SINUMERIK 840D sl. Service - Configuring Commissioning. Manual (2011-2020)

Tips for personnel changing over from another system

7.2 Migrating projects

Add from the hardware catalog the devices that belong to your migrated user program and

make the settings as in the STEP 7 V5.x project.

Note

Set the module addresses correctly before copying the tag table

If you copy the migrated tag table (see step 6) into the newly created NCU before you

correctly set the module addresses in the device properties, the "Tags in module" dialog is

displayed.

Do not click "Rewire tags with the new module address" in the dialog.

Otherwise, the tags are assigned incorrectly to the tag table and you must correct it

manually or recopy the tag table.

See also: Rewiring variables in the module (Page 112)

In the project tree, delete the "Main [OB1]" block under "CNC_x > PLC_x > program blocks".

Copy the migrated data from the not specified SIMATIC CPU into the newly created

SINUMERIK NCU:

- Copy the migrated blocks to the "Program blocks" folder of the newly created device.

- Copy the migrated tag tables to the newly created device.

- Copy the migrated PLC data types (UDT) to the "PLC data types" folder of the newly

created device.

- Copy the migrated technology objects (TO) to the "Technology objects" folder of the

newly created device.

Upgrade the PLC basic program by means of the master copies folder "840D sl PLC Basic

Program (upgrade)".

See: Upgrading the PLC basic program (Page 104)

Interconnect the devices and re-establish the connections.

See: Configuring of connections (Page 121)

Compile all the program blocks. If errors or warnings are issued during the compilation, help

is available in Section Troubleshooting (Page 107).

10.Check the migration log in the project tree under "Shared data > Logs" and systematically

work through the notes contained in the migration log.

Section "Troubleshooting (Page 107)" also provides help for frequently asked questions

concerning migrated SINUMERIK projects.

Result

The program blocks and symbols of the PLC have been migrated and assigned to the new

project in the TIA Portal.

If errors or warnings are issued during the migration, help is available in Section

Troubleshooting (Page 107).

The PLC data types (UDT) contained in the SINUMERIK basic program for STEP 7 V5.x are

transferred during the migration. The data blocks of the PLC basic program in the TIA Portal

(e.g. axis DBs), however, do not use them. (See: Using user-defined data types (UDT)

(Page 123))

SINUMERIK 840D sl STEP 7 Toolbox V16

102

Getting Started, 12/2019, 6FC5397-1GP40-0BA1

Tips for personnel changing over from another system

7.2 Migrating projects

You can now familiarize yourself with the TIA Portal when migrating from STEP 7 V5.x. Section

"Comparison of functionality (Page 114)", for example, is interesting for migration. It contains

information about the functionality and handling compared with STEP 7 V5.x.

7.2.4

Migrating software and hardware configurations

The general procedure for the migration with focus on the special considerations during the

migration of a SINUMERIK project follows.

General information about migration is contained under Migrating STEP 7 projects (S7-300,

S7-400) (help for the TIA Portal) or in the system manual STEP 7 Professional (https://

support.industry.siemens.com/cs/products?search=STEP

%207%20Professional&dtp=Manual) in the section on "Migrating projects".

Requirement

● The project to be migrated is upgraded to SINUMERIK 840D sl Toolbox 4.5 SP2 or higher

for STEP 7 V5.5 SP4 or higher.

● The project to be migrated contains only those modules supported in the TIA Portal.

Use the Readiness Check Tool to check whether the used modules are supported.

Alternative modules will be displayed if modules are not supported in the TIA Portal.

Readiness Check Tool (http://support.automation.siemens.com/WW/view/en/60162195 )

● FC1007, FC1008 and FC1010 are not contained in the project.

FC1007, FC1008 and FC1010 are no longer part of the basic program and cannot be

migrated. If these functions are contained in your user program, delete them and the

associated calls.

● The STEP 7 project to be migrated is consistent and can be executed.

If your project cannot be executed, you must correct it in STEP 7 V5.x before you migrate

it. You can check the consistency with SIMATIC Manager and restore by compiling the

blocks.

● All option packages used to create the project in STEP 7 V5.x are installed and licensed

(e.g. the option package for SCL).

Procedure overview

Ste

Description

Preparations of the starting project

● To keep the reworking effort low, you can adapt the project prior to the migration (Page 98).

● If STEP 7 V5.x and the TIA Portal are not installed on the same PG/PC or the starting project is an integrated project,

you must convert the starting project to a migration file using the migration tool.

See: Migration tool (help for the TIA Portal)

Migrating the project

You can import the complete project (hardware configuration, program blocks, PLC symbols) by activating the "Include

hardware configuration" checkbox.

See: Migration of projects with the TIA Portal (help for the TIA Portal)

SINUMERIK 840D sl STEP 7 Toolbox V16

Getting Started, 12/2019, 6FC5397-1GP40-0BA1

103

Tips for personnel changing over from another system

7.2 Migrating projects

Ste

Description

Upgrading the PLC basic program (Page 104)

If errors or warnings are issued during the compilation, help is available in Section Troubleshooting (Page 107).

Checking the migration log

● A migration log is created for each migration. It contains notes for changed project components. You can fetch the

migration log is displayed in the TIA Portal. Check the log after completion of the migration.

● If the migration failed, an XML file is created as log under "\Logs" in the project directory. You can open it with any

XML editor and view the causes for the failed migration.

Post-editing a migrated project

Because the configurations of the starting project are not always fully compatible with the TIA Portal, all configurations

are not necessarily transferred identically in the migrated project. Consequently, systematically work through the notes

contained in the migration log.

The "Problem solution (Page 107)" section contains help for frequently asked questions concerning migrated SINU-

MERIK projects.

Result

The project has been migrated to the TIA Portal.

You can now familiarize yourself with the TIA Portal when migrating from STEP 7 V5.x. Section

"Comparison of functionality (Page 114)", for example, is interesting for migration. It contains

information about the functionality and handling compared with STEP 7 V5.x.

Category

C1¹⁾

C2²⁾

C3³⁾

C4⁴⁾

Voltage, current

< 1,000 V

≥ 1,000 V

≥ 400 A

Line system

TN, TT

TN, TT, IT

Expert

No request

Installation and commissioning must be performed by

authorized personnel.

1) No products are on offer for category C1.

2) Drive systems installed by qualified personnel can be used in the first environment category C2 in

accordance with EMC product standard IEC 61800-3.

3) The drive systems described in this document with the associated filters in accordance with EMC

product standard IEC 61800-3 can be used in the second environment category C3.

4) To ensure the EMC in the category C4, it is necessary that the plant manufacturer and the plant

operators agree an EMC plan that specifies individual, plant-specific measures. If prescribed by

the product description, drive systems can also be used in non-grounded systems (IT systems) in

accordance with EMC product standard IEC 61800-3.

3.3

EMC-zone concept

Interference suppression measures within the plant or the control cabinet are easiest to

implement and most cost-effectively by installing interference sources and sinks physically

separated from each other. This separation must already be taken into consideration during

the planning.

First, it must be decided for each used device whether it is a potential interference source or

sink.

● Typical interference sources are, for example, frequency converters, braking modules*,

switched-mode power supplies, coils for contactors.

● Typical interference sinks are, for example, automation devices, encoders and sensors

as well as their evaluation electronics.

● The entire area of the plant or the control cabinet is then divided into EMC zones and the

devices assigned to the zones. The following example explains the zone concept in

greater detail.

* Depending on the device series, terms such as braking chopper, pulsed resistor module or

similar are also in use.

EMC installation guidelines / basic system requirements

Configuration Manual, (PH1), 01/2012, 6FC5297-0AD30-0BP3

Information on planning, design and installation

3.3 EMC-zone concept

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Zone A System connection

The limit values for the conducted interference emission and interference immunity must be

observed

Zone B Power electronics

Interference sources: Converters consisting of rectifiers, possibly braking choppers,

inverters and possibly motor-side reactors and filters

Zone C Controller and sensors

Interference sinks: Sensitive open-loop and closed-loop control electronics and sensors

Zone D Signal interfaces for the I/O

The limit values for the interference immunity must be observed

Zone E Motor and motor cable

Interference sources

Figure 3-1

Classification of the control cabinet or the drive system into EMC zones

EMC installation guidelines / basic system requirements

Configuration Manual, (PH1), 01/2012, 6FC5297-0AD30-0BP3

Information on planning, design and installation

3.4 Openings in the housing, e.g. ventilation openings

Specific requirements regarding the interference emission and the interference immunity

apply within each zone. The zones must be decoupled electromagnetically. This decoupling

can, for example, be achieved with large physical separations (approx. 20 cm). Better and

space-saving is decoupling using separate metal enclosures or large metal partitions.

Cables of different zones must be separated and must not be laid in shared cable harnesses

or cable ducts. Where necessary, filters and/or coupler blocks must be deployed at the zone

interfaces. Coupler blocks with electrical isolation can effectively prevent the interference

propagation between the zones.

All communication and signal cables that exit the control cabinet must be shielded.

Additional isolation amplifiers must be used for longer analog signal cables.

3.4

Openings in the housing, e.g. ventilation openings

Ventilation holes, inspection windows, operator controls, etc., impair the shielding effect of

the control cabinet. Each opening half the size of the wavelength λ of the interference

frequency acts as an antenna and radiates electromagnetic fields. In practice, the slit lengths

should be less than λ/20. The following openings have proven themselves:

● In the first environment, openings with a maximum diameter of 30 mm

● In the second environment, openings with a maximum diameter of 100 mm

Openings with a diameter larger than 100 mm must be covered with a metal hood. It must

have a good metallic-conducting contact with the cabinet panel.

3.5

Equipotential bonding

To ensure the problem-free interaction of the components in a complex system, a good

equipotential bonding is necessary that acts effectively for technical frequencies and high

frequencies in the area above 10 MHz.

To achieve this, all metallic parts must have a large surface-area contact with each other and

so form an equipotential area.

This also prevents shields applied on both sides from being damaged or burnt due to high

equalizing currents or components from being subjected to interference, damaged or

destroyed because of an excessive voltage difference.

Signal cables to stations outside this equipotential area must be equipped with electrically-

isolating coupling blocks.

EMC installation guidelines / basic system requirements

Configuration Manual, (PH1), 01/2012, 6FC5297-0AD30-0BP3

Information on planning, design and installation

3.5 Equipotential bonding

3.5.1

Equipotential bonding within a control cabinet

The equipotential bonding within a control-cabinet is achieved by connecting all metallic

parts to one another at as many positions as possible over a large area, such as control-

cabinet panels or stays. Cabinet doors should be connected to the stays or side panels with

the shortest-possible copper ribbons at least at the top and bottom. The housing of the

devices and components installed in the cabinet element (e.g. converters, line filters, control

units, terminal modules, sensor modules, etc.) must be connected with each other using a

good-conducting (galvanized) mounting plate over a large surface area.

This mounting plate must have a large surface area electrically-conductive connection with

the cabinet frame, PE or shield buses of the cabinet element.

Painted control-cabinet panels, mounting plates or mounting equipment with a small

mounting footprint do not fully satisfy this requirement. If painted control-cabinet panels or

mounting plates need to be used, an adequately-good contact must be ensured. To do this,

the cable glands must be freed of paint during the installation or contact washers used.

Corrosion protection is necessary, e.g. painting after installation.

If several mounting plates are connected with each other using cables or ribbon wires, the

connection must be made close to the signal or power cable (minimization of the enclosed

area).

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Example for the optimum connection of mounting

Example for an unfavorable connection of

plates

mounting plates

The larger surface area of ribbon connections makes them more favorable than round

connections with regard to EMC.

EMC installation guidelines / basic system requirements

Configuration Manual, (PH1), 01/2012, 6FC5297-0AD30-0BP3

Information on planning, design and installation

3.5 Equipotential bonding

Figure 3-2

Example for the connection with braided-copper ribbon

3.5.2

Equipotential bonding between several cabinet elements

The equipotential bonding between several cabinet elements for larger cabinet units is made

with an interconnecting PE bar that passes through all these cabinet elements. In addition,

the frames of the individual cabinet elements are screwed together several times with good

conductivity ensured through the use of contact washers. If very long rows of cabinets are

installed back-to-back, the two PE bars must be connected with each as often as possible

(recommended value: ten screw connections per cabinet element).

3.5.3

Equipotential bonding inside the machine/plant

The equipotential bonding within the machine/plant for technical frequencies is made by

connecting all the electrical and mechanical drive components (transformer, control cabinet,

motor, gear unit and driven machine) to the grounding system. These connections are made

with standard, heavy-duty PE conductors. For high frequencies, the equipotential bonding is

made using the shields of the motor cables to all components of the drive train (motor, gear

unit and driven machine).

The following diagram illustrates all grounding and high-frequency equipotential bonding

measures using the example of a typical high-power installation comprising several

SINAMICS S120 Cabinet Modules.

Note

Compared with the shown rod grounding, the mesh grounding provides better results.

EMC installation guidelines / basic system requirements

Configuration Manual, (PH1), 01/2012, 6FC5297-0AD30-0BP3

Information on planning, design and installation

3.5 Equipotential bonding

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The ground connections shown black form the conventional grounding system for the drive

[0]

components. They are made with standard, heavy-duty PE conductors without special high-frequency

properties and ensure low-frequency equipotential bonding as well as protection against injury.

The connections shown dark red inside the control cabinets provide good conductivity for high-

[1]

frequency protection between the metal housings of the integrated converter components and the PE

bar and EMC shield bus of the cabinet. These internal connections can be established over the

greatest possible surface area using the metallic construction of the cabinet unit, whereby the contact

surfaces must be bare metal and have a minimum cross-section of several cm² at each contact point.

Alternatively, these connections can be established by means of short, finely-stranded, braided copper

wires with a large cross-section (> 95 mm²).

The shields of the motor cables shown in orange provide the high-frequency equipotential bonding

[2]

between the inverters or motor modules and the motor terminal boxes. The finely stranded, braided

copper cables shown in red can be routed in parallel with these when cables with poor high-frequency

properties are used or in installations with inferior grounding systems.

The connections shown in red provide a good-conducting high-frequency connection for the motor

[3], [4], [5]

terminal box or the gear unit and the driven machine bond to the motor housing.

Figure 3-3

Grounding and high-frequency equipotential-bonding measures for equipotential bonding in the drive system

via ground

EMC installation guidelines / basic system requirements

Configuration Manual, (PH1), 01/2012, 6FC5297-0AD30-0BP3

Information on planning, design and installation

3.6 Cables

3.5.4

Equipotential bonding of components to moving parts/slides

When components are mounted on moving parts/slides, an additional equipotential-bonding

conductor (at least 10 mm²) should, if possible, be laid in parallel and near the cable

(bundled). This equipotential-bonding conductor must be connected as close as possible to

the component on the slide and directly at the PE connection for the associated module on

the cabinet.

Note

The cables must be suitable for trailing.

3.6

Cables

3.6.1

General

Power and signal cables, even shielded, must always be routed separately. For this purpose,

it is practical to arrange the various cables according to cable groups. Cables belonging to a

group can be combined in a bundle. The various cable groups must be routed with the

necessary clearance between them. A minimum clearance of 20 cm has proven itself in

practice. As an alternative, shielding plates with the appropriate contacts at several locations

can be used between the cable bundles.

In order to reduce crosstalk, all cables must be laid as close as possible to the (grounded)

structural parts connected to the cabinet ground. These are, for example, mounting plates or

frame parts of the cabinet.

In order to minimize the antenna effect, all cables should be kept as short as possible.

Although signal and power cables may cross each other (if absolutely necessary), they must

never be routed close to each other over longer distances.

Signal cables must be routed with a minimum clearance of 20 cm from strong magnetic

fields (motors, transformers). Alternatively, shield plates with the appropriate contacts at

several locations along their length can be used to provide the appropriate clearance.

CAUTION

Cables for the 24 V supply should be treated just like signal cables. Adequate bending

radiuses of the signal and power cables must be ensured.

EMC installation guidelines / basic system requirements

Configuration Manual, (PH1), 01/2012, 6FC5297-0AD30-0BP3

Information on planning, design and installation

3.6 Cables

WARNING

Capacitive coupling causes charging. To discharge these charges, at least one end of the

unused conductors for unshielded and shielded cables and their shields must be placed on

a grounded housing potential. Non-compliance may cause potentially fatal touch voltages

to develop at non-grounded insulated conductors and shielding.

3.6.2

Shielded cables

To achieve the smallest possible transfer resistances in the high-frequency area, cable

shields must always be connected at both ends with the largest possible surface area, if

possible using spring-loaded elements that enclose the shield.

The shield must be uninterrupted.

An example of a good uninterrupted cable routing

An example of an impermissible interrupted cable

from the motor to the motor module

routing from the motor to the motor module

If a break in the cable cannot be avoided, a bridging of the shields such as that shown in the

figure below must be provided.

EMC installation guidelines / basic system requirements

Configuration Manual, (PH1), 01/2012, 6FC5297-0AD30-0BP3

Information on planning, design and installation

3.6 Cables

①

Protective conductor

②

Shield connection

Figure 3-4

Example of good shield bridging with braided-copper ribbon

Braided shields should be favored. Foil shields should be avoided because their current-

carrying capacity is smaller and so the shields can be damaged.

Shield connections may not also serve as strain relief. The strain relief must be implemented

separately so that the shield connection is free from tensile forces.

As an alternative to the shielding inside control cabinets, measures are permitted that

achieve similar results as shielding, such as routing behind mounting plates or in metal cable

channels, suitable clearances, etc.

3.6.2.1

Plug connections for shielded cables

If cable shields are connected via connector enclosures, continuous metallic contact in the

connector must be ensured. Metalized plastic is not suitable in plants with converters for

providing sufficient contact over the plant service life because the metallic coating will be

abraded by vibrations or eroded by the shield current. If such connectors or connectors with

an unknown internal design are used, the shield must also be connected close to the

connector; see Figure 3-7 Examples of good types of shield connection (Page 29).

EMC installation guidelines / basic system requirements

Configuration Manual, (PH1), 01/2012, 6FC5297-0AD30-0BP3

Information on planning, design and installation

3.6 Cables

3.6.3

Cables in the power line

Power cables in converter systems, in particular motor cables, are some of the largest

generators of interference signals. For this reason, all cables from the output of the drive line

filter must be laid twisted/bundled and shielded without interruption to the motor. Experience

has shown that short connections under 1 m within the control cabinet can be laid

twisted/bundled without shield, e.g. the connection filter to the reactor, reactor to the infeed

DC-link connections. The information from Section Drive line filter arrangement, line reactor,

drive group (Page 32) must also be observed.

3.6.3.1

Bundling, parallel connection of cables

For the routing of three-phase systems using single-core cables (e.g. unshielded power

supply cables), the three phases L1, L2 and L3 must be bundled symmetrically and so

minimize the magnetic leakage fields. This is true even when high currents mean several

parallel single-core cables must be laid for each phase of a three-phase system. The

following diagram shows an example of this using a three-phase system with two parallel

single-core cables per phase:

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Figure 3-5

Bundling of cables

When more than one motor cable is routed in parallel, note that each individual motor cable

must contain all three conductors of the three-phase system. This helps to minimize the

magnetic leakage fields and thus also the magnetic interference of other loads.

Figure 3-6

Example of three motor cables routed in parallel

3.6.3.2

The motor cable shield connection at the motor modules

The provided shield connections must be used at the motor modules for built-in units. If this

cannot be done due to space limitations, the shield must be connected to the mounting plate

as close as possible to the motor modules. The shield is connected to the central grounding

bar for cabinet units.

EMC installation guidelines / basic system requirements

Configuration Manual, (PH1), 01/2012, 6FC5297-0AD30-0BP3

Information on planning, design and installation

3.6 Cables

3.6.3.3

Shield connection of the motor cable to the motor terminal box

To ensure a large-area shield connection, cable glands with EMC inserts must be used on

the terminal box, e.g. PG glands. If space requirements mean this is not possible, the shield

must be connected as close as possible to the motor housing; see for example Figure 3-7

Examples of good types of shield connection (Page 29).

3.6.3.4

Shield connection for cables with connector

The shield must be connected in the connector at the motor and converter side as described

by the connector manufacturer.

3.6.3.5

Protective conductor in the motor cables (green/yellow)

The protective conductor included in the motor cables must be connected directly to the

motor module at the PE connection for the cabinet for built-in units. For cabinet units, the

connection is made to the central grounding bar. The protective conductor must be

connected at the provided PE connection in the connector or in the terminal box at the

motor.

3.6.3.6

The last meter to the motor

The position of the connector means the required distances of 20 cm between the motor and

encoder cable cannot always be observed on the motor.

Experience has shown that a bundling of motor and encoder cables for mechanical reasons

is possible for the last meter to the motor.

3.6.3.7

DC-link connection, braking resistor

If the DC link is further connected to other groups, an equalizing conductor with the two

cables must be provided. This must be connected to the motor modules at the provided

connections. The three cables must be twisted or be bundled. For lengths exceeding approx.

1 m, a shield instead of the equipotential conductor should be provided. This must be

connected at both ends at the provided connections or, for lack of space, at the mounting

plates near the drive groups.

The same requirements apply to the cable for the braking resistor.

3.6.3.8

Cable lengths in the power line

If the permissible total cable length is exceeded, the increased shield currents can cause

additional losses in the line filter, the line reactor, the infeed module and motor modules or

saturation in the line filter, which then become ineffective. This leads to an overheating of the

components and thus failures or a reduction of the service life. Information about maximum

permissible cable lengths is contained in the device-specific technical user documentation.

EMC installation guidelines / basic system requirements

Configuration Manual, (PH1), 01/2012, 6FC5297-0AD30-0BP3

Information on planning, design and installation

3.6 Cables

3.6.4

Brake cables

Cables for brakes must be shielded. If the brake cables are combined with the motor cables

in a common cable, the twisted motor cores with the protective conductor must be routed in

a common shield and the twisted brake cores in another separate shield.

The same requirements apply to the shield connection as for the motor cables. See Section

The motor cable shield connection at the motor modules (Page 25).

Note

Wiring; see Section Wiring of coils (Page 33).

3.6.5

Encoder cables

Encoders and encoder cables are some of the most sensitive parts of the equipment. In this

case, faulty signals, for example in machine tools, can cause surface flaws or sporadic errors

of the machine. For double-shielded encoder cables, whereas the outer shield must be

connected at both ends, the inner shield is connected at only one side to the drive group.

3.6.5.1

Encoder cables with plug connectors

The shield is usually connected at the connector. When particularly high requirements apply,

such as an environment with very high EMC levels, another connection close to the

connector is recommended.

3.6.5.2

DRIVE-CLiQ encoder connections

The shield contacting of the DRIVE-CLiQ encoder cables is made at the connector.

3.6.5.3

Cable lengths for encoders

Maximum cable lengths appropriate for the encoder must be observed. Details can be taken

from the device-specific technical user documentation.

3.6.6

DRIVE-CLiQ connections

The shield contacting of the DRIVE-CLiQ connections between the components of the drive

group is made at the connectors.

The different connector types (integrated 24 V supply) means the use of commercially

available Ethernet cables is not permitted.

EMC installation guidelines / basic system requirements

Configuration Manual, (PH1), 01/2012, 6FC5297-0AD30-0BP3

Information on planning, design and installation

3.6 Cables

The maximum total cable length for DRIVE-CLiQ is 100 m.

Note

Depending on the used cable type, the cable lengths may be shorter.

3.6.7

Field bus

Field buses must be particularly resistant to faults. To achieve this robustness, the following

points according to the manufacturer's instructions of the connected bus components must

be observed:

● Sufficient distance from the power cables

● Shield connection to the bus components

● Shield connection at the control cabinet input

● Equipotential bonding

3.6.7.1

PROFIBUS, PROFINET

● The minimum distance between PROFIBUS or PROFINET cables to power cables is 20

cm.

● The shield connection to the PROFIBUS or PROFINET components is implemented at

the plug connector. If the component is not mounted on a metal mounting plate, an

additional equipotential bonding conductor with 4 mm² cross-section must be laid for the

protective equipotential bonding.

● The shield connection at the control cabinet inlet is necessary in order to comply with the

immission limit values must be observed in the first environment. The shield connection is

recommended for operation in the second environment.

● For PROFIBUS or PROFINET connections between different buildings or parts of

buildings, an equipotential bonding must be laid parallel to the PROFIBUS or PROFINET

cable.

The following minimum cross-sections according to IEC 60364-5-54 are required:

- Copper: 6 mm²

- Aluminum: 16 mm²

- Steel: 50 mm²

For further information, see under

(http://www.profibus.com/fileadmin/media/wbt/WBT_Assembly_V10_Dec06/en/Seiten/0_1_V

orwort.html)

EMC installation guidelines / basic system requirements

Configuration Manual, (PH1), 01/2012, 6FC5297-0AD30-0BP3

Information on planning, design and installation

3.7 Laying cables on cable racks/routes at the plant

3.6.8

Analog signals

The shields of cables for analog signals must be connected on both sides, see Figure 3-7

Examples of good types of shield connection (Page 29). A good equipotential bonding

between output and input is required.

3.6.9

Examples of shield connections

Figure 3-7

Examples of good types of shield connection

3.7

Laying cables on cable racks/routes at the plant

If cables cannot be routed directly from the control cabinet to the machine, they must be laid

on cable racks/routes. In this case, all cable shields should also be connected at the cable

entry of the control cabinet in order to comply with the immission limit values in the first

environment. The shield connection is recommended for operation in the second

environment.

The same requirements for the distance and shielding as described in Section General

(Page 22) apply to the cable routing. The following figure shows a laying example.

EMC installation guidelines / basic system requirements

Configuration Manual, (PH1), 01/2012, 6FC5297-0AD30-0BP3

Information on planning, design and installation

3.7 Laying cables on cable racks/routes at the plant

①

Signal, data, bus and single-core cables with U < 60 V

②

Signal cables and single cables with U = 60 V to 10 V

③

Power cables with low interference level

(e.g. unshielded power supply cables with U > 230 V. ..1 kV)

④

Power cables with a high noise level

(e.g. motor cables and cables between the braking unit and the braking resistor) with U > 230

V. ..1 kV

⑤

Medium-voltage cables with U > 1 kV

Figure 3-8

Cable installation

The cable racks/routes must be included in the equipotential bonding. In order to also

achieve an effect in the high-frequency range, large surface area mechanical connections

must be made to the cabinet and to the motor casing. The individual rack parts must also

have a large surface area connection with each other.

For further information, see under

(http://www.rittal.de/downloads/TechInfo/de/EMV_Praxis.pdf )

EMC installation guidelines / basic system requirements

Configuration Manual, (PH1), 01/2012, 6FC5297-0AD30-0BP3

Information on planning, design and installation

3.8 Connection to the line supply

3.8

Connection to the line supply

Equipment with converters also have low-frequency negative effects on the line supply that

can be suppressed not at all or only to a very limited extent by the line filters. Such limited

suppression can make itself apparent as flickering lights, overheating or even other defective

devices, etc.

To prevent this, the connection conditions, such as the short-circuit power of the line supply

and loop impedance, stated in the technical user documentation must be observed.

3.8.1

Drive line filter, cabinet line filter

The drive line filter that belongs to the converter system is tailored exclusively to the

converter system and should only be used for this. For other consumers, a commercially

available line filter should be installed as close as possible behind the main switch and fuse

protection at the cabinet entry. Further consumers are supplied via this line filter.

To prevent the filter becoming ineffective because of over-coupling, the filtered cables must

be laid with unfiltered cables in accordance with Section Drive line filter arrangement, line

reactor, drive group (Page 32).

Filters must be installed as close as possible to the cable entry of the control cabinet with a

large contact area. Exceptions are special drive filters that should be installed as close as

possible to the drive group or filters integrated in devices, such as for SITOP power supplies.

A large contact surface must be ensured during installation.

Incoming cables and filters to filter outgoing cables must always be installed separately.

For examples, see Figure Good laying with distance (Page 32) and Figure Good laying with

shield plate (Page 32).

Filtered and unfiltered cables must never be laid together.

EMC installation guidelines / basic system requirements

Configuration Manual, (PH1), 01/2012, 6FC5297-0AD30-0BP3

Information on planning, design and installation

3.8 Connection to the line supply

3.8.2

Drive line filter arrangement, line reactor, drive group

Branching to the drive is made behind the main switch and the fuse protection but before the

line filter. The housings of drive line filters and the infeed of the drive group must be

connected together with low resistance for high-frequency interference currents. For this

purpose, the components must be mounted close together on a common conducting

(galvanized) mounting plate on which they must have a large-area, permanent conductive

connection. The line reactor must be installed close to the filter and infeed.

2XWSXW

)LOWHU

,QSXW

6KLHOG SODWH

8QVKLHOGHG

Good laying with distance

Good laying with shield plate

Impermissible laying

It is recommended that the power cables are laid shielded starting at the control cabinet inlet.

Note

Reactors and filters can also be combined, for example, as an AIM

EMC installation guidelines / basic system requirements

Configuration Manual, (PH1), 01/2012, 6FC5297-0AD30-0BP3

Information on planning, design and installation

3.9 Miscellaneous

3.9

Miscellaneous

3.9.1

Wiring of coils

When

● mechanical switch contacts are used for switching,

● unconnected PLC outputs are used for switching,

to avoid switching overvoltages, all connected actuators, contactor coils, solenoid valves,

holding brakes, etc., should be connected using surge-suppression devices (e.g. RC

elements, varistors), if possible, directly at the interference source.

NOTICE

Increased run times can occur for circuits with free-wheeling diodes.

3.9.2

Bearing currents

For converter operation, the motor voltages are generated by pulse-width modulation. The

steep edges generate parasitic currents in the motor because of the winding capacitance.

Some of these currents can flow through the motor bearings and so damage them. This can

reduce the bearing service life.

Up to and including axis height 100, a good stator grounding by means of an EMC-compliant

installation in accordance with the figure (see Figure 3-3 Grounding and high-frequency

equipotential-bonding measures for equipotential bonding in the drive system via ground

(Page 21)) must be provided over the shields of the cables [ 2] or an insulated coupling to

ensure that the bearing currents are kept sufficiently small.

Above axis shaft height 100, an additional good high-frequency equipotential bonding to the

driven machine and from the motor terminal box to the motor housing as shown in the figure

(see Figure 3-3 Grounding and high-frequency equipotential-bonding measures for

equipotential bonding in the drive system via ground (Page 21)) via the cables [ 5] is required

and possibly an insulated bearing at the non-drive end.

du/dt or sine-wave filters can also be used at the converter output instead of an insulated

bearing in the motor, provided this is permitted.

EMC installation guidelines / basic system requirements

Configuration Manual, (PH1), 01/2012, 6FC5297-0AD30-0BP3

Preface

SINUMERIK documentation

The SINUMERIK documentation is organized in the following categories:

● General documentation

● User documentation

● Manufacturer/service documentation

Additional information

You can find information on the following topics at www.siemens.com/motioncontrol/docu:

● Ordering documentation/overview of documentation

● Additional links to download documents

● Using documentation online (find and search in manuals/information)

Please send any questions about the technical documentation (e.g. suggestions for

improvement, corrections) to the following address:

docu.motioncontrol@siemens.com

My Documentation Manager (MDM)

Under the following link you will find information to individually compile OEM-specific machine

documentation based on the Siemens content:

www.siemens.com/mdm

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. http://support.automation.siemens.com

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

Table of contents

Preface

Fundamental safety instructions

1.1

General safety instructions

1.2

Industrial security

Introduction

Ctrl-E Analysis

3.1

SENTRON PAC3200/4200

3.1.1

Hardware

3.1.2

Commissioning the Power Monitoring Device

3.1.3

Commissioning the PAC PROFIBUS expansion module (840D sl)

3.1.4

Commissioning the expansion module PAC PROFINET (828D)

3.2

Commissioning the PLC for SENTRON PAC

3.2.1

SINUMERIK 840D sl

3.2.1.1

Commissioning the PLC with PROFIBUS

3.2.1.2

Commissioning the PLC with PROFINET

3.2.2

SINUMERIK 828D

3.3

Commissioning the PLC for Ctrl-E Analysis

3.3.1

Configuring the energy consumption display for SINUMERIK 840D sl

3.3.1.1

PLC user program for SINUMERIK 840D sl programming

3.3.2

Configuring the display of energy consumption for SINUMERIK 828D

3.3.2.1

Programming the PLC user program for SINUMERIK 828D

3.4

Commissioning the HMI for Ctrl-E Analysis

3.4.1

Changing display texts of the auxiliary systems

3.5

Long time measurement

3.6

Power display in the status line of the "Machine" operating area

Ctrl-E Profiles

4.1

Commissioning the PLC for Ctrl-E Profiles

4.1.1

Overview

4.1.2

Automatic state machine PLC functions

4.1.3

Checking the energy-saving states

4.1.4

PLC user program

4.1.5

Interface signals 840D sl

4.1.5.1

Signals for controlling energy-saving profiles

4.1.5.2

Signals for parameterization

4.1.6

Interface signals 828D

4.1.6.1

Signals for controlling energy-saving profiles

4.1.6.2

Signals for parameterization

4.2

Creating and editing energy-saving profiles

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

Fundamental safety instructions

1.1

General safety instructions

WARNING

Risk of death if the safety instructions and remaining risks are not carefully observed

If the safety instructions and residual risks are not observed in the associated hardware

documentation, accidents involving severe injuries or death can occur.

● Observe the safety instructions given in the hardware documentation.

● Consider the residual risks for the risk evaluation.

WARNING

Danger to life or malfunctions of the machine as a result of incorrect or changed

parameterization

As a result of incorrect or changed parameterization, machines can malfunction, which in turn

can lead to injuries or death.

● Protect the parameterization (parameter assignments) against unauthorized access.

● Respond to possible malfunctions by applying suitable measures (e.g. EMERGENCY

STOP or EMERGENCY OFF).

1.2

Industrial security

Note

Industrial security

Siemens provides products and solutions with industrial security functions that support the

secure operation of plants, solutions, machines, equipment and/or networks. They are

important components in a holistic industrial security concept. With this in mind, Siemens’

products and solutions undergo continuous development. 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. Third-party products that may be in use should also

be considered. For more information about industrial security, visit this address (http://

www.siemens.com/industrialsecurity ).

To stay informed about product updates as they occur, sign up for a product-specific

newsletter. For more information, visit this address (http://support.automation.siemens.com ).

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

Fundamental safety instructions

1.2 Industrial security

WARNING

Danger as a result of unsafe operating states resulting from software manipulation

Software manipulation (e.g. by viruses, Trojan horses, malware, worms) can cause unsafe

operating states to develop in your installation which can result in death, severe injuries and/

or material damage.

● 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/

industrialsecurity).

● Make sure that you include all installed products into the holistic industrial security concept.

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

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.

Ctrl-Energy

You will find an overview of the complete range of functions under the following link:

www.siemens.com/sinumerik/ctrl-energy

Acquisition, evaluation, and control of energy consumption

The functions Ctrl-E Analysis to acquire and evaluate the energy consumption of the machine

and Ctrl-E Profiles, to control energy-saving states of the machine are available in SINUMERIK

Operate. Additional energy-saving functions or user know-how on this topic can be added in

this area of SINUMERIK Operate.

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

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.

Additional consumption-relevant data can be retrieved and displayed at the control using the

additional SENTRON PAC Power Monitoring Device.

Depending on where the SENTRON PAC measuring transducer is installed, you have the

possibility of either measuring the power of the whole machine or only a specific load.

With an integrated measuring function, the energy consumption during a measuring period

can be acquired for all drives together with an additional measuring location - and the electrical

power drawn for a selected load can be recorded with respect to time.

Display of energy consumption

● The user can see a graphic of the current power consumption in the first status line of the

"Machine" operating area.

● Additionally, in the Ctrl-Energy initial display the user is shown the consumption in the form

of colored bars, which indicate the current power and the results of today's and yesterday's

long time measurement.

Maximum measuring time

The maximum measuring time for energy between start and stop as well as for an NC part

program is, as a result of the trace recording, 922 seconds (00:15:22).

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

Ctrl-E Analysis

3.1 SENTRON PAC3200/4200

3.1

SENTRON PAC3200/4200

3.1.1

Hardware

Hardware components

You require the following hardware in order to be able to use all of the "Ctrl-Energy" functions:

●

SENTRON PAC3200 (Firmware ≥ V2.2.0)

http://support.automation.siemens.com/WW/view/de/25240652/130000

●

SENTRON PAC4200 (Firmware ≥ V1.4.0)

http://support.automation.siemens.com/WW/view/de/31675630/130000

●

SENTRON PAC - accessories

http://www.automation.siemens.com/btlv-static/

Lowvoltage_LV10-1_complete_German_2011.pdf

- Power Monitoring Device (page 11/27 ff)

- Current transformer (Page 11/39)

●

The expansion modules must be temporarily removed in order to upgrade the firmware

using powerconfig.

●

Protection/fusing of the supply and measuring voltages according to Configuration Manual

●

Expansion module PAC PROFINET; order number 7KM 9300-0AE01-0AA0

●

Expansion module PAC PROFIBUS; order number 7KM 9300-0AB01-0AA0

●

PC software powerconfig (≥ V2.2)

http://support.automation.siemens.com/WW/view/de/50246395

●

Current transformer depending on

- the connection type at the SENTRON PAC

- Accuracy requirements

- Currents

DANGER

Open current transformer circuits result in electric shock and arcing

If not observed, will cause death, serious injury or considerable property damage.

Only measure the current using external current transformers. DO NOT protect the

circuits using a fuse. Do not open the secondary circuit of the current transformer under

load. 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, 10/2015, 6FC5397-0EP40-5BA3

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. For the voltage tap, please observe the usual protection/fusing.

References

Information on the installation, configuration and operation of the Power Monitoring Device

and the expansion module can be found in the following references:

● SENTRON PAC3200 Power Monitoring Device Manual

(Document order number A5E01168664A-05)

● SENTRON PAC4200 Power Monitoring Device System Manual

(Document order number A5E02316180A-03)

● PAC PROFIBUS DP, SWITCHED ETHERNET PROFINET Expansion Module Manual

(document order number A5E01168846A-06)

3.1.2

Commissioning the Power Monitoring Device

A detailed description of commissioning of the SENTRON PAC Power Monitoring Device is

provided in the corresponding manuals.

Preconditions

● The device has been installed.

● The optional expansion modules have been installed.

● The device has been connected in accordance with the possible connection methods.

● The battery has been inserted into the battery compartment (only for the SENTRON

PAC4200).

General procedure when commissioning the device

● Connected the supply voltage

● Parameterizing SENTRON PAC

● Connect the measuring voltage

● Connect the current to be measured

● Check the displayed measured values

● Check the polarity and phase assignment of the measuring transducer

Ctrl-Energy

System Manual, 10/2015, 6FC5397-0EP40-5BA3

SINUMERIK 840D sl. Service - Configuring Commissioning. Manual (2011-2020) - page 109