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MICROMASTER User Documentation A pplications Handbook Issue A 1 ...
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ii MICROMASTER Applications Handbook Further inform ation is available on the Internet under: http: //www .siemens.d e/mi croma ster Approved Siemens Qualit y for Software and Training is to DIN ISO 9001, Reg. No. 2160-01 The reproduction, t ransmission or use of this document, or its contents is not permitted unl ess authorized in writing. Offende ...
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MICROMASTER Applications Handbook iii Valid for A1 Rele ase Inverter T ype Control V ersion MICROMAST ER MM4 Issue: A1 MICROMASTER A pplications Handbook User Documentation Introduction 1 Siemens Dr ives Product Range 2 Selecting a Driv e 3 Getting Sta rted 4 Simple A pplications 5 Electromagnet ic Compatibility 6 Real A pplications 7 A d vanced A ...
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iv MICROMASTER Applications Handbook ...
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Internatio nal E nglish Contents MICROMASTER Applications Handbook v Table of Contents 1 Introduction ............................................................................................................... 1 1.1 W hat is a Variable Speed Drive? ................................................................................ 1 1.2 The Varia ...
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Contents Interna tional Englis h vi MICROMA STER A pplications Handbook 6 Elect romagnetic Compatibility (EM C) ..................................................................... 29 6.1 W hat is EMC? ............................................................................................................. 29 6.2 Minim ising the problem of EMI ...
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Internatio nal E nglish Contents MICROMASTER Applications Handbook vii List of Figures Figure 1-1 Induction M otor. Simplified Cross Section ............................................. 1 Figure 1-2 Torque Spee d Characterist ics of an Indu ction Motor ................................................................................................ ...
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Contents Interna tional Englis h viii MICROMASTER Applications Handbook Figure 7-1 Fan Application ....................................................................................... 35 Figure 7-2 Extractor Syste m using Close d Loop Flow Control ................................................................................................... ...
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Internatio nal E nglish Introduct ion MICROMASTER Applications Handbook 1 1 Introducti on This manual is intended to help us ers of variable s peed dr ives suc cessf ully insta ll and utilize Siem ens Standa rd Drives. It includ es an intro duction t o drives, which m ay be inf ormative to f irst tim e users . Detailed tec hnica l inf orm ation and ...
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Introduct ion Interna tional Englis h 2 MICROMASTER Applications Handbook This field cross es the air ga p betwee n the stator and ro tor and caus es curr ents to flow in the r otor windings . T his produces a f orce on the rotor as the cur rent interacts with the c hangin g m agnetic field, and the r otor turns . If the windings are arrange d in s ...
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Internatio nal E nglish Introduct ion MICROMASTER Applications Handbook 3 Torque Flux, Voltage Speed ( X 50/60) Torque Capability 0 0.5 1.0 1.2 1.5 Figure 1-3 Torque Reduction abov e Base Speed Theref ore in order t o contro l the spee d of a sta ndard A C motor , the applied frequenc y and vo ltage m ust be co ntrolled. Althou gh it is diffic ult ...
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Introduct ion Interna tional Englis h 4 MICROMASTER Applications Handbook The s upply, which c an be s ingle phase ( usual ly at low power) or three-p hase is fed to a full wave rec tifier which s upplies t he DC link capacitor s. The c apacitor s reduce th e voltag e ripple ( espec ially on s ingle-phas e supp lies) a nd suppl y energ y for s hort ...
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Internatio nal E nglish Introduct ion MICROMASTER Applications Handbook 5 · The PW M output vo ltage c ontains m any high f requenc y harmonic s (becaus e of the fast s witching) and ca n be a m ajor sour ce of EMI. · The input rectif ier draws cu rrent on ly at the peak of the suppl y waveform , so the input cur rents hav e a poor form factor ( ...
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Introduct ion Interna tional Englis h 6 MICROMASTER Applications Handbook ...
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Internatio nal E nglish Product Range MICROMASTER Applications Handbook 7 2 Siemens Dri ves Product Range The c urrent product r ange consists of severa l dif ferent produc t types: The MICROM ASTER Vector (MM440). A VSD hi gh perf ormance inv erter for general pur pose applic ations available in var ious volta ge ranges. The MICROM ASTER ( MM420) ...
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Product Ran ge Internatio nal Eng lish 8 MICROMASTER Applications Handbook ...
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Internat ional E nglish Selectin g a Dr ive MICROMASTER Applications Handbook 9 3 Selecting a Dri v e Often dr ive selec tion is s traight forward , as a m otor is alread y instal led and the speed ra nge requir ement is not ex cessive. However , when a dr ive s ystem is selected from first princ iples, c areful c onsiderati on m ay avoid pr oblem ...
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Selectin g a Dr ive Interna tiona l Eng lish 10 MICROMASTER Applications Handbook Supplies at the en d of long power li nes in rem ote area s can ris e excess ively in t he evening and week ends when large lo ads are no longe r present. Industries with loc ally contr olled and generate d suppl ies can ha ve po or regulat ion and contr ol. Power s y ...
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Internat ional E nglish Selectin g a Dr ive MICROMASTER Applications Handbook 11 3.2.3 Ungrounded Supplie s Certain i ndustrial instal lations oper ate with s upplies that ar e isol ated fr om the protective earth ( IT suppl y). This permits equipment to continue to run f ollowing a n earth faul t. However, MICRO MASTERs are designe d to oper ate o ...
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Selectin g a Dr ive Interna tiona l Eng lish 12 MICROMASTER Applications Handbook Figure 3-3 Typical H armonic currents i n 230 V single an d three-phase sup plies, (750 W Inver ter). In order to calcula te the h arm onics in a particul ar suppl y system it is ess ential t hat the suppl y im pedance is k nown. T his is us uall y stated in t erms of ...
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Internat ional E nglish Selectin g a Dr ive MICROMASTER Applications Handbook 13 Torque Speed ( X 50/60) 0 0.5 1.0 1.2 1.5 Possible limited operation due to motor cooling Short term overload capability (60 seconds) Continuous operating area 100% 150% Figure 3-4 Operating Capabiliti es of Motor/Inverter Combinat ions High spee d operat ion of standa ...
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Selectin g a Dr ive Interna tiona l Eng lish 14 MICROMASTER Applications Handbook Figure 3-5 Torque/Speed Characteristi cs 3.4.1 Variabl e Torque A pplications Some loads have a Varia ble T orque character istic. T hat is, t he torque increas es with the sp eed. T ypical var iable t orque l oads are c entrifugal pum ps and fans . In these app licat ...
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Internat ional E nglish Selectin g a Dr ive MICROMASTER Applications Handbook 15 3.4.2 Other Loads. Many other loads have non -linear or var ying torque r elatio nships . The torqu e requirem ent of the load sh ould be unders tood bef ore the inver ter an d motor is sele cted. By com paring th e load/spe ed requir ement with the m otor capab ilit y ...
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Selectin g a Dr ive Interna tiona l Eng lish 16 MICROMASTER Applications Handbook 3.6 Environment al Considerations The inv erter is d esigned f or operat ion in a n industri al env ironment. Ho wever ther e are certai n lim itations which m ust be cons idered; t he follo wing chec k list s hould help: · Check that the airf low through th e invert ...
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Internatio nal Eng lish Getting S tarted MICROMASTER Applications Handbook 17 4 Getting St arted w ith an Inverter 4.1 Mounti ng the Inverter Mount the i nverter us ing th e mounting holes pr ovide d as desc ribed in th e Operating I nstructio ns. En sure the cor rect tor que ratings for the f ixing bolts are not exceeded . The unit m ay be m ounte ...
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Getting S tarted Internatio nal Eng lish 18 MICROMASTER Applications Handbook If the supp ly is con nected t o the m otor/output terminal s, the in verter will be damaged. Check the wiring bef ore s witching on. In partic ular, is the unit c onnect ed to th e correc t suppl y, (low vo ltage uni ts will be dam aged if co nnected to a high er voltage ...
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Internatio nal Eng lish Getting S tarted MICROMASTER Applications Handbook 19 4.3.1 A Typical Installation M ISOLATOR EMERGENCY STOP CONTACTOR FUSE INVERTER Control Connections Supply Figure 4-5 Typical Installati on Supply The s upply ma y be either s ingle or thr ee phas e, depen ding on the inverter type. T he recom mended wire si zes are st ate ...
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Getting S tarted Internatio nal Eng lish 20 MICROMASTER Applications Handbook 4.4 First Switch On The Getting Started G uide or Operat ing Instr uctions th at are su pplied with the inverter will giv e detail ed ins tructions on how to st art and s et up t he invert er. However, s ome gener al poi nts are wort h noting: · The inv erter wil l usual ...
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Internat ional E nglish Simple A pplicat ions MICROMASTER Applications Handbook 21 5 A p plications and Possibilities Most inv erters used in in dustr y are control led via t he control term inals, not t he front panel. T his sec tion desc ribes som e simple c ontrol pos sibilit ies using t hese inputs, and som e of the pro gramm able features that ...
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Simple A pplicat ions Interna tional E nglis h 22 MICROMASTER Applications Handbook 7 6 5 8 MICROMASTER DIN 1 +24 V Output DIN 2 DIN 3 Digital Inputs Figure 5-2 Using all the Digital I nputs 5.3 Selecting and Using the Fixed Freq uencies The digi tal inputs c an be us ed to s elect fixed frequenc ies. Se t param eter P100 0 to 3 (select f ixed fr e ...
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Internat ional E nglish Simple A pplicat ions MICROMASTER Applications Handbook 23 Advanced F eatures: 025 Enable DC brake. T he DC brak e feature c an be enab led to pro vide a holding tor que if requir ed. See sect ion 8. 2. 013/014 Increase/dec rease f requenc y (Motor Po tentiom eter func tion). 099 BiCo Func tional ity. Man y com plex f unctio ...
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Simple A pplicat ions Interna tional E nglis h 24 MICROMASTER Applications Handbook 5.6 Curr ent Limit and Protection Systems The inv erter m ust protect it self , the motor and s ystem from overload an d possibl e damage. Cur rent lim it now oper ates ver y rapid ly, lim iting the cur rent and preventi ng a trip oc curring. Most inv erters ha ve s ...
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Internat ional E nglish Simple A pplicat ions MICROMASTER Applications Handbook 25 Overtem perature in the in verter is usual ly caused by a hig h ambient temper ature, a fault y or block ed fan, or bl ocked air inlet or outlet. 5.8 Some A dditional F eatures The MICROM ASTER h as m any useful feat ures bui lt into the sof tware and availab le for ...
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Simple A pplicat ions Interna tional E nglis h 26 MICROMASTER Applications Handbook 5.8.5 Start on the Fly Normall y if the inverter att em pts to start a m otor that is already rotat ing it will current lim it, stall or slo w the m otor down. If Start o n the Fl y is selecte d it wil l sense the speed of the motor and r am p the motor from that sp ...
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Internat ional E nglish Simple A pplicat ions MICROMASTER Applications Handbook 27 5.8.7 Slip Compens ation The m otor speed is reduced de pendin g on the l oad, due to the slip as descr ibed earlier. Slip ca n cause a speed regu lation b y as m uch as 10% with sm all m otors. The inv erter can com pensa te for this by inc reasing t he output f req ...
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Simple A pplicat ions Interna tional E nglis h 28 MICROMASTER Applications Handbook 5.8.9 Boost. P1310, 11 and 12. At low outp ut freque ncies t he output voltage is low t o k eep the flux lev el cons tant, as descr ibed ear lier. Howe ver, t he voltag e ma y be too low to overcom e losse s in the syst em. The vo ltage ca n be incr eased usi ng par ...
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Internatio nal E nglish Electro magnet ic Compa tibility MICROMASTER Applications Handbook 29 6 Electromagne tic Comp atibility (EMC) 6.1 What is E M C? All elec tronic an d electr ical equ ipm ent generate unwanted s ignals. T hese s ignals can be em itted fr om the pr oduct either via cab les that a re connecte d to th e product (Input, out put, ...
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Electro magnet ic Compa tibility Interna tiona l Englis h 30 MICROMASTER Applications Handbook · The output of all i nverters generat es high fr equenc y, high vol tage s witching waveform s in the o utput ca bles bet ween the m otor and in verter . · A lot of E MI occurs at high f requenc y. At hig h freque ncies the s hape and length of the cab ...
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Internatio nal E nglish Electro magnet ic Compa tibility MICROMASTER Applications Handbook 31 6.2.2 EM C Guidelines The guid elines for instal lation a nd wiring ar e detai led in the Operat ing Instruc tions , but the k ey points are as fol lows: 1. Ensur e all eq uipm ent in the c ubicle is well eart hed, usi ng thick , short earthi ng cable. E a ...
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Electro magnet ic Compa tibility Interna tiona l Englis h 32 MICROMASTER Applications Handbook 4. Sup press rela y, contac tor coils etc. us ing R-C, f lywheel d iode, or varistor suppress ers fitted at the coils . Diode (DC Coils only) - Good Varistor - Better Resistor/Capacitor - Best Figure 6-5 Suppression of Cont actor Coils 5 . Use s creened o ...
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Internatio nal E nglish Electro magnet ic Compa tibility MICROMASTER Applications Handbook 33 6.3 EM C Rules and Regulations The regula tions concern ing EMC ar e com plex, changi ng and var y from countr y to countr y. The m ost impor tant point to rem em ber is that if there is no prob lem ther e is unlik ely to b e a lega l issu e, and in a ny c ...
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Electro magnet ic Compa tibility Interna tiona l Englis h 34 MICROMASTER Applications Handbook ...
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Internatio nal E nglish Real Appl ications MICROMASTER Applications Handbook 35 7 Real A pplicatio ns The f ollowing ex am ples are based on applic ations where Si emens Drives h ave been suc cessf ully applie d. In som e cases the circuitr y and par ameter settings have been s im plified. T he settings and par ameter s refer to Siem ens MICROMAST ...
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Real Appl ications Interna tiona l Englis h 36 MICROMASTER Applications Handbook 7.1.3 Key Parameter Detail s Table 7-1 Fan Application with Manual Control Number Value Mean ing P1000 1 Motorised po tentiometer enabled. This allows the p ush buttons o n the AOP to be used to c ontrol the speed . P0003 3 Allows all parameters to b e adjuste d and se ...
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Internatio nal E nglish Real Appl ications MICROMASTER Applications Handbook 37 7.2.2 Sy stem Specifications Motor 4 pole 11 kW 420 V 3-phase induc tion m otor Control Syst em Closed lo op PI s ystem Sensor 4 –20 m A flow rate s ensor Drive MICROM ASTER 11 kW 40 0 V Factory Fum e bur ner system 11kW fan and m ot or Heat ers 11kW MIDIMA STER Flow ...
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Real Appl ications Interna tiona l Englis h 38 MICROMASTER Applications Handbook 7.2.3 Key Parameter Detail s Table 7-2 Fan Application with Closed Loop Control Number Value Meaning P1000 1 Digital s et point preset i n MIDIM ASTER. Manual adju stment not norma lly required. P1040 20 Nominal setpoint P0003 3 Allows all parameters to b e adjuste d a ...
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Internatio nal E nglish Real Appl ications MICROMASTER Applications Handbook 39 7.3 Control ling Lift Door Operation Lift doors need to c lose at v arying sp eeds. Start ing slow ly, acceler ating fast and slowing a gain as the y appr oach closur e. In this case, the d oors are held clos ed by the motor running at low f requenc y at zero spe ed. Th ...
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Real Appl ications Interna tiona l Englis h 40 MICROMASTER Applications Handbook 7.3.3 Key Parameter Detail s Note. Careful s electio n of the in puts is needed to ensure the corr ect com bination of forward a nd revers e frequ encies is poss ible. Table 7-3 Ke y Parameters. Lift Door Operation Number Value Meaning P1000 3 Fixed Frequencie s select ...
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Internatio nal E nglish Real Appl ications MICROMASTER Applications Handbook 41 7.4 A Conveyor Application using several MICROMA STERs MICROMAST ERs are used to c ontrol shor t con veyors. Eac h conv eyor is use d as a holding point while prod ucts are sorted. T he produc ts are m oved f orward b y rapid ac celeratio n of th e conve yors under c om ...
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Real Appl ications Interna tiona l Englis h 42 MICROMASTER Applications Handbook 7.4.4 Key Parameter Settin gs Table 7-4 Ke y Parameters. Conve y o r Application Number Value Meaning P1120 0.6 Ramp up P1121 0.6 Ramp dow n. Fast ramping possible w ith these sett ings P1000 003 Fixed frequen cy operatio n P0003 3 Allows all parameters to b e adjuste ...
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Internatio nal E nglish Real Appl ications MICROMASTER Applications Handbook 43 7.5 A M aterial Handling A pplicati on Severa l MICROM ASTERs are us ed to han dle sheets of lar ge, fragile pieces of mater ial. The s ystem is controlled by a Progr amm able Logic Co ntroller ( PLC) using the digital and analo gue i nputs. Rela ys are used to contr ol ...
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Real Appl ications Interna tiona l Englis h 44 MICROMASTER Applications Handbook 7.5.4 Key Parameter settin gs Table 7-5 Key Parameters. Material H andling Operation Number Value M eaning P1120 0.3 Ramp up P1121 0.3 Ramp dow n P0003 003 Allows all para meters to be ad justed an d set. P1082 100 Maximum O utput Frequency. This w ide speed range is p ...
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Internatio nal E nglish Real Appl ications MICROMASTER Applications Handbook 45 7.6 A n Exercise M achine A pplication A runnin g m achine uses a vari able spe ed drive t o contr ol the run ning b elt spee d from a slow walk to a f ast run. 7.6.1 A d vantages · Excell ent low s peed torque ensures sm ooth operatio n even at low belt s peeds with a ...
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Real Appl ications Interna tiona l Englis h 46 MICROMASTER Applications Handbook 7.6.4 Key Parameter Settin gs Table 7-6 Key Parameters. An Exercis e Machine Operation Number Value Meaning P0003 003 Allows all para meters to b e adjusted an d set. P1080 3 Minimum O utput Frequency P1082 83 Max imum Output Frequency P2000 83 Frequency Refer ence for ...
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Internatio nal E nglish Advance d App licatio ns MICROMASTER Applications Handbook 47 8 A d vanced Applicatio ns Information 8.1 Usi ng Closed Loop Control 8.1.1 What is Closed Loop Control? Closed lo op contr ol is widely use d in indus trial app licat ions to co ntrol a bro ad variet y of proces ses. Con trol eng ineering is a com plex s ubject, ...
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Advance d App licatio ns Intern ationa l Eng lish 48 MICROMASTER Applications Handbook Setpoint P2260 KK Setpoint Source P2253 KK Feedback Source P2264 Kp Tn P Gain P2280 I Gain P2285 x y r2294 PID Output PID in upper limit/lower limit P53.10/P53.11 + PID Output UpperLimit P2291 PID Output Lower Limit P2292 P2293 Accel/Decel time of PID limits Ramp ...
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Internatio nal E nglish Advance d App licatio ns MICROMASTER Applications Handbook 49 · Start with the PID ga ins sti ll on their f actor y settings - P gai n =1, no integr al or diff erential acti on. · Select f ast ram p up and do wn times as other wise these will lim it close d loop perform ance. · Make s ure the scalin g para meter s match t ...
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Advance d App licatio ns Intern ationa l Eng lish 50 MICROMASTER Applications Handbook 8.2.2 Braking and Stopping with an Inv erter Ramping Down and Braking As stated above, if the inve rter reduc es the o utput fr equency (i.e. Ram ps do wn) the motor and load wil l slow d own. If the load and motor inertia is high, reg eneratio n will occur . In ...
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Internatio nal E nglish Advance d App licatio ns MICROMASTER Applications Handbook 51 corres ponds to a p ercentag e of the ful l load cur rent in t he motor. In practice i t is not poss ible to calc ulate th e brak ing torque this will produce. Continuous use of the DC brak ing wil l cause o verheating in the m otor an d suita ble protec tion s ys ...
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Advance d App licatio ns Intern ationa l Eng lish 52 MICROMASTER Applications Handbook · Param eters can be s et up and c hanged via the i nterface. · Perform ance can be cont inuousl y monitore d and con trolled. 8.4 Using PROFIBUS 8.4.1 What is PROFIBUS? PROFIBU S is an open stan dard comm unication protoc ol which has been designe d and devel ...
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Internatio nal E nglish Advance d App licatio ns MICROMASTER Applications Handbook 53 8.5 V ector and FCC Control 8.5.1 What is a Vector Driv e? Vector c ontrol is a com plex m athematic al control f unction th at im proves the perform ance of an AC drive . It is nec essar y to understa nd conve ntional Voltage to frequenc y control and Flux curren ...
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Advance d App licatio ns Intern ationa l Eng lish 54 MICROMASTER Applications Handbook Vector co ntrol is best und erstood b y consider ing the operatio n of a D C mac hine. A DC mac hine consists of a fi eld windi ng and ar matur e winding. T heref ore the arm ature Current (T orque) and f ield curren t (Flux) can be contr olled independ ently. In ...
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Internatio nal E nglish Advance d App licatio ns MICROMASTER Applications Handbook 55 At low spe eds it is very diffic ult to predic t the m otor perform ance and th e hence th e rotor posi tion. Si em ens standard vector drives use a com plex m athem atical system , first deve loped for their e ngineered drives, which gi ves ver y good Sensor less ...
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Advance d App licatio ns Intern ationa l Eng lish 56 MICROMASTER Applications Handbook ...
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Internat ional E nglish Option s MICROMASTER Applications Handbook 57 9 Options for Siemen s S t and ard Dri v es 9.1 Introduction Severa l options are av ailable f or use with Siem ens Standar d drives ; som e are described belo w. These ar e inten ded to ass ist produc t selec tion, inst allation and comm issioning in cert ain appl ications. 9.2 ...
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Options Internat ional Eng lish 58 MICROMASTER Applications Handbook 9.3 Braking M odules and Braking Resistors During rege neratio n (see s ection 8.2 .2) it ma y be n ecessa ry to dissip ate the energ y that is retur ned to th e invert er. MICRO MASTE R MM420 units do not have the capab ility to dis sipate r egenerate d energ y. Som e Siemens inv ...
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Internat ional E nglish Append ix A MICROMASTER Applications Handbook 59 A Environment al Protection L evels (IP rating) Table A-1 gives t he def initions of DIN40050, BS EN 60529 an d IEC529. T hese refer to the IP num bers and the dif ferent le vels of protec tion availab le. Table A-1 Protection levels (IP Rat ing) FIRST NUMBER 0 No prot ecti on ...
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Append ix A Interna tiona l Englis h 60 MICROMASTER Applications Handbook SECOND NUMBER 0 No prot ecti on No speci al prot ection. 1 Prot ecti on against wat er drippi ng vert icall y W ater drops fal ling vert icall y must not have any harmful effec t. 2 Prot ecti on against wat er drippi ng non-ver tical ly W ater drops fai ling at any angl e up ...
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Internat ional E nglish Append ix B MICROMASTER Applications Handbook 61 B Some Useful F ormulae B.1 T orque and Power Rel ationships If the stead y state t orque is k nown, the power require ment c an be calcu lated: Power [kW ] = (Tor que [Nm] X Spe ed [rev/m in])/ 9550 or Torque [Nm ] = (9550 X Po wer [kW ])/ Speed [r ev/min] Acceler ation T orq ...
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Append ix B Interna tiona l Englis h 62 MICROMASTER Applications Handbook Moment of Inertia The load m om ent of inertia can be ref erred to t he motor shaft J*lo ad = Jloa d/ I 2 or J*lo ad = Jloa d. (Nlo ad) 2 / (Nm otor) 2 Output Power Output Po wer = (Inpu t Power ) X (Gear box eff iciency) Output Torque Output Tor que = (I nput T orque) X (G e ...
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Internatio nal E nglish Index MICROMASTER Applications Handbook 63 Index A Accel eration 1 5 Advance d App licatio ns closed loop contr ol 47 Advance d Opera tor Pan el benefits 57 B Brak ing 15 brak ing modules 58 compound br aking 51 DC brak ing 50 described 50 regenerati on 50 Brak ing Modules 58 Brak ing Resistor s 58 C Cable Capac itance chok ...
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Index Inter nationa l Englis h 64 MICROMASTER Applications Handbook Protect ion Featur es current l imit 24 I2t protec tion 24 internal o vertem perature 24 Overvolt age 24 ptc resi stors 24 Pulse W idth Modulat ion described 4 S Sensor less Vect or Control 54 Serial I nterface Installat ion 51 USS protoco l 51 Serial Link PROFIBU S 52 PROFIBU S 52 ...
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MICROMASTER Applications Handbook 65 Suggestions and/or Corrections To: Technical Documentati on Manager Siemens Au tomation & Inv erters Suggestions Correctio ns Siemens plc Automation & Inverter s Varey Road, Congl eton, CW12 1PH For Pub lication/M anual: MICROMASTER App lic ati ons Handbo ok Fax: +4 4 (0)1260 283603 Em ail: Technica l.do ...
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66 MICROMASTER Applications Handbook ...
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