Electric Drive Systems: AC Machine (DC Sinamics) Presented To: Professor Lothar

Practical Presentation SS 2022
Electric Drive Systems

AC Machine (DC Sinamics)
Presented to : Professor Lothar
Group B:
Syed Khizar Hayat Matrikel No 454166
Fahad Jamshaid Matrikel No 455923
A K MD Bodiuzzaman Matrikel No 455910
Dated 16 May 2022

Accompanying Course Information 1
Contents
Goal / Tasks
Introduction
Parts & Components
Circuit & Operation
Commissioning
Safety Measures
Conclusion

Goal / Tasks
 Operate Three Phase AC fan.

 Operate Three Phase AC Machine.
(Make sure Machine will run only when Fan is operating).
 Measure Rotational Speed of Machine.
 Control Speed using Frequency Converter.
 Rotation of Motor in both directions.
(Clock-wise and Anti clock wise direction).
 Stop Machine in case of Emergency.

Introduction
AC Machine with DC Sinamics
 Three Phase AC Machine

 DC Input
 AC Output (Three Phase with 50Hz Frequency)
Three Phase AC Supply
DC Supply
3 Phase Inverter, Control
Unit, Electric Components,
Speed Control Unit etc.
Fig 1. AC machine wirh DC Sinamics

Presentation PART – I
Components

Parts and Components
Previously Discussed (RECAP) Discussed in today’s
Presentation
 Rectifier  Hardware Part
 Control Unit
 Inverter
 Incremental Encoder
 Three Phase AC Motor  Tachometer (BGS Technic Revolution
counter)
 Temperature sensor
 Oscilloscope
 Potentiometer  Digital Voltmeter
 Clamp
 Circuit Breakers
 Potentiometer(Pedal)
 Push Buttons, Switches  25MHz Differential Probe
 Relays  Emergency Stop Button
 Software Part
 Overview of Starter Software

Parts and Components (RECAP)
Rectifier
 A rectifier is an electrical device that converts alternating current, which periodically
reverses direction, to direct current, which flows in only one direction.
Inverter
 Inverter is used to convert DC voltage from rectifier to three phase AC voltage to run
the 3 Phase AC motor.
Temperature Sensor
 Used to measure the temperature of motor in order to prevent it from over
heating and to keep the motor within extreme limits.
Relay
 The Relay is a switching device which gives a signal to the circuit breaker as
soon as the fault occurs in the power system.
Circuit Breaker
 Electrical safety device
 Received signal from the relay.
 Protect an electrical circuit from damage caused by an overcurrent or short
circuit.

3 Phase AC Motor (RECAP)
Parts of AC Motor
Three Phase Motor has mainly two parts:
 Stator Windings
 Stationary part placed in stator of
motor.
Fig 1. Stator of AC Motor
 Stator Frame, outer part (covering,
protection and mechanical strength)
 Stator core (reduce eddy current &
Hysteresis loss)
 Stator or field windings (3 windings,
120 degree apart, wound on the stator
of AC machine. Produces three phase Fig 2. Parts of the Motor
magnetic field.
3 Phase AC Motor (RECAP)
 Rotor
 Rotating Part of Motor.
 Contains conductors in the form of Aluminum or copper bars connected

to form a circuit.
 The rotor surrounds the motor shaft and is the motor component that
rotates to produce the mechanical energy output of the motor.
 The spinning fan draws ambient air from outside across the stator
and rotor for cooling.
Fig 3. Rotor of 3 phase AC Machine

Components
 Control Unit
 The control Unit can control the whole operations.
 It acts as a brain of the whole system.
 Power Management control: short circuit protection ,Overvoltage
protection
 Speed Control for efficient use of the motor
 Temperature Control : Overheating
 Emergency safety control
Fig 5. Control Unit Starter

Components
 Incremental Encoder
 The incremental encoder is used to measure the position of the motor
shaft.
 The information can be about rotary position (as with rotary encoders) or
linear position with linear encoders.
– Operating Principle
 As the encoder shaft spins a codewheel, an incremental encoder generates
two pulse trains, A and B (by the PWM from the software).
 Magnetic field sensors (Hall effect sensors) or light sensors can generate
these pulse trains (LEDs and phototransistors or photodiodes).
 The code wheel could be composed of an opaque material with slots or of a
transparent (glass or plastic) material with opaque lines.
Fig 6. depicts the latter approach, which is utilized in optical encoders [13] Fig 7. Tachometer Vs Encoders [14]

Components
 It is done in the software in the Lab (STARTER).
Fig 8. Incremental Encoder in STARTER software

Components
 Tachometer (BGS Technic Revolution counter with Laser)
 This device is used to measure the Rotational speed (RPM-Revolution per
minute) of the motor.
 The laser is point on the shaft of the motor and the display shows the speed
(RPM).
– Operating Principle
 Optical/Photo Tachometers operate by shining a light source, typically a LED
light or Class 2 laser beam, against the rotating element.
 This light source creates a focused beam of light which will be reflected
back off of a reflective object that is placed in its path.
 The optical sensor of the tachometer will be triggered as the light is
reflected back towards the tachometer.
 By measuring the rate that the sensor receives the signal, a measurement
of the rotational speed can be determined.
Fig 9. BGS Technic Revolution Counter with LASER [11] Fig 10. Tachometer measuring the RPM of a motor [12]

Components
 Oscilloscope
 The oscilloscope is used to display the signals in the time domain.
 We can see the current and voltage signals on the oscilloscope for the
measurement of maximum values, minimum values, time delay, peak to
peak etc.
 The current sinusoidal signal is shown here is the yellow (Channel 1) while
the voltage signal shown here is the green color (Channel 2).
Fig 11. Oscilloscope showing real time signal (I,V) of the motor

Components
 Digital Multimeter
 Digital multimeter are measuring equipment capable of measuring voltage,
current, and resistance.
 Measured data are shown on a digital display.
 It gives accurate and more precise measured values.
Fig 12. DC output voltage is measured by the multimeter in the lab

Components
 Clamp current meter
 The clamp current meter is used to measure the current.
 The clamp is placed around the conductor wire and it displayed the current
flowing through the wire.
 Fig 13 shows the current clamp used in the lab and is connected to the
oscilloscope to display the current signal.
 Fig 14 shows the current clamp used to measure the current and display the
values on the screen.
Fig 13 Clamp meter used in the Lab for Oscilloscope Fig 14 Clamp meter for displaying values on the screen

Components
 Potentiometer Pedal
 It is used to control the speed of motor.
 It has three terminal, one with maximum, one with minimum value and
other is sliding terminal.
 It acts as a voltage divider, when it is pressed it provide the maximum
voltage to the motor which can increase the speed of motor.
Fig 15. Pedal used in the Lab to change the speed of the motor

Components
 25MHz Differential Probe
 A 25-MHz low-cost high-voltage differential probe to make safe and
accurate floating measurements with an oscilloscope.
 The two wires from the motor for the voltage signal cannot be directly
inserted to the Oscilloscope.
 We used this device in the lab to see the voltage signal on the oscilloscope
Fig 16. 25MHz differential probe in the Lab experiment

Components
 Emergency Stop Button
 The red round button placed in the panel is Emergency Stop button.
 Press the button in case of emergency to avoid any bad things.
Fig 17. Emergency Stop Button
 It can stop all the operations and provides protection.

Software
 SINAMICS STARTER SIEMENS
 The STARTER software in the Laboratory we used for the commission of our lab
task.
Fig 18. STARTER Software for Commission

Presentation PART – II
Operation

Steps to Operate Motor
In order to operate the three AC Machine, there are
some initial conditions which need to be fulfilled.
 Operation of Fan (Cooling purpose).
 Emergency Switch (Digital pin DI 3)
 Enable Connection (Digital pin DI 4)
 K12 Contactor (Digital pin DI 0)
 Function of control unit and Motor
 Direction Reversal (Digital pin DI5)

Circuit Diagram

Steps to Operate Motor
 Emergency Switch (Digital pin DI 3)
 Enable Connection (Digital pin DI 4)
 K12 Contactor (Digital pin DI 0)

DC Supply via Rectifier
 For three Phase AC voltage of 400 Vrms

 DC bus Voltage is approximately sqrt(2) x 400 = 565V DC.
 Input DC Voltage = 220V

Motor Operation without External Control
 Speed vs. Voltage
 Speed vs. Frequency
 Speed Vs. Current
 Output Power vs. Effective Power

Ramp Function Generator

Motor Potentiometer

Direction Reversal
 Port X132 can used the
change the direction of
Motor.
 24V DC is given to X132 using

a switch is series.

Motor Temperature
 Motor Temperature Settings

Motor Operation with Control Circuit
 Power = V x I
 162.3 x 2.90
 0.471 Watts
 Effective Power = .11KW
 Power = V x I
 162.5 x 2.87
 0.467 Watts
 Effective Power = .12KW
 Rest of the Power (Major portion) is reactive power.

Operation of 3 Phase AC Motor
• Three Phase AC Supply in given to the Stator windings.
• AC currents are phase-shifted by 120o, the magnetic polarity of the

three coils are not all identical at the same instant of time.
• Produces three phase changing magnetic field, known as Rotating

Magnetic field.
• Changing magnetic field from the stator induces a current in the

rotor coils by EMF (Faraday’s Law).
• Rotor induced current results in opposing magnetic field by rotor.

(Lenz’s Law)
• The rotor seeks to align its polarity against that of the stator field,
the result being a net torque is applied to the shaft

Motor Slip
The synchronous speed ns of the motor is calculated by:
120∗𝑓𝑠 50
ns = = 120 ∗ = 1000 [rpm]
𝑃 6
where ,𝑓𝑠 is the synchronous stator frequency in Hz, p is the number of stator
poles.
The load torque is produced by slip frequency. The motor speed is characterized
by a slip.
(ns − nr )
𝑆𝑙𝑖𝑝 =
ns
1000−962
Slip = = 0.038
1000
1000 − 100
Slip = = 0.90
1000
1000−200
Slip = = 0.80
1000

Soft Starter
• An induction motor draws current more than the rated capacity

during starting phase.
• Might results in damaging of stator windings of three phase induction

motor.
• To avoid the problem of high starting current, voltage is increased

gradually from lower to higher level using smooth and soft starters.
• A smooth and soft starter is employed in a three phase induction

motor to eliminate the surge in current and electromagnetic torque
during starting.
• The surge in current and torque are eliminated temporarily using soft
started at the time of starting.
• This in turn reduces the stress applied on an electric motor and shaft
attached with rotor

Wires Color Coding
DC Supply
• Red Wire: Used for positive DC
• Blue Wire: Used for negative DC / Gnd
Single Phase AC Supply

• Black Wire : Used for Live phase
• Blue Wire: Used for Neutral
Three Phase AC Supply

• Black, Grey, Brown is used for three phase AC supply
Potential Earth
• Yellow: used for potential Earth

Presentation PART – III
Safety

Safety
Safety used to keep movement safe
 Power safety
 Wiring safety
 Prevention of unexpected start-up
 Emergency stop
 Safely-limited speed, safe acceleration/deceleration
 Safe direction (of rotation)
 Safe control of a mechanical
 brake
Figure: Industrial drive [1]

Safety functions module
Figure: safety concept[1]

 Safely stop the application
 Safely monitor the speed and react accordingly if
needed
 Safely monitor the direction of the rotation of
the motor
 Prevent unexpected start-up of the application
 Minimize waste and downtime with controlled
safe stopping
 Provide safety encoder feedback for the drive
control and safety system
 Safety inputs and outputs for the field devices
(e.g. E-stop, limit switches etc.)
 Overheating safety control

Safety Integrated extended functions
Safe Stop 2 (SS2)

 The SS2 function brakes the motor
safely with a subsequent transition to "Safe
Operational Stop" (SOS). This function
is active within the ramp
down phase.
Safe Operational Stop (SOS) Figure : SS2 time [2]

 "Safe Operational Stop" (SOS) protects against unintentional movements. The
drive is
in closed-loop control mode and is not disconnected from the power supply.
Safely Limited Speed (SLS)

 The "Safely Limited Speed" (SLS) protects against excessively high drive speeds.
Safe Speed Monitor (SSM)
 The SSM function reliably monitors the speed limit and issues a safe output
signal, but without a response function.

Industrial Machinery Safety
 Safety Integrated basic functions
 These functions are part of the standard scope of the drive.
 Safe torque off (STO)
 STO is a safety function that prevents the drive from restarting unexpectedly, in
accordance with EN 60204-1, Section 5.4.
 Safe Stop 1 (SS1, time controlled)
 After "Safe Stop 1" is set at the OFF3 ramp (p1135), the drive
 brakes and changes to the Safe Torque Off (STO) status on expiration of the
delay time (p9356/p9556), or after having reached the shutdown speed
(p9360/p9560).
 Safe Brake Control (SBC)
 The SBC function permits the safe control of a holding brake

Properties of Safety Integrated parameters
 During startup, a checksum (Cyclic Redundancy Check, CRC) over the

safety parameters is generated and checked. The display parameters are
not contained in the CRC.
 Data storage: The parameters are stored on the non-volatile

CompactFlash card.
 Factory settings for safety parameters password-protected against

accidental or unauthorized changes.
 During commissioning, the actual checksum must be transferred to the

corresponding parameter for the specified checksum

Probability of failure of the safety functions (PFH value)
The probability of the failure of safety functions must be specified in the form
of a PHF value
(Probability of Failure per Hour) in accordance with IEC 61508, IEC 62061 and
ISO 13849-1.
 The PFH value of a safety function depends on the safety concept of the
drive unit and it’s hardware configuration, as well as on the PFH values of
other components used for this safety function.
 Corresponding PFH values are provided for the SINAMICS S120 drive
system, depending on the hardware configuration (number of drives,
control type, number of encoders used, ...).

Residual risk
The fault analysis enables the machine manufacturer to determine the

residual risk at his machine with regard to the drive unit. The following
residual risks are known:
 Violation of limits may briefly lead to a speed higher than the speed set
point, or the axis may pass the defined position to a certain extent,
depending on the dynamic response of the drive and on parameter
settings.
 Mechanical forces greater than the maximum drive torque may force a
drive currently operated in position control mode out of the Safe
Operational Stop state (SOS) and trigger a category 1 stop function to IEC
60204-1 (fault reaction function STOP B).

Commissioning

Power up the device
Figure: Power up device[3]

Off responses
● OFF1-When zero speed is detected, the motor holding brake (if parameterized) is closed
(p1215).Zero speed is detected if the actual speed drops below the threshold (p1226) or if the monitoring time (p1227) started
when the speed setpoint ≤ speed threshold (p1226)
has expired.
Acknowledgement
 We are thankful to Professor Lothar for his continues support and
guidance during the project.

Thank You for the Attention 
Please feel free to ask Questions
Questions are Appreciated !!!

References
[1] https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.electronics-tutorials.ws%2Fpower%2Fthree-phase-
rectification.html&psig=AOvVaw2F8GxsDQN-
7zX_NyOq88ok&ust=1650756747774000&source=images&cd=vfe&ved=0CAwQjRxqFwoTCPjDh57qqPcCFQAAAAAdAAA
AABAD
[2] https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.electricalvolt.com%2F2019%2F06%2Frotating-magnetic-
field-in-three-phase-induction-
motor%2F&psig=AOvVaw0lOYFgxzaKt23DEikPhhMS&ust=1650761197736000&source=images&cd=vfe&ved=0CAwQjRxq
FwoTCKCD4Ib7qPcCFQAAAAAdAAAAABBD
[3] Construction of Three Phase Induction Motor _ Electrical4U
[4] https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.flaktgroup.com%2Fen%2Fnews%2Fnews-
archive%2F2020%2Fjuly%2Fbasic-principles-of-ac-induction-
motors%2F&psig=AOvVaw2YH2N13OlzEMaxpDIA_NM_&ust=1650762740156000&source=images&cd=vfe&ved=0CAwQjR
xqFwoTCODgtseAqfcCFQAAAAAdAAAAABAS
[5] What is a 3-Phase Motor and How Does it Work_
[6] 3 Phase Induction Motor Definition And Working Principle
[7] https://www.allaboutcircuits.com/uploads/articles/ezgif.com-gif-maker_(1)_.gif
[8] https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.researchgate.net%2Ffigure%2Fthree-phase-inverter-
output-voltage-and-current-waveforms-cut-diode-7-The-
difference_fig5_303331885&psig=AOvVaw0JPblOYnbEC8RSM6TEzLLi&ust=1650899162113000&source=images&cd=vfe&
ved=0CAwQjRxqFwoTCOi-3OL8rPcCFQAAAAAdAAAAABAb
[9]. 3-Phase AC Motor Control with V/Hz Speed Closed Loop Using the 56F800/E
https://www.nxp.com/docs/en/application-note/AN1958.pdf
[10].https://cache.industry.siemens.com/dl/files/231/34682231/att_80493/v1/1PL628_BE_0308_en.pdf
[11]. https://www.bueromarkt-ag.de/drehzahlmesser_bgs-technic_2188_digital,p-2188,l-google-css,pd-
b2c.html?gclid=Cj0KCQjwmuiTBhDoARIsAPiv6L_M2PqFA4caOK5pH79T6Icn9ILGm-
iJf2oiKX3s6rLswddReVgA5jsaAn0mEALw_wcB
[12] https://www.designworldonline.com/faq-whats-difference-tachometer-encoder/
[13] https://www.sciencedirect.com/topics/engineering/incremental-encoder
[14] https://www.precisionmicrodrives.com/tachometers-vs-encoders-whats-the-difference
[15] PROFIsafe safety functions module, FSPS-21 – ABB
[16]. /FH1/ SINAMICS S120 Function Manual.
[17]. commissioning_manual
https://media.distributordatasolutions.com/seimens/2017q1/9c1db79cd1354a4817968488041c230d41d03df0.pdf

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Practical Presentation SS 2022

Electric Drive Systems

Fahad Jamshaid Matrikel No 455923

A K MD Bodiuzzaman Matrikel No 455910

Dated 16 May 2022

Parts & Components

Circuit & Operation

Accompanying Course Information 2

 Operate Three Phase AC fan.

Accompanying Course Information 3

AC Machine with DC Sinamics

 Three Phase AC Machine

Three Phase AC Supply

Fig 1. AC machine wirh DC Sinamics

Accompanying Course Information 4

Accompanying Course Information 5

Accompanying Course Information 6

Accompanying Course Information 7

 Rotating Part of Motor.

 Contains conductors in the form of Aluminum or copper bars connected

Fig 3. Rotor of 3 phase AC Machine

Accompanying Course Information 9

Fig 5. Control Unit Starter

Accompanying Course Information 10

Accompanying Course Information 11

Fig 8. Incremental Encoder in STARTER software

Accompanying Course Information 12

Accompanying Course Information 13

Accompanying Course Information 14

Fig 12. DC output voltage is measured by the multimeter in the lab

Accompanying Course Information 15

Accompanying Course Information 16

Accompanying Course Information 17

Fig 16. 25MHz differential probe in the Lab experiment

Accompanying Course Information 18

 Press the button in case of emergency to avoid any bad things.

Fig 17. Emergency Stop Button

 It can stop all the operations and provides protection.

Accompanying Course Information 19

Fig 18. STARTER Software for Commission

Accompanying Course Information 20

Accompanying Course Information 21

 Operation of Fan (Cooling purpose).

 Emergency Switch (Digital pin DI 3)

 Enable Connection (Digital pin DI 4)

 K12 Contactor (Digital pin DI 0)

 Function of control unit and Motor

 Direction Reversal (Digital pin DI5)

Accompanying Course Information 22

Accompanying Course Information 23

 Emergency Switch (Digital pin DI 3)

 Enable Connection (Digital pin DI 4)

 K12 Contactor (Digital pin DI 0)

Accompanying Course Information 24

 For three Phase AC voltage of 400 Vrms

Accompanying Course Information 25

 Speed vs. Voltage

 Speed vs. Frequency

 Speed Vs. Current

 Output Power vs. Effective Power

Accompanying Course Information 26

Accompanying Course Information 27

Accompanying Course Information 28