SINAMICS DCM as three-phase AC power controller for heating applications SINAMICS DCM https://support.industry.siemens.com/cs/ww/de/view/10975 2280 Siemens Industry Online Support Siemens AG 2018 All rights reserved This article originates from Siemens Industry Online Support. The terms of use specified there apply (www.siemens.com/terms_of_use). Security information Siemens provides products and solutions with industrial security functions that support the secure operation of plants, systems, machines and networks. In order to protect plants, systems, machines and networks against cyber threats, it is necessary to implement - and continuously maintain - a holistic, state-of-the-art industrial security concept. Siemens products and solutions constitute only one element of such a concept. Customers are solely responsible for preventing unauthorized access to their plants, systems, machines and networks. 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NOTICE The following should be observed when using this application document: The manufacturer/party marketing an electrical system is also fully responsible for complying with the requirements of the Low Voltage Directive. Conformance with the Low Voltage Directives can be declared by applying harmonized standards (e.g. EN 61439). The operating instructions of the products being used must always be carefully reviewed and observed. SINAMICS DCM DC Converter - Manual https://support.industry.siemens.com/cs/ww/de/view/109478240 SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 2 Table of contents 1 General information ........................................................................................... 4 2 Dimensioning ..................................................................................................... 4 3 Possible power topologies ............................................................................... 5 3.1 3.2 4 General settings and commissioning ............................................................ 11 5 Open-loop control mode ................................................................................. 13 5.1 5.2 5.3 5.4 Phase angle control ............................................................................ 14 Full-wave control ................................................................................ 15 Half-wave control ................................................................................ 17 Common functions for full and half-wave control ............................... 17 6 Soft start function ............................................................................................ 20 7 Line load equalization ..................................................................................... 22 7.1 Siemens AG 2018 All rights reserved Topology 1: 6-conductor connection with load in a star connection ............................................................................................ 5 Topology 2: Using an external power unit for the three-phase AC power controller and an DCM Control Module ............................... 7 Implementation example .................................................................... 23 8 Parameter overview ......................................................................................... 25 9 Appendix .......................................................................................................... 26 SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 3 1 General information General information 1 Under certain preconditions, SINAMICS DCM can be used as three-phase AC power controller for heating applications - for example industrial ovens, tunnel drying ovens of painting systems etc. The load can either be ohmic (resistive) or inductive (e.g. transformers). As a consequence, in certain cases, SIVOLT A three-phase AC power controllers can be replaced by SINAMICS DCM converters. Note 2Q devices represent a practical approach for these types of applications; however, 4Q devices can also be used. Dimensioning 2 Observe the following points when dimensioning a SINAMICS DCM: 1. It is not permissible that the phase-to-phase line voltage exceeds the amateur input "ARMATURE INPUT" 1 . 2. It is not permissible that the phase current of the heating system exceeds the input Siemens AG 2018 All rights reserved current "ARMATURE INPUT" specified on the rating plate of the DCM 2 . 3. As standard, the gating unit in the SINAMICS DCM and in the Control Module (factory setting, frequency range 45 - 65 Hz) automatically adapt themselves to the line voltage. An extended frequency range is possible on request. 4. For the full and half wave control modes, the power unit of the three-phase AC power controller must be dimensioned for the specific load It is not permissible that it is under dimensioned. NOTICE If the phase current of the heating system exceeds the input current "ARMATURE INPUT" 2 of the SINAMICS DCM, then external protective measures must be provided to prevent the thyristors from being overloaded. Fig. 2-1 Example of a rating plate 1 Note 2 Tools such as the DT Configurator and SINAMICS DCM pro cannot be used when dimensioning the system. SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 4 3 Possible power topologies 3 Possible power topologies As a result of the internal interconnection of the power of the SINAMICS DCM, the power unit topology "6-conductor connection with load in a star connection" is possible. Other interconnections are possible when using the power unit of a three-phase power controller. 3.1 Topology 1: 6-conductor connection with load in a star connection Siemens AG 2018 All rights reserved Preconditions: * The load must be configured for a star connection. * All 6 load connections must be brought out. * A symmetrical load is operated in a star connection. * An isolating measuring amplifier is required to sense the synchronizing voltage. The following devices can be recommended: Varitrans P42000 D3 from the Knick company or DVL1000 from the LEM company * A clockwise phase sequence must be connected at the infeed. * The line supply must be symmetrical. Fig. 3-1 Power unit topology 1 Isolating measuring amplifier + - + - DCM X177:29 CUD 30 AI 2 XP1:5U1 190V ... 240V / 380V ... 480V or 24V= with option L05 Electronics supply XP1:5W1 XP1:5N1 Power Interface Cable protection fuses Load L1 L2 L3 Notice: Ensure a clockwise rotating field SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 V1 V3 V5 1C1 V4 V6 V2 1D1 1U1 1V1 1W1 Power unit 5 3 Possible power topologies The following block diagram shows a different depiction of the DCM power unit, and clearly shows the circuit as three-phase AC power controller. Fig. 3-2 Block diagram L1 Cable protection fuse Load 1U1 DCM V4 1D1 V1 1C1 V3 V2 Siemens AG 2018 All rights reserved 1W1 V5 V6 1V1 Load Cable protection fuse Load Cable protection fuse L2 The following power unit topologies generally used for three-phase AC power controllers are not possible: * 4-conductor connection (star connection with the neutral point brought out) * 6-conductor connection (open delta connection) * Economy circuit connection with load in a star connection * Economy circuit connection with load in a delta connection Conductor cross-sections and series fuses The conductor cross-sections must be dimensioned for the rated current of the heating elements, taking into account the interconnection; this also dimensions the series fuses. Semiconductor fuses are not required as series fuses; slow-acting cable protection fuses can be used. The precondition is that the three-phase AC power controller is dimensioned for the maximum load current that occurs. Note In some fault situations, for example, for ground faults in the power unit in conjunction with a TN line system, it is possible that the series fuses do not rupture. To protect persons, additional protection in the form of an RCD must be provided. If the three-phase AC power controller is underdimensioned with respect to the load, semiconductor fuses must be provided (for the assignment, see DCM Operating Instructions, Chapter 6.7.2). When using an external power unit of the three-phase AC power controller in combination with a DCM Control Module, the fuses specified by the power unit manufacturer must be used. SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 6 3 Possible power topologies 3.2 Topology 2: Using an external power unit for the three-phase AC power controller and an DCM Control Module If you are already using a three-phase AC power controller power unit, then you can implement a heating application using a DCM Control Module. This can be helpful when retrofitting old systems, where the existing power unit is used. The following topologies generally used for three-phase AC power controllers are possible: * 4-conductor connection (star connection with the neutral point brought out) * 3-conductor connection with load in a star connection * 3-conductor connection with load in a delta connection * 6-conductor connection (open delta connection) * Economy circuit connection with load in a star connection * Economy circuit connection with load in a delta connection Fig. 3-3 Power unit topology 2: 4-conductor connection (star connection with the neutral point brought out) L1 Siemens AG 2018 All rights reserved L2 L3 Mp AK1 AK3 AK5 * XU2 XV2 XW2 Voltage sensing V1 V4 V3 V6 V5 V2 Control Module AK2 * Connection points XU/V/W1...6 of the voltage sensing depend on the line voltage. External power unit AK4 AK6 Load SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 7 3 Possible power topologies Fig. 3-4 Power unit topology 2: 3-conductor connection with load in a star connection L1 L2 L3 AK1 AK3 AK5 * XU2 XV2 XW2 Voltage sensing V1 V4 V3 V6 V5 V2 Control Module External power unit AK2 AK4 AK6 Siemens AG 2018 All rights reserved * Connection points XU/V/W1...6 of the voltage sensing depend on the line voltage. Load Fig. 3-5 Power unit topology 2: 3-conductor connection with load in a delta connection L1 L2 L3 AK1 AK3 AK5 * XU2 XV2 XW2 Voltage sensing V1 V4 V3 V6 V5 V2 Control Module AK2 * Connection points XU/V/W1...6 of the voltage sensing depend on the line voltage. AK4 AK6 External power unit Load SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 8 3 Possible power topologies Fig. 3-6 Power unit topology 2: 6-conductor connection (open delta connection) L1 L2 L3 AK1 AK3 AK5 * XU2 XV2 XW2 Voltage sensing V1 V4 V3 V6 V5 V2 Control Module AK2 Load Siemens AG 2018 All rights reserved * Connection points XU/V/W1...6 of the voltage sensing depend on the line voltage. External power unit AK4 AK6 SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 9 3 Possible power topologies Fig. 3-7 Power unit topology 2: Economy circuit connection with load in a star connection L1 L2 L3 * XU2 XV2 XW2 Voltage sensing V1 V4 V5 V2 Control Module Siemens AG 2018 All rights reserved External power unit * Connection points XU/V/W1...6 of the voltage sensing depend on the line voltage. Load Fig. 3-8 Power unit topology 2: Economy circuit connection with load in a delta connection L1 L2 L3 * XU2 XV2 XW2 Voltage sensing V1 V4 V5 V2 Control Module External power unit * Connection points XU/V/W1...6 of the voltage sensing depend on the line voltage. Load SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 10 4 General settings and commissioning 4 General settings and commissioning You configure the drive using STARTER: 1. In STARTER, you configure the following parameters offline using the Wizard (see the operating instructions, Chapter 8.4): Table 4-1 Siemens AG 2018 All rights reserved Parameter Function Value p50100 [0] Rated motor armature current 0.1 A p50101 [0] Rated motor armature voltage 10 V p50102 [0] Rated motor excitation current 0.1 A p50114 [0] Motor thermal time constant 0s p50083 [0] Selection of the speed controller actual value Analog tachometer p2000 Reference speed > 6 rpm, < 210000 rpm p50082 Field power module operating mode No field These parameters are relevant for the closed-loop control of the converter; however, with this application as three-phase AC power controller, they are not required. However, you must always use plausible values for these parameters. If process data (voltage, current etc.) are to be displayed, then you must set the corresponding reference parameters for this data in the 2000 parameter range. 2. After configuring the drive object, set the following parameters using an expert list that you created yourself: Table 4-2 Parameter Function Value p51400 Three-phase AC power controller control mode >0 p51404 Line voltage sensing Analog input scaling dependent on the measuring amplifier measuring range p51405 Three-phase AC power controller Synchronization voltage selection 1 p51406 Three-phase AC power controller duty cycle (setpoint) Signal source dependent on the setpoint source p50357 Tachometer interruption monitoring threshold 100% p50067 Load class 1 (factory setting) p50075 Power unit I2t monitoring response 0 (factory setting) p50590 Message set/act val dev 1 signal source for speed setpoint 0 p50600 Signal source for armature gating unit input 0 SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 11 4 General settings and commissioning Note Most measuring amplifiers have several measuring ranges; in parameter p51404 you can set the measuring range that the measuring amplifier currently maps. You select a measuring range that can completely map the line voltage, and which lies the closest to the peak value of the line voltage. For example, 10V output voltage for a 600V input voltage 3. Using STARTER, load the parameterization into the DCM. 4. To backup the parameterization, carry out a "RAM to ROM" after the download. 5. Carry out a "Power on reset" to activate analog input AI2. You do not have to carry out any optimization runs as neither a speed controller nor a current controller is being used. Siemens AG 2018 All rights reserved Note SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 12 5 Open-loop control mode 5 Open-loop control mode When using SINAMICS DCM as three-phase AC power controller with firmware version 1.5 or higher, an appropriate gating unit is available. The phase angle control mode must be used when using inductive loads, e.g. transformers. One of 3 different control modes can be selected: p51400 * Phase angle control * Full-wave control * Half-wave control Control type 0 B6C bridge, this means not used as three-phase AC power controller [factory setting] 1 Three-phase AC power controller with phase angle control 2 Three-phase AC power controller with full-wave control 3 Three-phase AC power controller with half-wave control p51404 Line voltage sensing, analog input scaling Siemens AG 2018 All rights reserved Here, set which instantaneous value of the line voltage (in V) should be mapped to 10 V at the analog input. p51405 Three-phase AC power controller synchronizing voltage selection 0 Internal synchronizing voltage [factory setting] 1 External synchronizing voltage (terminal X177.29/30) Synchronizing voltage When using the SINAMICS DCM as three-phase AC power controller, the load is connected to the three-phase side. This is the reason that the synchronizing voltage must be sensed using an external voltage transformer (PT) - and fed into the CUD via analog input AI2 (terminal X177.29/30). The voltage between phases U and V must be sensed. Based on this voltage characteristic, the DCM derives the line zero crossover points of all 3 phases - where a clockwise phase sequence is assumed. This means that when interconnecting the power (load, line supply), users must always ensure the correct phase sequence (clockwise phase sequence). p51406 Three-phase AC power controller duty cycle signal source For phase angle control, the following applies: 0% to 100% corresponds to 180 to 0 For full and half-wave control, the following applies: 0% to 100% corresponds to 0% to 100% Duty cycle (= on time/cycle time) Closed-loop control, signal source for the duty cycle Both a higher-level control (temperature control) - as well as a subordinate control (I-, I2-, U-, U2-, R-, P control) must be implemented in the higher-level open-loop control using the integrated technology controller - or using a DCC chart. The output of the higher-level closed-loop control must be interconnected to the input for the duty cycle (p51406). Closed-loop control, signal source for actual value sensing The transformer (CT) values r52952[2], r52952[3] and the rms line phase current r52108 are available to sense the current. All of the other signals (r52114, r52117 and r52126) cannot be used for heating operation as they are designed for another topology. If additional signals are required to sense actual values, then external devices must be used. SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 13 5 Open-loop control mode 5.1 Phase angle control For phase angle control, current flows through the controlled load during each line voltage half wave. The current flows from the firing instant up to its natural zero crossover. For phase angle control, as standard, there is no current limiting. The current amplitude is exclusively determined by the load and the phase control factor (firing angle). If current limiting is required, then this can be implemented using a higher-level closed-loop control - or using a parameterizable limit function block that is internally connected in series. This would limit the phase control factor (firing angle), and therefore the current to the maximum value permissible for the power unit. This limit value depends on the load, which means that the limit value of the limit block must be empirically determined. In the case of an overcurrent condition, a closed-loop control system would reduce the phase control factor of the threephase AC power controller. Note The thyristors can be damaged if the maximum load current exceeds the maximum input current of the power unit. Fig. 5-1 Current and voltage characteristic when using phase angle control to control a resistive load U~ Siemens AG 2018 All rights reserved iTh1 t = 180 iTh2 ULoad U~ ULoad t = 45 Control device iTh1 iTh2 t = 45 The diagrams show the current and/or voltage characteristic of a phase Table 5-1 Legend U~ Line voltage iTh1 Load current through thyristor 1 U Load Load voltage iTh2 Load current through thyristor 2 I Load Load current Firing angle t Time-dependent phase angle The angle between the zero crossover of the line voltage and firing the thyristors is called firing angle . By changing the firing angle, the mean value of the AC voltage at load resistor R can be continuously varied between its maximum value at = 0 and 0 V at = 180. SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 14 5 Open-loop control mode The relationships for a firing angle = 45 are shown in Fig. 5-1. At = 0 , the system is fully-controlled, i.e. the line voltage is continuously available at the load. Contrary to this, at = 180, the voltage is available as blocking voltage across the thyristor module during the complete half wave. At an angle of 45, the dotted line indicates the voltage characteristic when the thyristor is in a high ohmic (blocking) state. Properties This control mode is suitable for resistive (ohmic), inductive and resistive-inductive loads. In the first case, the load current and voltage have the same phase relationship, while in the two other cases, the current lags the voltage. Benefits The advantages of phase angle control include the fine energy dosing and short response time; this means that it can be used for extremely fast control loops. Further, the current can be limited when using this control mode. Disadvantages Siemens AG 2018 All rights reserved The disadvantage of this control mode results from the harmonics caused by the steep edges of the chopped voltage half waves - which result in HF disturbance. Another disadvantage is the reactive power, that even occurs for resistive (ohmic) loads. For resistive loads, this is caused entirely by the phase angle control, and is therefore known as control reactive power. 5.2 Full-wave control For full-wave control, complete sinusoidal oscillations are switched-in or switched-out. The mean power is obtained from the ratio between the on-time and off-time. As a consequence, a low level of radio frequency interference is achieved - along with low levels of harmonics and a low reactive power. p51411 Three-phase AC power controller full wave control distribution 1 = block distribution [factory setting] 2 = uniform distribution Block distribution All of the full waves that are switched-on are concentrated in a block - the pause as well. The load temperature is not constant, but fluctuates depending on how high the thermal time constant of the load is compared to the cycle time. SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 15 5 Open-loop control mode Fig. 5-2 Full-wave control with block distribution ULoad ?t Te T Load voltage Line voltage Firing pulse Siemens AG 2018 All rights reserved The diagram shows the current and/or voltage characteristic of a phase Uniform distribution All of the full waves that are switched-on are uniformly distributed over the cycle time. This control mode is better suited for fast control loops. Fig. 5-3 Full-wave control with uniform distribution with 66.6% duty cycle ULoad t T The diagram shows the current and/or voltage characteristic of a phase p51412 Minimum switch-on duration [1 to 50 line periods, factory setting = 1] Advantages of full-wave control when compared to phase angle control * Minimum radio interference as the thyristors for resistive loads are always fired at the zero crossover of the voltage. * No harmonics, the load current is purely sinusoidal * No control reactive power If only resistive loads are controlled, then the line supply is not inductively loaded. There is no lagging reactive current. SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 16 5 Open-loop control mode Disadvantage of full-wave control when compared to phase angle control Voltage fluctuations on the line supply cable (voltage flicker). If the line supply is too weak (low fault rating), voltage fluctuations can occur on the line supply cable as a result of load pulsing. For lighting system connected to the same line supply, this results in unpleasant fluctuations in the lighting level (flicker). The associated limit values can be taken from EN 61 000-3-3. 5.3 Half-wave control For half-wave control, complete sinusoidal half waves are switched-in or switched-out. This control mode reduces the power fluctuations when compared to full-wave control. The following attributes apply: * In every cycle, the same number of positive and negative half waves are always switched-in or switched-out. This therefore ensures that no DC components occur, which would significantly load the line supply or upstream transformers. * The positive and negative half waves that are switched-on are, as far as possible, uniformly distributed over the cycle time. Siemens AG 2018 All rights reserved Fig. 5-4 Half-wave control with 25% duty cycle ULoad t T The diagram shows the current and/or voltage characteristic of a phase 5.4 Common functions for full and half-wave control General When using inductive loads, e.g. transformers, full and half-wave control modes cannot be used. Current limiting cannot be implemented for full and half-wave control. The current amplitude is only defined by the load, and cannot be influenced or limited by the three-phase AC power controller. As a consequence, the three-phase AC power controller power unit may not be underdimensioned with respect to the connected load. For full and half wave control, the thyristors conduct a certain number of current half waves depending on the firing angle. The relevant thyristor is damaged by a current half wave with high overcurrent. Note The thyristors can be damaged if the maximum load current exceeds the maximum input current of the power unit. SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 17 5 Open-loop control mode Cycle generation p51410 Three-phase AC power controller cycle time 5 to 5000 line periods, factory setting = 50 Extending the cycle time has the advantage that the setpoint resolution improves, i.e. the setpoint can be set more finely. The disadvantage is that for longer cycle times and heating systems with a very low thermal time constant, the temperature fluctuations are greater than for short cycle times. p51415 Three-phase AC power controller starting firing angle Setting the initial firing angle for full and half wave control when used as three-phase AC power controller. The firing angle for the first half wave of a contiguous pulse group - this is why it is also called an Start - can be set between 0 el and 90 el. Fig. 5-5 Full-wave control with chopped first line voltage half wave Siemens AG 2018 All rights reserved ULoad t Start Te T Load voltage Line voltage Firing pulse The diagram shows the current and/or voltage characteristic of a phase Chopped last (and last but one) line voltage half wave The power can be continuously adjusted, even for full-wave control (especially for block distribution) as the phase is chopped at a half period of the switch-on time. SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 18 5 Open-loop control mode Fig. 5-6 Full-wave control with chopped line voltage half wave ULoad t Te T Load voltage Line voltage Firing pulse Siemens AG 2018 All rights reserved The diagram shows the current and/or voltage characteristic of a phase p51416 waves Three-phase AC power controller, full-wave control with chopped line voltage half 0 = no phase angle control - phase not chopped [factory setting] 1 = phase of the last half wave chopped 2 = phase of the last two half waves chopped SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 19 6 Soft start function 6 Soft start function Application The soft start function means that when first switched on a high power is not applied to the load. As a consequence, you have additional operational reliability for transformer loads. This soft start function is used when controlling transformer loads and resistive loads, whose resistance significantly changes with the temperature (e.g. Rcold : Rwarm 1 : 16 for Kanthal Super heating elements). * The power is continually increased and applied to the load from 0 up to the corresponding duty cycle. * The transformer is pre-magnetized and can then be operated with its full power rating. * The rush effect (inrush) is suppressed. Principle Phase angle controlled operation is always started each time that the system switched on. The firing angle starts with 180 (A,softstart), and is shifted towards the front along an adjustable ramp. "Phase angle control" control mode Siemens AG 2018 All rights reserved The soft stop ramp is exited if the firing angle matching the specified duty cycle is reached. "Full-wave control" and "Half-wave control" control modes The soft start ramp is exited when a firing angle of E,Softstart is reached. The system then automatically switches over to full-wave control or half-wave control. Normally, E,Softstart = 0. However, it can also make sense to already exit the soft start ramp for a firing angle of 90 (E,Softstart). This is because for a resistive (ohmic) load, the maximum peak current is reached. For the subsequent full-wave control or half-wave control for a transformer load, by setting a start angle Start between 0 and 90, the first half wave of each pulse package can be chopped. Fig. 6-1 Soft start for full-wave control ULoad t Load voltage Line voltage Firing pulse The diagram shows the current and/or voltage characteristic of a phase If the off duration is longer than a time that can be parameterized, when it is switched-on again, three-phase AC power controller restarts with a soft start ramp. SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 20 6 Soft start function p51420 Three-phase AC power controller, duration of the soft start ramp [0 to 500 line periods, factory setting = 0] The "Soft start ramp duration" is defined as: Number of line periods in which the firing angle would be shifted forward from 180 to 0. This time defines the change of the firing angle per line cycle. The actual duration of the soft start can be shorter, e.g. if a final control angle not equal to 0 is set. Note For full and half-wave control, the soft start ramp duration should be set shorter than "2 *cycle time* max. duty cycle", to prevent any overload condition during the soft start. p51421 Three-phase AC power controller soft start final firing angle ( E,Softstart) [0 to 180, factory setting = 0] Siemens AG 2018 All rights reserved p51422 AC power controller max switch off duration w/out a new soft start [0 to 100s, factory setting = 0] SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 21 7 Line load equalization Line load equalization 7 For partial load operation in the full-wave or half-wave control mode, unnecessary load peaks can occur if several three-phase AC power controllers are involved and the individual devices are not switched in a coordinated fashion. Using a higher-level control system, the loads within a group of three-phase AC power controllers can be equalized. Note The line load equalization control is not implemented in SINAMICS DCM, instead, the function must be realized in a higher-level control system. Example Controller 1 and controller 2 have a duty cycle = 50%. Cycle period is 1 s. Without any coordination between controller 1 and controller 2, then it is possible that both simultaneously conduct current for 1/2 second - and then both simultaneously do not conduct current for 1/2 second. With load equalization control, controller 1 conducts current for 1/2 second and controller 2 does not conduct current - and vice versa. Siemens AG 2018 All rights reserved Note * * A line load equalization control is only effective if the individual three-phase AC power controllers have duty cycles that are less than 100%. Line load equalization control is only possible in the full-wave and half-wave control modes. For phase angle control, there is no periodic switching on/switching off that can be coordinated over several controllers. It results in a uniform current flow for all three-phase AC power controllers. SINAMICS DCM offers functions that facilitate and support higher-level line load equalization control. p51410 Cycle time The cycle time must be set the same for all devices that participate in line equalization, otherwise the line equalization control function does not function. For phase angle control, setting the cycle time has no relevance. r51430 Cycle output not shifted This output supplies a type of staircase signal (0% to 100%), which specifies how many line periods of the clock cycle periods have already taken place. Shifting the clock cycle by the signal specified in p51437 is not taken into account. r51431 Actual cycle output The same as r51430, however, the shift by the signal specified in p51437 is taken into account. p51435 Cycle generation type 1 = internal cycle [factory setting] 2 = external cycle (signal source specified in p51436) SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 22 7 Line load equalization p51436 Selection of the signal source for the external cycle [factory setting = 0] p51437 Selection of the signal source for the cycle shift [factory setting = 0] A higher-level control system can specify by how many percent (0% to 100%) the clock cycles of individual three-phase AC power controllers should be shifted. 7.1 Implementation example A circuit suggestion is shown in the following example. It shows the BICO connections that are required for the line load equalization control of a group of three-phase AC power controllers based on SINAMICS DCM. SINAMICS DCM 1 outputs its unshifted internal cycle (e.g. via the parallel interface) to all other DCMs. This means that all DCMs run in synchronism. * The "subordinate control", running in a higher-level control system, specifies the duty cycle to each individual DCM (e.g. via PROFINET). * The line load equalization control specifies a cycle shift for each individual DCM (e.g. via PROFINET). This allows the line load to be kept as uniform as possible. Siemens AG 2018 All rights reserved * SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 23 7 Line load equalization Fig. 7-1 Example of line load equalization control Profinet Parallel interface SIMATIC - Higher-level closed-loop control - Lower-level closed-loop control (specifies the duty cycle) - Line load equalization control (specifies the cycle shift) CI: PZD2 p2051[0] r51430 CO: int. cycle r51430 Duty cycle 1 CI: Set s_s CO: PZD2 r2050[1] p51406 r2050[1] Cycle shift 1 CI: Cyc intercon s_s CO: PZD3 p51437 r2050[2] + DCM 1 r2050[2] p51435 = 1 Duty cycle 2 CI: Set s_s Siemens AG 2018 All rights reserved CO: PZD4 r2050[3] CI: Cyc intercon s_s CO: PZD5 p51437 r2050[4] Ext. cycle CCI: Ext cycle s_s CO: PZD1 p51436 p51406 r2050[3] Cycle shift 2 r52700[0] r2050[5] r52700[0] DCM 2 r2050[4] p51435 = 2 Duty cycle 3 CI: Set s_s CO: PZD6 CI: P2P PZD1 CO: int. cycle p51814[0] r51430 r51430 Ext. cycle CCI: Ext cycle s_s CO: PZD1 p51436 p51406 r2050[5] r52700[0] r52700[0] Cycle shift 3 CI: Cyc intercon s_s CO: PZD7 p51437 r2050[6] DCM 3 r2050[6] SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 p51435 = 2 24 8 Parameter overview 8 Parameter overview Table 8-1 Parameter Function General functions for three-phase AC power controllers p51400 Open-loop control mode 0: B6C bridge not used as three-phase AC power controller [factory setting] 1: Three-phase AC power controller with phase angle control 2: Three-phase AC power controller with full-wave control 3: Three-phase AC power controller with half-wave control p51404 Scaling of the synchronizing voltage Here, set which peak value of the line voltage (in V) should be mapped to 10 V at the analog input. p51405 Selects the synchronizing voltage 0: Internal synchronizing voltage [factory setting] 1: External synchronizing voltage (terminal X177.29/30) p51406 Signal source for the duty cycle Siemens AG 2018 All rights reserved Functions for full and half-wave control p51410 Cycle time [5 to 5000 line periods, factory setting = 50] p51411 Full-wave distribution type 1: Block distribution [factory setting] 2: Uniform distribution Soft start function p51420 Soft start ramp duration [0 to 500 line periods, factory setting = 0] p51421 Final firing angle [0 to 180, factory setting = 0] p51422 Max. off duration without a new soft start ramp [0 to 100s, factory setting = 0] Functions for line load equalization control r51430 Cycle output not shifted This output supplies a type of staircase signal (0% to 100%), which specifies how many line periods of the clock cycle periods have already taken place. Shifting the cycle by the signal specified using p51437 is not taken into account. r51431 Actual cycle output The same as r51430, the shift by the signal specified using p51437 is taken into account, however. p51435 Cycle generation type 1: Internal cycle [factory setting] 2: External cycle (signal source specified in p51436) p51436 Selection of the signal source for the external cycle [factory setting = 0] p51437 Selection of the signal source for the cycle shift [factory setting = 0] A higher-level control system can specify by how many percent (0% to 100%) the clock cycles of individual three-phase AC power controllers should be shifted. Factory setting SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 25 9 Appendix 9 Appendix Siemens AG 2018 All rights reserved Table 9-1 Type-related line voltages and input currents Order number Line voltage Line current at full load 6RA8013-6DV62-0AA0 3AC 400V 3AC 13A 6RA8018-6DV62-0AA0 3AC 400V 3AC 25A 6RA8025-6DS22-0AA0 3AC 400V 3AC 50A 6RA8028-6DS22-0AA0 3AC 400V 3AC 75A 6RA8031-6DS22-0AA0 3AC 400V 3AC 104A 6RA8075-6DS22-0AA0 3AC 400V 3AC 174A 6RA8078-6DS22-0AA0 3AC 400V 3AC 232A 6RA8081-6DS22-0AA0 3AC 400V 3AC 332A 6RA8085-6DS22-0AA0 3AC 400V 3AC 498A 6RA8087-6DS22-0AA0 3AC 400V 3AC 706A 6RA8091-6DS22-0AA0 3AC 400V 3AC 996A 6RA8093-4DS22-0AA0 3AC 400V 3AC 1328A 6RA8095-4DS22-0AA0 3AC 400V 3AC 1660A 6RA8098-4DS22-0AA0 3AC 400V 3AC 2490A 6RA8025-6FS22-0AA0 3AC 480V 3AC 50A 6RA8028-6FS22-0AA0 3AC 480V 3AC 75A 6RA8031-6FS22-0AA0 3AC 480V 3AC 104A 6RA8075-6FS22-0AA0 3AC 480V 3AC 174A 6RA8078-6FS22-0AA0 3AC 480V 3AC 232A 6RA8082-6FS22-0AA0 3AC 480V 3AC 374A 6RA8085-6FS22-0AA0 3AC 480V 3AC 498A 6RA8087-6FS22-0AA0 3AC 480V 3AC 706A 6RA8091-6FS22-0AA0 3AC 480V 3AC 996A 6RA8025-6GS22-0AA0 3AC 575V 3AC 50A 6RA8031-6GS22-0AA0 3AC 575V 3AC 104A 6RA8075-6GS22-0AA0 3AC 575V 3AC 174A 6RA8081-6GS22-0AA0 3AC 575V 3AC 332A 6RA8085-6GS22-0AA0 3AC 575V 3AC 498A 6RA8087-6GS22-0AA0 3AC 575V 3AC 664A 6RA8090-6GS22-0AA0 3AC 575V 3AC 913A 6RA8093-4GS22-0AA0 3AC 575V 3AC 1328A 6RA8095-4GS22-0AA0 3AC 575V 3AC 1660A 6RA8096-4GS22-0AA0 3AC 575V 3AC 1826A 6RA8097-4GS22-0AA0 3AC 575V 3AC 2324A 6RA8086-6KS22-0AA0 3AC 690V 3AC 598A 6RA8090-6KS22-0AA0 3AC 690V 3AC 830A 6RA8093-4KS22-0AA0 3AC 690V 3AC 1245A 6RA8095-4KS22-0AA0 3AC 690V 3AC 1660A 6RA8097-4KS22-0AA0 3AC 690V 3AC 2158A 6RA8097-4KS22-0AA0 3AC 690V 3AC 2158A SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 26 9 Appendix Line voltage Line current at full load 6RA8088-6LS22-0AA0 3AC 830V 3AC 789A 6RA8093-4LS22-0AA0 3AC 830V 3AC 1245A 6RA8095-4LS22-0AA0 3AC 830V 3AC 1577A 6RA8096-4MS22-0AA0 3AC 950V 3AC 1826A Devices can be adapted to specifically address customer requirements based on a comprehensive range of options. Siemens AG 2018 All rights reserved Note Order number SINAMICS DCM as three-phase AC power controller for heating applications Entry ID: 109763610, V1.1, 08/2018 27