Limiting Function (applicable to all precharge types) ...........................................................270
9.18.3 Pre-charge using Dedicated I/O...........................................................................................271
9.18.4 Type 4 Pre-charge (resonant-open transfer-capacitors only) ..............................................271
9.18.5 Preconditions for Pre-charge Types 5 and 6........................................................................275
9.18.6 Type 5 (Open) Pre-charge ...................................................................................................277
9.18.7 Type 6 (Closed) Pre-charge.................................................................................................282
9.19 Paralleling Multiple Drives....................................................................................................289
9.19.1 Parallel Drive Control ...........................................................................................................289
9.19.2 Master-Slave Drive Control ..................................................................................................291
9.20 Torque Mode........................................................................................................................292
9.20.1 Extended Torque During Ride-Through for ESP Applications .............................................293
9.21 High Performance Control....................................................................................................295
9.21.1 Low Speed Operation ..........................................................................................................295
9.21.2 High Starting Torque Mode ..................................................................................................295
9.22 Conveyor Application ...........................................................................................................297
9.22.1 Network Fast Access for Conveyor Applications .................................................................297
9.22.2 PLC Directed High Starting Torque Mode for Conveyor Applications..................................298
9.22.3 PLC-based Active Dampening for Conveyor Applications ...................................................303
9.23 Long Cable Applications ......................................................................................................306
9.23.1 Cable Inductance Compensation .........................................................................................306
Table of contents
6
NXGpro Control
Operating Manual, AJ, A5E33474566_EN
9.23.2 Damping of Resonance due to Output Cable ......................................................................307
9.23.3 Operating Parallel Motors over Long Cables .......................................................................307
9.24 Drive with Output Transformers ...........................................................................................309
9.25 Motor Equivalent Circuit Parameters ...................................................................................311
10 Software User Interface............................................................................................................................313
10.1 SIMATIC Keypad .................................................................................................................314
10.1.1 SIMATIC Keypad User Interface .........................................................................................314
10.1.2 Fault Reset Key and Fault LED Indicator.............................................................................315
10.1.3 Automatic Key ......................................................................................................................318
10.1.4 Stop Key...............................................................................................................................318
10.1.5 Start Key ..............................................................................................................................319
10.1.6 Numeric Keys.......................................................................................................................319
10.1.7 Enter/Cancel Key .................................................................................................................321
10.1.8 Shift Function Keys ..............................................................................................................322
10.1.9 Arrow Keys...........................................................................................................................323
10.1.10 Diagnostic Indicators............................................................................................................327
10.1.11 Display .................................................................................................................................327
10.1.12 Summary of Common Shift Key and Arrow Key Sequences ...............................................334
10.1.13 Adjusting the SIMATIC KTP700 HMI Display Brightness ....................................................336
10.2 Multi-Language Keypad .......................................................................................................340
10.2.1 Fault Reset Key and LED Indicator......................................................................................341
10.2.2 Automatic Key ......................................................................................................................344
10.2.3 Manual Stop Key..................................................................................................................344
10.2.4 Manual Start Key..................................................................................................................345
10.2.5 Numeric Keys.......................................................................................................................345
10.2.6 Enter/Cancel Key .................................................................................................................348
10.2.7 Shift Function Keys ..............................................................................................................348
10.2.8 Arrow Keys...........................................................................................................................349
10.2.9 Diagnostic Indicators............................................................................................................353
10.2.10 Display .................................................................................................................................353
10.2.11 Summary of Common Shift Key and Arrow Key Sequences ...............................................360
10.3 NXGpro ToolSuite ................................................................................................................362
10.4 Communication Interface .....................................................................................................363
10.4.1 Available Networks...............................................................................................................363
10.4.2 Multiple Networks.................................................................................................................363
10.5 Security Measures ...............................................................................................................364
10.5.1 Overview ..............................................................................................................................364
10.5.2 Industrial Security.................................................................................................................364
10.5.3 Benefits ................................................................................................................................365
10.5.4 Parameter Security Levels ...................................................................................................365
10.5.5 Write Protection....................................................................................................................365
10.5.6 Network Protection...............................................................................................................365
10.5.7 Field Bus Protection .............................................................................................................366
10.5.8 USB Connection...................................................................................................................366
10.5.9 Virus Protection / Memory Card ...........................................................................................367
11 Operating the Software.............................................................................................................................369
11.1 SOP Development and Operation........................................................................................370
Table of contents
NXGpro Control
Operating Manual, AJ, A5E33474566_EN 7
11.2 SOP Logic Functions ...........................................................................................................371
11.3 SOP Evaluation....................................................................................................................372
11.4 Input Flags ...........................................................................................................................373
11.5 Output Flags.........................................................................................................................374
11.6 Downloading the SOP..........................................................................................................375
11.7 Uploading the SOP ..............................................................................................................376
11.8 Multiple Configuration Files..................................................................................................377
11.9 Selecting the active SOP .....................................................................................................378
12 Troubleshooting Faults and Alarms .........................................................................................................379
12.1 Faults and Alarms ................................................................................................................380
12.2 Drive Faults and Alarms.......................................................................................................382
12.3 Cell Faults and Alarms .........................................................................................................415
12.3.1 Troubleshooting General Power Cell and Power Cell Circuitry Faults.................................425
12.3.2 Troubleshooting Cell Over Temperature Faults ...................................................................427
12.3.3 Troubleshooting Overvoltage Faults ....................................................................................427
12.3.4 Troubleshooting Cell Communications and Link Faults .......................................................428
12.3.5 Status Indicator Summaries for MV Mechanical Bypass Boards .........................................428
12.4 User Faults and Alarms........................................................................................................429
12.5 Unexpected Output Conditions ............................................................................................430
12.5.1 Speed Rollback ....................................................................................................................430
12.6 Drive Input Protection...........................................................................................................433
12.7 Flash Disk Corruption...........................................................................................................436
12.8 Loss of Communication to Keypad ......................................................................................437
A NEMA Table .............................................................................................................................................439
B Abbreviations............................................................................................................................................443
C Historical Logger.......................................................................................................................................449
C.1 Historic Log ..........................................................................................................................449
C.2 Historical Logger ..................................................................................................................450
Glossary ...................................................................................................................................................455
Index.........................................................................................................................................................465
| Spare Part | Item | Part Number | Description | MLFB | OLD PN | |
| NXG pro DCR | NXGpro DCR 12 Cell | A5E33032452 | GH180 NXGpro controller 12 cell | 6SR0960-0CC12-0AD0 | ||
| NXGpro DCR 15 Cell | A5E37764609 | GH180 NXGpro controller 15 cell | 6SR0960-0CC15-0AD0 | |||
| NXGpro DCR 18 Cell | A5E33032455 | GH180 NXGpro controller 18 cell | 6SR0960-0CC18-0AD0 | |||
| NXGpro DCR 21 Cell | A5E37764770 | GH180 NXGpro controller 21 cell | 6SR0960-0CC21-0AD0 | |||
| NXGpro DCR 24 Cell | A5E33032458 | GH180 NXGpro controller 24 cell | 6SR0960-0CC24-0AD0 | |||
| NXGpro CF | A5E35236834 | GH180 NXGpro compact flash card | 6SR0960-0CC08-0AD0 | |||
| SIB | A5E36968571 | GH180 NXGpro System Interface Board | 6SR0960-0CC16-0AD0 | A5E32168144 | ||
| User I/O board 24VDV | A5E32100313 | GH180 24VDC User IO Board | 6SR0960-0CC07-1AD0 | |||
| Fiber Optic For USER I/O | A5E41987327 | FIBER OPTIC ASSY, DUPLEX | 6SR4900-0LM01-0AM0 | A5E36881503 | ||
| USER I/O board POWER SUPPLY | A5E37356659 | GH180 NXGpro USER I/O board POWER SUPPLY | 6SR5902-0CM00-0AM0 | |||
| NXGpro CPS 15VDC | A5E37876282 | Power Supply NXGpro CPS +/-15V | 6SR0960-0CC32-0AD0 | |||
| NXGpro CPS 15VDC U55 | A5E34916937 | Power Supply NXGpro CPS +/-15V High Alt. | 6SR0960-0CC05-1AD0 | A5E34916905 | ||
| NXGpro CPS 15&24VDC | A5E37877003 | Power Supply NXGpro CPS 15&24VDC | 6SR0960-0CC50- 0AD0 | |||
| NXGpro CPS 15&24VDC U55 | A5E34916937 | Power Supply NXGpro CPS 15&24VDC High Alt. | ||||
| NXGpro CPS 15&24VDC | A5E44722441 | Power Supply NXGpro CPS 15&24VDC | 6SR0960-0CC40-0AD0 | |||
| NXGpro-Profibus-DP | A1A099201 | COMM. KIT,ANYBUS Profibus-DP,NXGpro | 6SR0960-0DC00-0AD0 | |||
| NXGpro-DeviceNet | A1A098628 | COMM. KIT,ANYBUS DeviceNet,NXGpro | 6SR0960-0DC01-0AD0 | |||
| NXGpro-ModbusTCP/Eth | A1A099202 | OMM. KIT,ANYBUS ModbusTCP/Eth,NXGpro | 6SR0960-0DC02-0AD0 | |||
| NXGpro-ControlNet | A1A099203 | COMM KIT,ANYBUS ControlNet,NXGpro | 6SR0960-0DC03-0AD0 | |||
| NXGpro-MODBUS | A1A10000441.00 | COMM. KIT, MODBUS,NXGpro | 6SR0960-0DC04-0AD0 | |||
| Keypad kit | A5E02669561 | KEYPAD KIT (Chinese) | 6SR0960-0CC10-0AD0 | LDZ252090.11NGSC | ||
| Keypad | A5E02624585 | MULTI LANGUAGE KEYPAD ASSEMBLY CHINESE | 6SR0960-0CB16-0AD0 | A1A460A68.23 | ||
| SHIELD CABLE RIBBON | A1A260913.08 | SHIELDED RIBBON CABLE ASSY,87" | 6SR0960-0QM04-0AD0 | |||
| FLAT MOUNT | A1A072323 | FLAT CABLE MOUNT,ADHESIVE BACK | ||||
| BACK COVER | A1A283739.00 | KEYPAD COVER, GLASTIC | ||||
| keypad kit | A5E02669560 | KEYPAD KIT (English) | 6SR3900-0SM20-0BD0 | LDZ252090.11NGSC | ||
| Keypad | A5E02363383 | MULTI LANGUAGE KEYPAD ASSEMBLY ENGLISH | 6SR0960-0CB15-0AD0 | A1A460A68.23 | ||
| SHIELD CABLE RIBBON | A1A260913.08 | SHIELDED RIBBON CABLE ASSY,87" | 6SR0960-0QM04-0AD0 | |||
| FLAT MOUNT | A1A072323 | FLAT CABLE MOUNT,ADHESIVE BACK | ||||
| BACK COVER | A1A283739.00 | KEYPAD COVER, GLASTIC | ||||
| keypad kit | A5E02982002 | KEYPAD KIT (Russia) | 6SR0900-0CM07-0AD0 | LDZ252090.11NGSC | ||
| Keypad | A5E02669580 | MULTI LANGUAGE KEYPAD ASSEMBLY RUSSIA | 6SR0960-0CB18-0AD0 | A1A460A68.23 | ||
| SHIELD CABLE RIBBON | A1A260913.08 | SHIELDED RIBBON CABLE ASSY,87" | 6SR0960-0QM04-0AD0 | |||
| FLAT MOUNT | A1A072323 | FLAT CABLE MOUNT,ADHESIVE BACK | ||||
| BACK COVER | A1A283739.00 | KEYPAD COVER, GLASTIC | ||||
| keypad kit | A5E39808478 | KEYPAD KIT (Simatic) | 6SR0960-0SM60-0AD0 | |||
| KEYPAD | A5E39206479 | DEV_CONTROL_SIMATIC HMI, KTP700 BASIC D | 6SR4900-0SM00-0AM0 | |||
| SHIELD CABLE | A5E39047590003 | 6SR5 KTP700 CABLE ASSEMBLY 96'' | 6SR5900-0QM00-0AD0 | |||
| NXGII DCR | NXGII DCR with FOHB kit | A5E33065979 | NXGII DCR with FOHB kit | 6SR0960-0CB01-0AM0 | ||
| NXGII DCR without FOHB Kit | A5E03931016 | NXGII DCR without FOHB Kit | 6SR0960-0CB21-0AD0 | A1A10000313.00 | ||
| NXGII DCR with FOHB kit U55 | A5E33561398 | NXGII DCR with FOHB kit U55 | 6SR0960-0CB02-0AM0 | |||
| NXGII DCR without FOHB Kit U55 | A5E33561420 | NXGII DCR without FOHB Kit U55 | 6SR0960-0CB04-0AM0 | |||
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