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Siemens SINUMERIK 840D sl Ctrl-Energy System Manual
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Siemens SINUMERIK 840D sl Ctrl-Energy System Manual

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See also: Operation and Programming Manual , Diagnostic Manual
SINUMERIK
SINUMERIK 840D sl / 828D
Ctrl-Energy
System Manual
Valid for
Control system
SINUMERIK 840D sl / 840DE sl / 828D
Software
CNC Software
01/2015
6FC5397-0EP40-5BA2
Version
4.7 SP1
Preface
Fundamental safety
instructions
Introduction
Ctrl-E Analysis
Ctrl-E Profiles
Reactive power
compensation
Flux reduction
User know-how
Appendix
1
2
3
4
5
6
7
A

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Summary of Contents for Siemens SINUMERIK 840D sl Ctrl-Energy

  • Page 1 Preface Fundamental safety instructions Introduction SINUMERIK Ctrl-E Analysis SINUMERIK 840D sl / 828D Ctrl-Energy Ctrl-E Profiles Reactive power compensation System Manual Flux reduction User know-how Appendix Valid for Control system SINUMERIK 840D sl / 840DE sl / 828D Software Version CNC Software 4.7 SP1 01/2015...
  • Page 2 Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.

  • Page 3: Preface

    Training For information about the range of training courses, refer under: ● www.siemens.com/sitrain SITRAIN - Siemens training for products, systems and solutions in automation technology ● www.siemens.com/sinutrain SinuTrain - training software for SINUMERIK FAQs You can find Frequently Asked Questions in the Service&Support pages under Product Support.
  • Page 4 Preface SINUMERIK You can find information on SINUMERIK under the following link: www.siemens.com/sinumerik Hotline and Internet address Technical Support You will find telephone numbers for other countries for technical support in the Internet under http://www.siemens.com/automation/service&support EC Declaration of Conformity The EC Declaration of Conformity for the EMC Directive can be found on the Internet at: http://support.automation.siemens.com/WW/view/de/10805517/134200...

  • Page 5: Table Of Contents

    Table of contents Preface.................................3 Fundamental safety instructions........................7 General safety instructions.......................7 Industrial security........................7 Introduction..............................9 Ctrl-E Analysis............................11 SENTRON PAC3200/4200....................12 3.1.1 Hardware..........................12 3.1.2 Commissioning the Power Monitoring Device................13 3.1.3 Commissioning the PAC PROFIBUS expansion module (840D sl)........14 3.1.4 Commissioning the expansion module PAC PROFINET (828D)...........15 Commissioning the PLC for SENTRON PAC................15 3.2.1 SINUMERIK 840D sl......................15...
  • Page 6 Table of contents Reactive power compensation........................53 Flux reduction.............................55 User know-how............................57 Commissioning user screen forms..................57 Appendix..............................59 Overview..........................59 Index................................61 Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2...

  • Page 7: Fundamental Safety Instructions

    Siemens recommends strongly that you regularly check for product updates. For the secure operation of Siemens products and solutions, it is necessary to take suitable preventive action (e.g. cell protection concept) and integrate each component into a holistic, state-of-the-art industrial security concept.
  • Page 8 ● Keep the software up to date. You will find relevant information and newsletters at this address (http:// support.automation.siemens.com). ● Incorporate the automation and drive components into a holistic, state-of-the-art industrial security concept for the installation or machine. You will find further information at this address (http://www.siemens.com/...

  • Page 9: Introduction

    The topics of energy efficiency and energy saving are also playing an increasingly important role in the machine tool environment. With SINUMERIK Ctrl-Energy, Siemens is offering an extensive range of components, functions, software tools and services to increase the efficiency of machine tools.
  • Page 10 Introduction Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2...

  • Page 11: Ctrl-E Analysis

    Ctrl-E Analysis In order to sensitize users to the topic of energy efficiency, the power and energy data of the machine are first acquired. Acquiring and evaluating energy consumption A control system with SINUMERIK Operate without a connected measuring instrument determines the power directly from the drives and displays this.

  • Page 12: Sentron Pac3200/4200

    Short circuit the secondary current terminals of the current transformer before removing this device. The safety information for the current transformers used must be carefully followed. Selection example Catalog, Siemens LV 1/Accessories and spare parts: Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2...

  • Page 13: Commissioning The Power Monitoring Device

    Ctrl-E Analysis 3.1 SENTRON PAC3200/4200 For a three-phase measurement according to connection type 3P4W (four conductors, unbalanced load, without voltage transformers, with three current transformers), accuracy class 1, primary rated current 100 A, secondary rated current 1A, three window-type transformers are recommended (4NC5117-0CC20). Note When measuring the complete machine, it is recommended that the current is sensed directly after the main switch.

  • Page 14: Commissioning The Pac Profibus Expansion Module (840D Sl)

    Ctrl-E Analysis 3.1 SENTRON PAC3200/4200 Parameterizing SENTRON PAC You have the option of parameterizing the measuring device in the following ways: ● Using the input keys and display of the SENTRON PAC ● Using a PC connected to the SENTRON PAC, which has the software this has been supplied (powerconfig).

  • Page 15: Commissioning The Expansion Module Pac Profinet (828D)

    Ctrl-E Analysis 3.2 Commissioning the PLC for SENTRON PAC 3.1.4 Commissioning the expansion module PAC PROFINET (828D) To communicate via PROFINET, the SENTRON SWITCHED ETHERNET PROFINET module in combination with Sentron PAC3200/4200 must be parameterized differently. 1. Select SENTRON PAC "Settings" > "SWITCHED ETHERNET". - OR - Select SENTRON PAC "Settings"...
  • Page 16 Ctrl-E Analysis 3.2 Commissioning the PLC for SENTRON PAC Preconditions ● Configure the hardware, save and compile the project ● Generating the system data for the PLC ● Install the Toolbox software, which also contains the libraries for the PLC basic program of an NCU 7x0.3.
  • Page 17 Ctrl-E Analysis 3.2 Commissioning the PLC for SENTRON PAC 4. Copy the sources, modules and symbols to the PLC program Figure 3-1 Hardware catalog after incorporating the GSD file Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2...
  • Page 18 Ctrl-E Analysis 3.2 Commissioning the PLC for SENTRON PAC 5. In HW Config, drag the selected module to the Profibus DP master system. 6. In the hardware catalog, open the required module and assign the subslots as shown in the diagram. Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2...

  • Page 19: Commissioning The Plc With Profinet

    ● Configure the hardware, save and compile the project ● Generating the system data for the PLC ● Install the Toolbox software, which also contains the libraries for the PLC basic program of an NCU 7x0.3PN. ● GSDML for PAC PROFINET http://support.automation.siemens.com/WW/view/de/50186868 Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2...
  • Page 20 Ctrl-E Analysis 3.2 Commissioning the PLC for SENTRON PAC Procedure You are on the main screen of the SIMATIC Manager. 1. Select the "File" > "Open" menu and then click on the "Libraries" tab. 2. Select the library for the PLC basic program "bp7x0_46" and confirm the dialog with "OK". 3.
  • Page 21 Ctrl-E Analysis 3.2 Commissioning the PLC for SENTRON PAC 5. In HW Config, drag the selected module to the Profinet IO system. 6. In the hardware catalog, open the required module and assign the subslots as shown in the diagram. Note Port interconnection To simplify commissioning, in HW Config configure the PAC PROFINET using port...

  • Page 22: Sinumerik 828D

    Ctrl-E Analysis 3.2 Commissioning the PLC for SENTRON PAC References Additional information about commissioning the PLC can be found in the following references: CNC Commissioning Manual: NCK, PLC, drive / SINUMERIK 840D sl 3.2.2 SINUMERIK 828D The PLC of the 828D has a fixed PLC I/O image. Using the general machine data MD12986[...], the possible peripheral connections (addresses) are activated or deactivated.

  • Page 23: Commissioning The Plc For Ctrl-E Analysis

    Ctrl-E Analysis 3.3 Commissioning the PLC for Ctrl-E Analysis For example, you activate the logical input address 132 by changing the machine data MD[...] with entry 132 to -1. ● SENTRON PAC3200 I address 144 ... 147 Total active power (value saved from SENTRON PAC) 148 ...
  • Page 24 Ctrl-E Analysis 3.3 Commissioning the PLC for Ctrl-E Analysis DB1001 Signal Meaning Identifier Format direction Name: SentronPac DB1001.DBX0.2 PLC -> HMI Imported active ener‐ FeedInEnergyReadSP BOOL gy is read from SEN‐ TRON PAC DB1001.DBX0.3 PLC -> HMI Exported active ener‐ FeedBackEnergyReadSP BOOL gy is read from SEN‐...
  • Page 25 Ctrl-E Analysis 3.3 Commissioning the PLC for Ctrl-E Analysis DB1001 Signal Meaning Identifier Format direction Name: SentronPac DB1001.DBD48 GP -> HMI Imported active ener‐ ActiveEnergyMonth REAL gy in kWh month to DB1001.DBD52 GP -> HMI Exported active ener‐ ReactiveEnergyMonth REAL gy in kWh month to DB1001.DBD56 GP ->...
  • Page 26 Ctrl-E Analysis 3.3 Commissioning the PLC for Ctrl-E Analysis Auxiliary system Start of the data structure End of the data structure Auxiliary system 7 (n=240) DB1001.DBB340 DB1001.DBB379 Auxiliary system 8 (n=280) DB1001.DBB380 DB1001.DBB419 Auxiliary system 9 (n=320) DB1001.DBB420 DB1001.DBB459 Auxiliary system 10 (n=360) DB1001.DBB460 DB1001.DBB499 DB1001...

  • Page 27: Plc User Program For Sinumerik 840D Sl Programming

    Ctrl-E Analysis 3.3 Commissioning the PLC for Ctrl-E Analysis DB1001 Signal Meaning Identifier Format direction Name: SentronPac DB1001.DBD(124+n) GP -> Active energy drawn by ActiveEnAuxMeasOFF REAL the auxiliary system at the measurement end in DB1001.DBD(128+n) GP -> Active energy supplied by ReActiveEnAuxMeasOFF REAL the auxiliary system at...
  • Page 28 Ctrl-E Analysis 3.3 Commissioning the PLC for Ctrl-E Analysis ● If the control bits DB1001.DBX0.2 and DBX0.3 are equal to 0, then the HMI counts the energy on the basis of the total active power transferred from the SENTRON between the start and stop.

  • Page 29: Configuring The Display Of Energy Consumption For Sinumerik 828D

    Ctrl-E Analysis 3.3 Commissioning the PLC for Ctrl-E Analysis The behavior for different signal sequences of both measurement control signals are described in the following: ● DBX1.0 is set first If DBX1.0 ("MeasAuto") is first set, and then remains statically present, every 0-1 edge of DBX2.0 ("MeasAct") deletes the measured value and then starts the measurement.
  • Page 30 Ctrl-E Analysis 3.3 Commissioning the PLC for Ctrl-E Analysis Data block DB9907 Signal Meaning Symbol Format direction Name: Sentron‐ DB9907.DBX0.0 PLC -> HMI Display manual value ManualVal BOOL DB9907.DBX0.1 PLC -> HMI SENTRON PAC rep‐ SentronPacMach BOOL resents the complete machine DB9907.DBX0.2 PLC ->...
  • Page 31 Ctrl-E Analysis 3.3 Commissioning the PLC for Ctrl-E Analysis DB9907 Signal Meaning Symbol Format direction Name: Sentron‐ DB9907.DBD36 FW -> HMI Exported active ener‐ ReactiveEnergyDay REAL gy in kWh current day to HMI DB9907.DBD40 FW -> HMI Imported active ener‐ ActiveEnergyPrevDay REAL gy in kWh previous...
  • Page 32 Ctrl-E Analysis 3.3 Commissioning the PLC for Ctrl-E Analysis Data block for auxiliary systems Up to 10 auxiliary systems are supported by the data block. A data structure is defined for each auxiliary system. In order to display the energy/power of an auxiliary system in the HMI, bit 0 of the first byte of the data structure must be set.

  • Page 33: Programming The Plc User Program For Sinumerik 828D

    Ctrl-E Analysis 3.3 Commissioning the PLC for Ctrl-E Analysis DB9907 Signal Meaning Identifier Format direction Name: SentronPac DB9907.DBD(116+n) FW -> Active energy drawn by ActiveEnAuxMeasON REAL the auxiliary system at the measurement start in DB9907.DBD(120+n) FW -> Active energy supplied by ReActiveEnAuxMeasON REAL the auxiliary system at...
  • Page 34 Ctrl-E Analysis 3.3 Commissioning the PLC for Ctrl-E Analysis Programming the PLC user program ● You take the total active power from the input address and transfer the value to DB9907.DBD20. This must be realized according to the following point "Adapt byte sequence".
  • Page 35 Ctrl-E Analysis 3.3 Commissioning the PLC for Ctrl-E Analysis Example for SINUMERIK 828D with SENTRON PAC3200 Swap over the byte sequence of the total active power in ID144: For the total active power, the numerical value of 18.4 is supplied from SENTRON. This corresponds to a hexadecimal value of 0x41933334, which is located just like this in the double word ID144.
  • Page 36 Ctrl-E Analysis 3.3 Commissioning the PLC for Ctrl-E Analysis Measurement control HMI → FW and PLC → FW ● With a 1 signal of the control bit "MeasAuto" (DBX1.0), the user requests that the firmware makes the measurement. If this bit is not set, then the user is responsible for calculating and writing the measured values.

  • Page 37: Commissioning The Hmi For Ctrl-E Analysis

    Text length (number of characters) lines Number of lines Procedure 1. Copy the "slnrgauxunits_deu.ts" template file from the directory: siemens/sinumerik/ hmi/template/lng. 2. Save the file to the /oem/sinumerik/hmi/lng or /user/sinumerik/hmi/lng directory. 3. If required, change the file name. If you wish to create texts for additional languages, then a separate file must be created for each language.

  • Page 38: Long Time Measurement

    Ctrl-E Analysis 3.6 Power display in the status line of the "Machine" operating area Long time measurement In order that you can read the usage values in the Ctrl-Energy initial window and in the "Long time measurement" window, program the PLC user program as specified in Chapter 2.3.1.1 (840D sl) or 2.3.2.1 (828D).

  • Page 39: Ctrl-E Profiles

    Ctrl-E Profiles To optimize the energy consumption, you have the option of defining energy saving profiles and saving them. Controlling the energy-saving states of the machine The following pre-defined energy-saving profiles are available when the system is delivered: ● Simple energy-saving mode (machine standby) A specific interface signal is initiated if the control has not exited the reset state after a defined time.

  • Page 40: Automatic State Machine Plc Functions

    Ctrl-E Profiles 4.1 Commissioning the PLC for Ctrl-E Profiles SINUMERIK 840D sl In SINUMERIK 840D sl, "Ctrl+Energy" is integrated in the basic program (FB15). Data for each energy-saving profile is saved in DB1000, which is supplied with the Toolbox. SINUMERIK 828D In SINUMERIK 828D, "Ctrl+Energy"...
  • Page 41 Ctrl-E Profiles 4.1 Commissioning the PLC for Ctrl-E Profiles An energy-saving profile runs through the displayed automatic state machine if the associated "energy-saving profile initialized" bit is set. The HMI resets this bit before changing the times or the signal mask, and sets it after the values have been consistently written into the PLC. When the "Energy-saving profile active"...

  • Page 42: Checking The Energy-Saving States

    Ctrl-E Profiles 4.1 Commissioning the PLC for Ctrl-E Profiles Transition to "OFF" DBX 10.1 == 1 ("deactivate profile") or delete the profile: highest priority and independent of the profile initialization - OR - 0-1 edge at the DBX 10.0 ("profile is initialized") - OR - At least one of the signals that have been enabled for evaluation using the following masking bits, is inactive (also see Chapter 3.1.5.2.):...

  • Page 43: Plc User Program

    Ctrl-E Profiles 4.1 Commissioning the PLC for Ctrl-E Profiles Signal Function Data transfer active This signal is set if data is being transferred. After completion of the data transfer, the HMI resets this bit. This includes the use of a USB memory medium, a V24 connection or a (state condition "No communi‐...

  • Page 44: Interface Signals 840D Sl

    Ctrl-E Profiles 4.1 Commissioning the PLC for Ctrl-E Profiles Signal Function Feedback signal, "prewarning This signal is set by the basic PLC program (FB15) if the timer has expired and the pre‐ time T expired" warning is output on the HMI. Feedback signal, "prewarning This signal is set by the basic PLC program (FB15) if, after the prewarning limit has been time T...

  • Page 45: Signals For Parameterization

    Ctrl-E Profiles 4.1 Commissioning the PLC for Ctrl-E Profiles Status signals DB1000 DBX4.0 Energy-saving profile is active DBX4.1 Prewarning limit T1 reached Actual values DB1000 DBW6 Actual value T DBW8 Actual value T 4.1.5.2 Signals for parameterization Retentive parameterization data. Effectiveness (HMI →...

  • Page 46: Interface Signals 828D

    Ctrl-E Profiles 4.1 Commissioning the PLC for Ctrl-E Profiles Maximum times (HMI → PLC) DB1000 DBW 16 Activation time T DBW 18 Time for the prewarning limit T Additional profile instances DB1000 DBW 20 Energy-saving profile 2 DBW 40 Energy-saving profile 3 DBW 60 Energy-saving profile 4 DBW 80...

  • Page 47: Signals For Parameterization

    Ctrl-E Profiles 4.1 Commissioning the PLC for Ctrl-E Profiles Status signals DB9906 DBX4.0 Energy-saving profile is active DBX4.1 Prewarning limit T1 reached Actual values DB9906 DBW6 Actual value T DBW8 Actual value T 4.1.6.2 Signals for parameterization Retentive parameterization data. Effectiveness (HMI →...

  • Page 48: Creating And Editing Energy-Saving Profiles

    Ctrl-E Profiles 4.2 Creating and editing energy-saving profiles Additional instances DB9906 DBW20 Energy profile 2 DBW40 Energy profile 3 DBW60 Energy profile 4 DBW80 Energy profile 5 DBW100 Energy profile 6 DBW120 Energy profile 7 DBW140 Energy profile 8 Creating and editing energy-saving profiles You can make the following changes in the list of energy-saving profiles in the commissioning mode: ●...
  • Page 49 Ctrl-E Profiles 4.2 Creating and editing energy-saving profiles Energy conditions The following criteria are available for configuring an energy-saving profile: State conditions Meaning No key on the operator panel pressed To activate the energy-saving profile, it is not permis‐ sible that an operator panel key is pressed. No key on the machine control panel pressed To activate the energy-saving profile, it is not permis‐...
  • Page 50 Ctrl-E Profiles 4.2 Creating and editing energy-saving profiles Procedure Select the "Startup" operating area. Press the "HMI" and "Ctrl-Energy" softkeys. The window "SINUMERIK Ctrl-Energy: Definition of the energy-saving profile" is opened. Newly creating/changing energy profiles Position the cursor on the line where you wish to create a new energy- saving profile and press the "New"...
  • Page 51 The text files are saved under a fixed name. All of the defined energy- saving profiles are always exported. Note: Please note that the energy-saving profiles supplied from Siemens are also deleted. It is recommended that the energy-saving profiles are al‐ ways exported and backed up.
  • Page 52 Ctrl-E Profiles 4.2 Creating and editing energy-saving profiles Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2...

  • Page 53: Reactive Power Compensation

    Reactive power compensation The Active Line Modules of the SINAMICS S120 series offer the option of compensating capacitive or inductive reactive current. As standard, this function is used to compensate for the system's own modules. In addition, within a sensible scope, this feature can be used to compensate other (generally inductive) loads connected to machine.
  • Page 54 Reactive power compensation Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2...

  • Page 55: Flux Reduction

    Flux reduction In the drive parameters (p1581 [0..n]), the rated magnetization for induction motors – which is normally 100% – can be permanently reduced. This includes the switching times for reducing and building up the flux (r1578, r1579[0…n]). In this case, not only can the magnetizing losses in the motors be reduced at standstill, but also during operations that only require a lower power.
  • Page 56 Flux reduction Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2...

  • Page 57: User Know-How

    User know-how Machine manufacturers are being increasingly confronted with special demands from users regarding proving energy consumption data or displaying limit values, for example. Using SINUMERIK Integrate Run MyScreens (Easy Screen), it is possible to visualize the functions obtained from these requirements, and also position them in the context of Ctrl- Energy.
  • Page 58 User know-how 7.1 Commissioning user screen forms PRESS(VS4) LM("maske_xxx","xxx.com") END_PRESS 　 HS7=("Start YYY") PRESS(HS7) LM("maske_yyy","yyy.com") END_PRESS //END These start calls directly access the specified screen forms of the relevant *.com files. A start softkey in these particular *.com files can be omitted. ●...

  • Page 59: Appendix

    Appendix Overview Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2...
  • Page 60 Appendix A.1 Overview Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2...

  • Page 61: Index

    Index Commissioning HMI, 39 Configuring Energy-saving profiles, 48 Ctrl Energy Functions, 9 Energy consumption display in status line, 38 Energy-saving profiles, 39 Edit, 48 Hardware, 12 PLC functions, 40 PLC user program, 43 Power Monitoring Device Commissioning, 13 PROFIBUS Commissioning the PLC (840D sl), 15 SENTRON PAC3200/4200 Commissioning the PLC (840D sl), 15, 19 Parameterizing, 14...
  • Page 62 Index Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2...

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Sinumerik 828d ctrl-energy

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