HSPWM Converter...< communication with PC (e.g. USB port) < external ballast resistor, if applicable We recommend also to connect the digital input D-IN2 with a quick stop func‐

SD2S Setup InstructionsHSPWM ConverterTraining documentation

P-TD-0000173.32013-08-27

SIEB & MEYERW

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2 SD2S Setup Instructions - HSPWM Converter

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1 Overview ........................................................................... 5

2 Device Connection and Software Startup ......................... 72.1 Install Software ........................................................................................... 72.2 SD2S Connection and Switch-on ................................................................ 72.3 Start Software ............................................................................................. 7

3 Create Parameter Set ....................................................... 9

4 Controller Adjustment ...................................................... 114.1 Set Current Controller ............................................................................... 114.2 Set Startup Behavior ................................................................................. 144.3 Set Compensation Flux Measuring ........................................................... 164.4 Set Load Compensation ........................................................................... 174.5 Set Motor Flux Delay Time (Asynchronous Motor) ................................... 194.6 Check Running Performance .................................................................... 204.6.1 Test with Maximum Speed .................................................................................... 214.6.2 Test with Maximum Load ...................................................................................... 22

5 Troubleshooting .............................................................. 23

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SD2S Setup Instructions - HSPWM Converter 3

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1 OverviewThis brief instruction shall help you to operate your SD2S as HSPWM converter (highspeed PWM converter).

The following flow chart provides an overview about the initial operation of your SD2S.

Fig. 1: Initial operation SD2S

The following chapters describe the different steps in detail.

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2 Device Connection and SoftwareStartup

Read the according hardware and software documentation of your deviceand pay attention to the safety instructions.

2.1 Install Software➮ Install the latest version of the software drivemaster2 on your PC.

This is located in the download directory of the SIEB & MEYER web page underwww.sieb-meyer.de. (Please use the guest login.)

2.2 SD2S Connection and Switch-onThe following connectors must be wired at the least:< power supply (single-phase/three-phase)< motor phases (U, V, W, PE)< OSSD (safety circuit)

! connection without safety function:X10 (0362140xy - 0362143xy): bridge pin 1 and pin 3 to pin 6X43 (0362145xy - 0362148xy): bridge pin 1 and pin 3 to pin 5

< communication with PC (e.g. USB port)< external ballast resistor, if applicable

We recommend also to connect the digital input D-IN2 with a quick stop func‐tion.

➮ Switch on the device now.The device driver has been copied during the software installation. After switch-onthe driver for the SD2S is selected automatically by the operating system.With USB connection the driver installation may take some time. When the driverwas installed correctly, the Windows Device Manager displays it as "LibUsb-Win32SM2 TUSB3410".

2.3 Start Software➮ Start the software drivemaster2.➮ Select the option "Setup connection to the device" in the start screen and config‐

ure the type of communication.➮ Click on the button "Search devices + connect" to apply your selection.✔ The connected SD2S is found by the software and appears in the user interface

as online device.

According to the delivery status of the device there are the following possibilities now:1. The device was delivered with a complete parameter set (incl. controller adjust‐

ment).a) The preset project is uploaded from the device. The device is ready for opera‐

tion.2. The device was delivered without parameter set.

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http://www.sieb-meyer.de/downloads-144.html

a) The parameter set must be created according to the data sheet of the motormanufacturer. The controller parameters must be set.

b) An existing parameter set must be written into the device.

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3 Create Parameter SetIf the device was delivered without parameter set, the following window is displayed af‐ter the device search.

➮ Click on the button "Create a parameter set ...". A respective wizard will beopened. It takes you step-by-step through the parameter set creation.

➮ The basic drive is recognized automatically by the software. Select the drive func‐tion "High Speed PWM Converter" and enter the motor data from the data sheetprovided by the motor manufacturer.

➮ After you have finished the parameterization with the wizard, select the menu

"Loader ÿ Write parameters to drive" or the button . Then the parameters areloaded into the device.

If the firmware of you device is not suitable for the parameterization, a re‐spective message will pop up. In this case update the firmware as describedin the dialog window.

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4 Controller AdjustmentThe following sections describe, how to set the current controller, the flux controllerand the compensation of load and of flux measuring.

For this purpose the tools drive-setup-tool and Oscar are available. Both can be startedvia the user interface.

Activate drive setup

➮ In order to control the drive via the drive-setup-tool , click the button "Drive SetupActive" and confirm the following inquiry with "OK".

4.1 Set Current ControllerThe current controller is adjusted online via the drive-setup-tool. The following parame‐ters are changed:< Amplification: Kp< Integration time: Ti

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Settings in the Oscar

➮ Select the menu "File ÿ Load settings" and open the file "HSPWM_CurrentCon‐troller.ocf". (This is to find in the installation directory of drivemaster2 under"SM_Ini".) Thus the trigger parameters in the Oscar are set for the test.

➮ Enter the trigger condition manually (half the rated motor current).

The trigger condition value must be greater than the magnetic alignment cur‐rent (motor measuring system). Otherwise the record starts immediately.

➮ Click on the button "Normal mode" to activate the trigger. Thus a record is startedon each operating start via the drive-setup-tool

Settings in the drive-setup-tool

➮ Switch to the tab page "Current controller" and select the function "Current - abso‐lute values".

➮ Set the parameter "Demand current" to the maximum rated current of the motor.(Increase the value until the maximum possible value is reached.)

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Controller adjustment

➮ In order to start the test click first on the button "Enable Operation " and then acti‐vate the button "Start" for a short time (max. 2 seconds). A second click on "Start"stops the operation.

➮ Examine the curve recorded in the Oscar.

➮ Now optimize the parameters of the current controller until the actual current fol‐lows the reference current as closely as possible.

Step 1: Kp value! Increase the amplification Kp (e.g. + 50 %) until the actual current overshoots

a little. (overshoot = the actual current exceeds its final value at first and thendrops down to it)

! Reduce Kp just to the value until the actual current does not overshoot any‐more. By now you have set the amplification Kp correctly.

Step 2: Ti value! Reduce the integration time Ti (e.g. - 50 %) until the actual current overshoots

a little.



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! Increase Ti just to the value until the actual current does not overshoot any‐more. Thus also the integration time Ti is set correctly. In the following figurethe values Kp and Ti are OK (no overshoot).

The current should be controlled after 0.5 ms.

➮ Load the new values for Kp und Ti to the drive via the button in the drive-set‐up-tool.

4.2 Set Startup BehaviorPay attention to the startup instructions of the motor manufacturer, if existent.


➮ Select the menu "File ÿ Load settings" and open the file "HSPWM_Profile.ocf".Thus the trigger parameters in the Oscar are set for the test.



➮ Switch to the tab page "Velocity controller" and select the function "Velocity - ab‐solute values".

➮ Check the values of the acceleration and deceleration ramp.➮ Set the parameter "Max.Current" to the peak current of the motor. (Increase the

value until the maximum possible value is reached.)➮ Set the demand velocity to approx. the half maximum speed.


➮ Load the motor with the maximum load.➮ In order to start the test click first on the button "Enable Operation " and then acti‐

vate the button "Start". A second click on "Start" stops the operation.



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The following figure shows the curve recorded by the Oscar.

Set starting current! Increase the starting current until it is greater than the acceleration current.

The acceleration current and the starting current depend on the massmoment of inertia of the spindle.

If the spindle shall be operated with different tools later, you should usethe tool of the greatest mass inertia for the test. If you do not know whichtools are to be used, you must allow for sufficient reserves (e.g. startingcurrent = rated current of the spindle).

! In the following figure the starting current is set correctly.

Set start threshold! Move the mouse pointer in the Oscar to the crossing point of I-Flux-Ref (blue)

and I-Flux-Act (green). The value here indicates the start threshold of the fluxcontrol.



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! Enter the actual speed (rpm) of the crossing point in the drive-setup-tool ("Ve‐locity Controller ÿ Start Threshold Flux Control"). In the following figure thestarting current and the start threshold are set correctly.

➮ Upload the new values for starting current and start threshold of the flux control to

the drive via the button in the drive-setup-tool.

4.3 Set Compensation Flux MeasuringThe flux compensation is only required in the low speed range. Thus the SD2S con‐trols earlier, when the starting threshold is set very low.


➮ Select the menu "File ÿ Load settings" and open the file "HSPWM_FluxCompen‐sation.ocf". Thus the trigger parameters in the Oscar are set for the test.




➮ Set the parameter "Start Threshold Flux Control" to the half maximum speed.➮ Set the parameter "Max. Current" to the rated current of the motor at maximum.➮ Set the demand velocity to the half maximum speed.


➮ In order to start the test click first on the button "Enable Operation " and then acti‐vate the button "Start". A second click on "Start" stops the operation.



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The following figure shows the curve recorded by the Oscar.

➮ Read the speed values for activation, changeover and deactivation point. Enterthese values on the parameter page "Flux ref. value" in the diagram "Compensa‐tion flux measuring".

➮ Calculate the percentage value of the activation and the changeover point fromthe maximum measured flux current. Enter these values also in the diagram.

➮ Load the new parameters to the drive via the button in the software drivemas‐ter2.

4.4 Set Load CompensationSettings in the Oscar

➮ Select the menu "File ÿ Load settings" and open the file "HSPWM_Load‐Step.OCf". Thus the trigger parameters in the Oscar are set for the test.

➮ Enter the trigger condition manually. It should be somewhat greater than the no-load current.


➮ Switch to the tab page "Load Compensation" and select the function "Velocity -absolute values".


➮ Load the motor e.g. with the rated load of the application.



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➮ In order to start the test click first on the button "Enable Operation " and then acti‐vate the button "Start" in the drive-setup-tool. Switch to the Oscar and click on thebutton "Normal mode" to activate the trigger. Thus a record is started on each loadvariation (load step). A second click on "Start" in the drive-setup-tool stops the op‐eration.

The following record shows a motor with a correctly adjusted load compensation.

➮ Examine the curve recorded in the Oscar. If necessary, you can change the be‐havior for no-load operation and operation under load in the drive-setup-tool or inthe software drivemaster2 (parameter page "Flux ref. value"). For this purposeadapt the parameters "Max. flux current" and "Min. flux current" in the diagram"Load compensation" accordingly (the higher the flux current, the greater the per‐formance).

➮ Load the new parameters to the drive via the button .



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4.5 Set Motor Flux Delay Time (AsynchronousMotor)If the reference current of your asynchronous motor overshoots exceedingly, you canset the motor flux delay time in drivemaster2 software.


➮ Select the menu "File ÿ Load settings" and open the file "HSPWM_RotorTime‐Constant.OCf". Thus the trigger parameters in the Oscar are set for the test.


➮ Switch to the tab page "Flux controller" and select the function "Velocity - absolutevalues".

➮ Set the demand velocity to a low speed (approx. 20 % of the der idle-runningspeed).


➮ In order to start the test click first on the button "Enable Operation " and then acti‐vate the button "Start" in the drive-setup-tool. Switch to the Oscar and click on thebutton "Normal mode" to activate the trigger. A second click on "Start" in the drive-setup-tool stops the operation.The following figure shows the curve recorded by the Oscar.

! Measure the motor flux delay time between a wave of the I-Ref curve and thecorresponding wave of the I-Flux-Act curve. For this purpose set a measuringpoint on the peak of the I-Ref wave by means of the menu "View ÿ Set/clearmeasurement point" and drag the cursor to the peak of the I-Flux-Act wave.Then the motor flux delay time is displayed in the field "Cursor" in millisec‐onds.



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! Enter the measured value for the motor flux delay time in the drivemaster2software or in the drive-setup-tool. Upload the new parameter to the drive via

the button .

➮ Record a new curve in the Oscar. The curve should look similar to the one in thefollowing figure.

4.6 Check Running PerformanceSettings in the Oscar

➮ Select the menu "File ÿ Load settings" and open the file "HSPWM_Profile.ocf".Thus the trigger parameters in the Oscar are set for the test.




➮ Set the parameter "Max.Current" to the peak current of the motor. (Increase thevalue until the maximum possible value is reached.)

➮ Set the demand velocity to approx. the half maximum speed.

Oscar curve

➮ In order to start the test click first on the button "Enable Operation " and then acti‐vate the button "Start". A second click on "Start" stops the operation.



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The following record shows a motor with a correctly adjusted flux controller.

[1] [2] Preset starting and braking currentThe starting and braking current is not controlled but impressed. The startingcurrent is greater than the acceleration current.

[3] Reference speed reachedThe current decreases (control active). The reference flux (blue) and the ac‐tual flux (green) are upon each other.

[4] LoadThe current increases quickly, when load is applied. After the load is removedthe current is controlled quickly and without time delay.

[5] Start threshold flux controlThe start threshold is low. Thus the control is already active at low speeds.

[6] Actual flux current (green)

4.6.1 Test with Maximum Speed

➮ Now set the demand velocity to the maximum speed in the drive-setup-tool andstart a test.

➮ Make sure that the reference current does not overshoot exceedingly. If this is thecase you can optimize the reference flux and reference current filter on the page"Flux controller". (Base value 20 ms to 10 ms; the smaller the values, the fasterthe reference value is controlled, e.g.10 ms to 5 ms). Synchronous systems mustcontrol faster than asynchronous ones.

➮ Load the new parameters to the drive via the button in the software drivemas‐ter2.



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4.6.2 Test with Maximum LoadFinally you should check the drive system for trouble-free operation when maximumload is applied.

Therefore you must test your appliance under real conditions and in all relevant appli‐cation scenarios. These are for example:< minimum and maximum speed< various materials< sudden changes in speed

➮ At first test the start-up from standstill in order to exclude resonances. If resonan‐ces are present, the flux controller adjustment might not be accurate or there areproblems with the mechanics.

➮ Then accelerate and decelerate the appliance over the whole speed range insmall and big steps.

➮ At last test a complete execution cycle of the appliance. Pay attention to the I²t va‐lues of motor, output stage and ballast resistor. If one of these parameters takeson a value that is too high, you should rethink the dimensions of your system.



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5 TroubleshootingThe following problems may occur during initial operation:

Code Description Possible cause Remedy

– Direction of rotation of spindle/motoris wrong

Wiring of motor phases is faulty. Correct the wiring of motor phases(U, V, W) according to the datasheet.

Wiring of motor measuring system isfaulty.

Correct the wiring of the motor mea‐suring system according to the datasheet.

Software: Bit for direction of rotationis set wrong.

Change parameter "Direction of rota‐tion" (CW/CCW) in drivemaster2(parameter page "Speed controller").

Software: Digital input "Speed direc‐tion" is set.

Correct the digital input "Speed di‐rection".

Analog reference speed value iswrong.

Correct the analog reference speedvalue.

Software: The analog referencespeed value is inverted.

Analog reference speed value: Cor‐rect the parameter "Inverter" (Pa‐rameter page "Analog inputs")

E31 Speed error or slip too high (only forsynchronous motors)

Software: Settings of error E31 arewrong.

Adapt parameter "E31 - Shutdownthreshold" (parameter page "Errors")

Wiring of motor phases is faulty. Correct the wiring of motor phases(U, V, W) according to the datasheet.

Wiring of motor measuring system isfaulty.

Correct the wiring of the motor mea‐suring system according to the datasheet.

E34 Power supply load monitoring ->mains voltage too low

On switch-on SAFETY is on. Make sure that SAFETY is off beforeswitch-on of the device.

– Digital inputs/outputs are not work‐ing.

No voltage supply for the inputs/outputs.

Connect X15, pin 9 to 24 V.

– Analog outputs are not working. Analog outputs are overloaded. Make sure that the analog outputsare loaded with max. 1 mA.

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Documents

HSPWM Converter...< communication with PC (e.g. USB port) < external ballast resistor, if applicable We recommend also to connect the digital input D-IN2 with a quick stop func‐