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    Ctrl-Energy 3,___________________ 7,___________________ 9,___________________ 35,___________________ 51,___________________ 53,___________________ 55,___________________ 57,___________________ SINUMERIK SINUMERIK 840D sl / 828DCtrl-Energy System Manual Valid for Control system SINUMERIK 840D...

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    Legal information Legal information Warning notice system This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, no...

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    Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 3 Preface SINUMERIK documentation SINUMERIK documentation The SINUMERIK documentation is organized in the following categories: ● General documentation ● User documentation ● Manufacturer/service documentation Additional information Yo...

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    Preface Ctrl-Energy 4 System Manual, 02/2012, 6FC5397-0EP40-3BA0 SINUMERIK You can find information on SINUMERIK under the following link: actionURI(http://www.siemens.com/sinumerik):www.siemens.com/sinumerik Hotline and Internet address Technical Support You will find telephone numbers for...

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    Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 5 Table of contents Preface ...................................................................................................................................................... 3,3 1 Introduction............................................

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    Table of contents Ctrl-Energy 6 System Manual, 02/2012, 6FC5397-0EP40-3BA0 A.1 Overview ..................................................................................................................................... 57,57 Index.............................................................

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    Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 7 Introduction 1 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...

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    Introduction Ctrl-Energy 8 System Manual, 02/2012, 6FC5397-0EP40-3BA0

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    Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 9 Ctrl-E Analysis 2 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 con...

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    Ctrl-E Analysis 2.1 SENTRON PAC3200/4200 Ctrl-Energy 10 System Manual, 02/2012, 6FC5397-0EP40-3BA0 2.1 SENTRON PAC3200/4200 2.1.1 Hardware Hardware components You require the following hardware in order to be able to use all of the "Ctrl-Energy" functions: ● SENTRON PAC3200 (Firmw...

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    Ctrl-E Analysis 2.1 SENTRON PAC3200/4200 Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 11 ● PC software powerconfig (≥ V2.2) actionURI(http://support.automation.siemens.com/WW/view/de/50246395):http://support.automation.siemens.com/WW/view/de/50246395 ● Current transformer depend...

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    Ctrl-E Analysis 2.1 SENTRON PAC3200/4200 Ctrl-Energy 12 System Manual, 02/2012, 6FC5397-0EP40-3BA0 2.1.2 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...

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    Ctrl-E Analysis 2.1 SENTRON PAC3200/4200 Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 13 2.1.3 Commissioning the PAC PROFIBUS expansion module (840D sl) To communicate via Profibus, the SENTRON PROFIBUS module in combination with Sentron PAC3200/4200 must be parameterized differently....

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    Ctrl-E Analysis 2.1 SENTRON PAC3200/4200 Ctrl-Energy 14 System Manual, 02/2012, 6FC5397-0EP40-3BA0 Specifying/changing the device name The device name can only be entered (it must be specified) using the powerconfig software in the submenu "Expansion slot1". ● Sentron PAC3200: pac32...

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    Ctrl-E Analysis 2.2 Commissioning the PLC for SENTRON PAC Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 15 2.2 Commissioning the PLC for SENTRON PAC 2.2.1 SINUMERIK 840D sl 2.2.1.1 Commissioning the PLC with PROFIBUS PROFIBUS is commissioned with the PLC Toolbox 4.5 or higher. Prec...

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    Ctrl-E Analysis 2.2 Commissioning the PLC for SENTRON PAC Ctrl-Energy 16 System Manual, 02/2012, 6FC5397-0EP40-3BA0 4. Copy the sources, modules and symbols to the PLC program Figure 2-1 Hardware catalog after incorporating the GSD file

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    Ctrl-E Analysis 2.2 Commissioning the PLC for SENTRON PAC Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 17 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.

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    Ctrl-E Analysis 2.2 Commissioning the PLC for SENTRON PAC Ctrl-Energy 18 System Manual, 02/2012, 6FC5397-0EP40-3BA0 PROFIBUS interface PROFIBUS must be configured with a data transfer rate of 12 Mbit/s. Setting the PROFIBUS address Set the PROFIBUS address of the expansion module either direct...

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    Ctrl-E Analysis 2.2 Commissioning the PLC for SENTRON PAC Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 19 2.2.1.2 Commissioning the PLC with PROFINET PROFINET is commissioned with the PLC Toolbox 4.5 or higher. This requires SIMATIC STEP7 V5.5 or higher. Preconditions ● Configure ...

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    Ctrl-E Analysis 2.2 Commissioning the PLC for SENTRON PAC Ctrl-Energy 20 System Manual, 02/2012, 6FC5397-0EP40-3BA0 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.

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    Ctrl-E Analysis 2.2 Commissioning the PLC for SENTRON PAC Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 21 Note Port interconnection To simplify commissioning, in HW Config configure the PAC PROFINET using port interconnection at the PROFINET ports of the NCU. This saves you from hav...

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    Ctrl-E Analysis 2.2 Commissioning the PLC for SENTRON PAC Ctrl-Energy 22 System Manual, 02/2012, 6FC5397-0EP40-3BA0 2.2.2 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 d...

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    Ctrl-E Analysis 2.3 Commissioning the PLC for Ctrl-E Analysis Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 23 2.3 Commissioning the PLC for Ctrl-E Analysis 2.3.1 Configuring the energy consumption display for SINUMERIK 840D sl The energy consumption is displayed in the "SINUMERIK...

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    Ctrl-E Analysis 2.3 Commissioning the PLC for Ctrl-E Analysis Ctrl-Energy 24 System Manual, 02/2012, 6FC5397-0EP40-3BA0 DB1001 Name: SentronPac Signal direction Meaning Identifier Format DB1001.DBD16 MeasAuto == 0: PLC -> HMI MeasAuto == 1: GP -> HMI Measured exported active energy in...

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    Ctrl-E Analysis 2.3 Commissioning the PLC for Ctrl-E Analysis Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 25 Note Evaluation of the energy consumption of the complete machine If you have installed SENTRON PAC in the main circuit of the machine or SENTRON PAC evaluates the energy c...

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    Ctrl-E Analysis 2.3 Commissioning the PLC for Ctrl-E Analysis Ctrl-Energy 26 System Manual, 02/2012, 6FC5397-0EP40-3BA0 Programming the PLC user program ● You take the total active power from the input address and transfer the value to DB1001.DBD20. ● You take the imported active power from...

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    Ctrl-E Analysis 2.3 Commissioning the PLC for Ctrl-E Analysis Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 27 Measurement carried out by the basic program: For these measurements, the cyclic increases in the energy values are accumulated in the measured variables. The behavior for di...

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    Ctrl-E Analysis 2.3 Commissioning the PLC for Ctrl-E Analysis Ctrl-Energy 28 System Manual, 02/2012, 6FC5397-0EP40-3BA0 2.3.2 Configuring the display of energy consumption for SINUMERIK 828D The energy consumption is displayed in the "SINUMERIK Ctrl-E Analysis" window. See also 45,Si...

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    Ctrl-E Analysis 2.3 Commissioning the PLC for Ctrl-E Analysis Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 29 DB9907 Name: SentronPac Signal direction Meaning Symbol Format DB9907.DBD24 PLC -> FW Imported active energy at tariff 1 (F) in Wh from SENTRON ActiveEnergySentron REAL DB...

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    Ctrl-E Analysis 2.3 Commissioning the PLC for Ctrl-E Analysis Ctrl-Energy 30 System Manual, 02/2012, 6FC5397-0EP40-3BA0 Note Evaluation of the energy consumption of the complete machine If you have installed SENTRON PAC in the main circuit of the machine or SENTRON PAC evaluates the energy c...

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    Ctrl-E Analysis 2.3 Commissioning the PLC for Ctrl-E Analysis Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 31 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 foll...

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    Ctrl-E Analysis 2.3 Commissioning the PLC for Ctrl-E Analysis Ctrl-Energy 32 System Manual, 02/2012, 6FC5397-0EP40-3BA0 Example for SINUMERIK 828Dsl 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 su...

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    Ctrl-E Analysis 2.3 Commissioning the PLC for Ctrl-E Analysis Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 33 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. ...

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    Ctrl-E Analysis 2.4 Commissioning the HMI for Ctrl-E Analysis Ctrl-Energy 34 System Manual, 02/2012, 6FC5397-0EP40-3BA0 2.4 Commissioning the HMI for Ctrl-E Analysis No additional adaptation is required. As soon as the DB1001 (840D sl) or the DB9907 (828D) is available and actively assigned wi...

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    Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 35 Ctrl-E Profiles 3 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 availa...

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    Ctrl-E Profiles 3.1 Commissioning the PLC for Ctrl-E Profiles Ctrl-Energy 36 System Manual, 02/2012, 6FC5397-0EP40-3BA0 3.1 Commissioning the PLC for Ctrl-E Profiles 3.1.1 Overview In every machine tool, the PLC is the central part of the control for the peripherals and mounted equipment/device...

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    Ctrl-E Profiles 3.1 Commissioning the PLC for Ctrl-E Profiles Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 37 The data for each energy-saving profile is saved in DB1000 for the 840Dsl and in DM9906 for the 828D. 3.1.2 Automatic state machine PLC functions The automatic state machine s...

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    Ctrl-E Profiles 3.1 Commissioning the PLC for Ctrl-E Profiles Ctrl-Energy 38 System Manual, 02/2012, 6FC5397-0EP40-3BA0 Figure 3-1 State monitoring Transition to "RUN" All of the signals that have been enabled for evaluation using the following masking bits, are inactive (also see...

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    Ctrl-E Profiles 3.1 Commissioning the PLC for Ctrl-E Profiles Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 39 Transition to "OFF" DBX 10.1 == 1 ("deactivate profile") or delete the profile: highest priority and independent of the profile initialization - OR - 0...

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    Ctrl-E Profiles 3.1 Commissioning the PLC for Ctrl-E Profiles Ctrl-Energy 40 System Manual, 02/2012, 6FC5397-0EP40-3BA0 Signal Function Generated by the HMI Keyboard has been used (state condition "No key pressed on the operator panel") This signal is set if in the last second the key...

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    Ctrl-E Profiles 3.1 Commissioning the PLC for Ctrl-E Profiles Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 41 3.1.4 PLC user program The following signals are available in the user program for controlling the energy-saving profiles. These signals are not masked within the energy profi...

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    Ctrl-E Profiles 3.1 Commissioning the PLC for Ctrl-E Profiles Ctrl-Energy 42 System Manual, 02/2012, 6FC5397-0EP40-3BA0 3.1.5 Interface signals 840D sl 3.1.5.1 Signals for controlling energy-saving profiles Dynamic data are cleared when the control powers up. The signals described in the follow...

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    Ctrl-E Profiles 3.1 Commissioning the PLC for Ctrl-E Profiles Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 43 3.1.5.2 Signals for parameterization Retentive parameterization data. Effectiveness (HMI → PLC) DB1000 DBX 10.0 Energy-saving profile configured DBX 10.1 Disable energy-s...

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    Ctrl-E Profiles 3.1 Commissioning the PLC for Ctrl-E Profiles Ctrl-Energy 44 System Manual, 02/2012, 6FC5397-0EP40-3BA0 Additional profile instances DB1000 DBW 20 Energy-saving profile 2 DBW 40 Energy-saving profile 3 DBW 60 Energy-saving profile 4 DBW 80 Energy-saving profile 5 DBW 100 Energ...

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    Ctrl-E Profiles 3.1 Commissioning the PLC for Ctrl-E Profiles Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 45 3.1.6 Interface signals 828D 3.1.6.1 Signals for controlling energy-saving profiles Dynamic data are cleared when the control powers up. Control signals (user program) DB9906...

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    Ctrl-E Profiles 3.1 Commissioning the PLC for Ctrl-E Profiles Ctrl-Energy 46 System Manual, 02/2012, 6FC5397-0EP40-3BA0 3.1.6.2 Signals for parameterization Retentive parameterization data. Effectiveness (HMI → PLC) DB9906 DBX10.0 Energy-saving profile configured DBX 10.1 Disable energy-sav...

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    Ctrl-E Profiles 3.2 Creating and editing energy-saving profiles Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 47 3.2 Creating and editing energy-saving profiles You can make the following changes in the list of energy-saving profiles in the commissioning mode: ● Creating new energ...

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    Ctrl-E Profiles 3.2 Creating and editing energy-saving profiles Ctrl-Energy 48 System Manual, 02/2012, 6FC5397-0EP40-3BA0 State conditions Meaning NC channel/channels in Reset To activate the energy-saving profile, NC channel/channels must be in the Reset state. Master computer signal prohibit...

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    Ctrl-E Profiles 3.2 Creating and editing energy-saving profiles Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 49 Newly creating/changing energy profiles 3. Position the cursor on the line where you wish to create a new energy-saving profile and press the "New" softkey. The w...

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    Ctrl-E Profiles 3.2 Creating and editing energy-saving profiles Ctrl-Energy 50 System Manual, 02/2012, 6FC5397-0EP40-3BA0 7. Select the required storage location and press the "OK" softkey. The language-neutral state data are stored in the XML format, the associated texts in a .ts f...

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    Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 51 Reactive power compensation 4 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. I...

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    Reactive power compensation Ctrl-Energy 52 System Manual, 02/2012, 6FC5397-0EP40-3BA0

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    Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 53 Flux reduction 5 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 (r157...

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    Flux reduction Ctrl-Energy 54 System Manual, 02/2012, 6FC5397-0EP40-3BA0

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    Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 55 User know-how 6 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 Scree...

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    User know-how 6.1 Commissioning user screen forms Ctrl-Energy 56 System Manual, 02/2012, 6FC5397-0EP40-3BA0 An additional neutral "aufruf.com" file is created with the following start softkeys: //S(START) VS4=("Start XXX") PRESS(VS4) LM("maske_xxx","xx...

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    Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 57 Appendix AA.1 Overview

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    Appendix A.1 Overview Ctrl-Energy 58 System Manual, 02/2012, 6FC5397-0EP40-3BA0

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    Ctrl-Energy System Manual, 02/2012, 6FC5397-0EP40-3BA0 59 Index C Commissioning HMI, 36,36 Configuring Energy-saving profile 47,s, 47 47, Ctrl Energy Functions, 7,7 E Energy-saving profiles, 36,36 36, 47,Edit, 47 H Ha 10,rdware, 10 P PLC functions, 37,37 PLC user program, 41,41 Power Mon...

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