Belt - Lift - V1-1 - EN (1) مثال حزام ناقل مصنع سيارات يستعمل S300

Belt lift for the
automotive industry
Siemens
V 1.1 Industry
Online
https://support.industry.siemens.com/cs/ww/en/view/102950703 Support
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Warranty and liability
Note The Application Examples are not binding and do not claim to be complete
regarding the circuits shown, equipping and any eventuality. The Application
Examples do not represent customer-specific solutions. They are only intended
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described in this Application Example shall be excluded. Such an exclusion shall
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Belt lift for the automotive industry

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Danger for personnel as a result of unintentional lowering

If the holding brake does not provide adequate protection, for vertical axes there
WARNING is danger for personnel as a result of unintentional lowering of the load. Plant or
machine builders must take this danger into account during the risk assessment
and must take the appropriate measures to minimize the risk of danger.
A description of the technical and organizational protective measures for different
operating modes is provided in \10\ Technical information sheet for axes subject
to gravity of the German Social Accident Insurance (DGUV).
This application document does not describe a machine safety concept that is
intended to minimize any danger corresponding to the information sheet of
vertical axes. The document only demonstrates how the control-related safety
functions of the products presented can be utilized.

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Table of contents
Table of contents
Warranty and liability ............................................................................................... 2
1 Description of the belt lift application ........................................................... 5
1.1 Mechanical system ............................................................................ 5
1.2 Sensor technology ............................................................................. 6
1.3 Drive train .......................................................................................... 6
2 Task................................................................................................................. 8
3 Solution........................................................................................................... 9
3.1 Overview of the solution................................................................... 10
3.2 Software functionality....................................................................... 10
3.3 Hardware and software components ................................................ 11
4 Drive Dimensioning ...................................................................................... 13
4.1 Configuring the mechanical system .................................................. 13
4.2 Selecting the geared motor .............................................................. 16
4.3 Selecting the drive ........................................................................... 24
5 Installation and commissioning................................................................... 26
5.1 Connecting-up the hardware ............................................................ 26
5.2 Basic commissioning ....................................................................... 27
5.2.1 Commissioning Wizard (offline)........................................................ 27
5.2.2 Drive functions................................................................................. 36

5.2.3 Basic positioner (EPos).................................................................... 39
5.2.4 Safe torque off (STO) ...................................................................... 43
5.3 Optimizing the lift drive (optional) ..................................................... 44
5.3.1 Optimizing the speed controller ........................................................ 44
5.3.2 Power and current limiting ............................................................... 46
5.3.3 Position controller ............................................................................ 47
6 Principle of operation of the application ..................................................... 49
6.1 Function description of the FC201.................................................... 49
6.2 Function description of the FB201 .................................................... 52
7 Operating the application............................................................................. 54
8 Attachment for dimensioning and commissioning ..................................... 60
8.1 Notes for dimensioning .................................................................... 60
8.1.1 Dimensioning with a 70Hz operating speed ...................................... 60
8.1.2 Project documentation from SIZER with parameters ........................ 60
8.2 Notes on commissioning .................................................................. 68
8.2.1 Converting the motor order number ................................................. 68
8.2.2 Technical data of the linear encoder and how to handle
problems ......................................................................................... 70
9 Checklist ....................................................................................................... 72
10 References .................................................................................................... 78
11 Contact person ............................................................................................. 78
12 History .......................................................................................................... 78

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1 Description of the belt lift application

In the automotive industry, lifts are used to move vehicles to different levels (floor
or height differences in the conveyor system). The lift can be implemented with a
roller conveyor or electric monorail system, depending on the conveyor system. A
lift with roller conveyor is described in the following.
Lifts can be used to raise loads by up to 30 m, and generally, the drive train is
located at the top. The lifts can be equipped with service platforms so that it is
easier to carry out maintenance work. Fig. 1-1 shows a belt lift in a two pillar design
(1), with counterweight (2), service platform (3), roller conveyor (4) and skid
(transport skids 5).
Fig. 1-1 Belt lift with two pillars
3
5 4
1
1.1 Mechanical system

Especially belts have established themselves for dynamic lifting applications. For
circulating belts, there is a constant ratio between the output speed at the running
wheel and the lifting speed. On the other hand, for a winding system, the drum
diameter increases. As a consequence, the required speed drops and the torque
increases for a constant lifting velocity.
Contrary to a scissors-type lifting table, the belt lift already provides a significant
proportion of the torque when holding the load in steady-state operation. The
torque required for holding the load can be reduced by using a counterweight.
However, the dynamic torque required increases due to the additional acceleration
and deceleration of the counterweight. For belt lifts, the weight of the counterweight
is calculated based on the weight of the lifting trolley plus half the payload, see
Table 1-1.

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Table 1-1 Weight of the lift in kilograms depending on the maximum payload
Max. payload 500 1000 2000 3000 4000 5000 6000
Weight of the
1800 1800 2500 4700 4700 7000 8000
lifting trolley
Counterweight 2050 2300 3500 6200 6700 9500 11000
The lift can be locked at its top and bottom holding positions using an electrical
interlocking system. The lift has usually a protective guard around it to protect
personnel.
1.2 Sensor technology

A lift is equipped with a multitude of sensors. Operator controls such as illuminated
pushbuttons or HMIs are provided for operating it in the manual mode. Various
states are detected using proximity switches; for example "Roller conveyor
occupied", "Interlocking system closed/open" and "Top/bottom holding position". A
light barrier monitors the gap between the lift roller conveyor and the roller
conveyor either taking the load or delivering the load. Hardware limit switches
monitor the maximum end positions of the lift at the top and bottom. An additional
limit switch monitors the belt for breakage or slack belt.
In the past, proximity switches were used to position the lifting system at defined
holding positions. Proximity switches are used at the top and bottom to switchover
between rapid traverse and crawl. When moving at a crawl velocity, an additional
proximity switch was used to position at the top or bottom holding position.
Faster positioning is now possible using distance measuring systems. Using a
motor encoder, the actual speed (incremental encoder) can be determined – or
using a machine encoder (absolute encoder), the actual position of the load. Linear
measuring systems such as barcodes, cable length encoders or laser measuring
systems are used as machine encoders. These can supply the actual absolute
position of the load. Faster HTL or TTL signals of the incremental encoder can be
used for closed-loop speed control. Absolute encoders with SSI or EnDat interface
are used for the closed-loop position control.
Load sensing systems are only infrequently used, as it can be assumed that
significantly fluctuating loads are generally not encountered in the automotive
industry.
1.3 Drive train

Fig. 1-2 shows the drive train of a belt lift with two geared motors, coupled via the
drum (1) and coupling (2), comprising a four-pole induction motor (3) and an axial
gearbox, such as a helical gearbox (4).
Fig. 1-2 Drive train of a belt lifter
1
3
2
4

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One geared motor is decoupled via the coupling, and is only coupled-in if the other
motor requires service1. A motor holding brake is mandatory for
hanging/suspended loads. For safety reasons, redundant braking systems are also
used. These are equipped with an additional operating brake or safety brakes. For
lifts, the geared motor is always operated with a converter.
The motor holding brake control can be integrated in the sequence control of the
converter. This means that no additional logic has to be generated to control the
holding brakes. The converter allows variable-speed operation and starting and
stopping along defined ramps. This significantly reduces the wear on the
mechanical components. The jerk limiting protects the belt, and the motor holding
brake can always be closed when the motor shaft is stationary. Further, the
converter can generate output frequencies that are higher than the line frequency;
this means that the motor can be operated in the field weakening range to quickly
lift lights loads.
Vector control with or without motor encoder is the control mode most often used.
In addition to closed-loop speed control, closed-loop position control can also be
implemented in the drive and not in the control system (PLC). This way PLC
program capacity can be increased.
When lowering, the motor goes into the generator mode and current flows from the
motor into the converter DC link. The converter must dissipate this regenerative
energy, either using a braking resistor, or the energy can be fed back into the line
supply.
1
For instance, a Flender ZAPEX ZWSE coupling can be used.

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2 Task
2 Task
The lift should be implemented corresponding to Fig. 1-1. A standard induction
geared motor with helical gearbox, motor holding brake and an HTL incremental
encoder is used. The motor should be operated with 87Hz characteristic. An
absolute encoder system is applied for closed-loop position control.
The task is described in Fig. 2-1 with the associated mechanical system – and
traversing profile data in Table 2-1 and Table 2-2.
Fig. 2-1: Description of the lift application task
Table 2-1: Mechanical data

N - payload H - lifting trolley weight G - counterweight T - drum diameter
3000 kg 4700 kg 6200 kg 320 mm
Table 2-2: Traversing profile data

Cycle Time Acceleration/deceleration Brake closed
1. Lifting unloaded 10 s 0.5 m/s² No

2. Load/pause 5s Yes
3. Lowering loaded 10 s 0.5 m/s² No
4. Unloaded 5s Yes

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3 Solution
3 Solution
Fig. 3-1 shows a solution tree for a lift based on SINAMICS G120 and SINAMICS
G120D, where the path marked in red is the solution that is then subsequently
described in detail.
Fig. 3-1: Solution tree for a lift based on SINAMICS G120 and SINAMICS G120D
A SINAMICS G120 with PM250 power module for energy recovery and the
CU250S-2 Control Unit for closed-loop position control with SSI machine encoder,
HTL motor encoder and Safety Integrated are used.

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3 Solution
3.1 Overview of the solution

Fig. 3-2 shows the overview of the automation solution of the lift subsequently
described. The roller conveyor shown is not part of the description, only the lift
drive itself.
Fig. 3-2: Automation solution of the belt lift
3.2 Software functionality

Table 3-1 shows the assignment of the sensor signals.
Table 3-1: Sensor signals of the automation solution.
Sensor Meaning
B201 Roller conveyor occupied
B202 Skid in position
B203 Lift at the bottom position
B204 Lift at the top position
N201 Bottom emergency end position reached
N202 Top emergency end position reached
S201 Broken belt or slack belt

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3 Solution
In the automatic mode, the lift evaluates the status of the roller conveyor and
automatically travels to the resulting position.
If the roller conveyor is not occupied (B201), then the lift travels to the top holding
position (B204). As soon as the roller conveyor issues the "Skid in position" signal
(B202), the lift travels to the bottom holding position (B203).
If the lift travels to the bottom (N201) or top (N202) emergency end position, a fast
stop is initiated (single channel).
Limit switch S201 monitors the lift for broken belt and slack belt.
The Emergency Stop switch safely switches the drive into a no torque condition
(STO according to SIL2).
The lift can be manually moved in the manual mode. In the manual mode, the
velocity is 50% of the automatic velocity. In the manual mode, the "Move up" and
"Move down" functions are available.
The "Jog up" and "Jog down" functions are available in the setting-up mode. These
functions can be used to adjust the absolute encoder.
3.3 Hardware and software components

The application describes the following hardware and software components.
Table 3-2: Hardware components
Component Qty. Order No. Note
CPU317F-2 PN/DP 1 6ES7317-2FK14-0AB0 Or another S7-300

S7 MICRO MEMORY 1 6ES7953-8LM20-0AA0
CARD
SINAMICS G120 1 6SL3225-0BE31-1AA0
PM250
SINAMICS 1 6SL3246-0BA22-1FA0 From FW 4.7 and higher
CU250S-2PN
SINAMICS SD card 1 6SL3054-4AG00-2AA0-Z Epos license
- Extended Functions E01
License
SIMATIC panel 1 6AV6647-0AD11-3AX0
KTP600
PROFINET cable 2 6XV1871-5BH20 Without PC/PG connection
taken into consideration
SM 326F 1 6ES7326-1BK02-0AB0 Fail-safe input module
SIMOGEAR helical 1 2KJ31111HG229AX1-Z Plus options (see
geared motor design/dimensioning)
SIRIUS position 2 3SE5232-0BE10 Roller lever, form E
switches
SIRIUS position 1 3SE5232-0LD03 Roller plunger, form C
switches

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3 Solution
Table 3-3: Software components

Component Qty. Order No. Note
SIMATIC STEP 7 1 6ES7810-4CC10-0YA5
V5.5
S7 Distributed Safety 1 6ES7833-1FC02-0YA5
V5.4 SP5
STARTER 1 Can be downloaded at no
V4.4 charge, link /3/ under Chapter
10
SIZER V3.11 1 Can be downloaded at no
charge, link /4/ under Chapter
10
WinCC Flexible 1 6AV6613-0AA51-3CA5
2008 SP3

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4 Drive Dimensioning
A description is provided below on how to dimension the mechanical system of a
lift and lay out the appropriate drive using SIZER.
4.1 Configuring the mechanical system

Create a new mechanical system.
Fig. 4-1 Partial view of mechanical systems
Assign a name, for example "Belt lift" and select "Hoist drive". Leave the "for
converter operation" checkbox activated and then open the mechanical system.
Fig. 4-2: Add mechanical system
You must first enter the mechanical data.
Note The continuous payload is zero, as in this example, the lift only has a load when
lowering. The load when lowering is entered in the traversing profile using
supplementary weight.

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Enter 4700 kg as internal mass and 6200 kg as counterweight. The diameter of the
drive wheel (drum) is 320 mm and the lift has no reeving.
Note 0.9 can be assumed as the mechanical system efficiency, if more detailed data is
not available. All additional data, if not specified any further, can be left at the
default values or zero.
Fig. 4-3: Entering the mechanical data

Then enter the traversing profile as "as trapez./triangular curves" with

"Trapezoidal > s, ab, av, t -> v" so that the maximum velocity is calculated.
Fig. 4-4: Select input

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Enter the values corresponding to Fig. 4-5. A cycle time of 30 s should be obtained.
Fig. 4-5: Specifying the traversing profile
Note Please note that the weight of the vehicle body and the skid is entered here
under additional mass in the section 2 "Backward" (lowering).
Set the checkmark for "Brake during pause" if the brake should be applied during
the pause. In this case, the motor is not controlled during the pause; this has an
effect on the average operating point of the motor.
Note The braking should be applied for long pauses. If this is not done, the
temperature of self-ventilated motors will increase too high at zero speed.
Further, please note that a switch-on delay of up to one second can occur as a
result of the brake release time and motor magnetization.
The calculated maximum velocity is 33.81 m/min. Display the load torque and load
speed curve in SIZER as shown in Fig. 4-6.
Fig. 4-6: Load torque and speed curve of the mechanical system
What is worth noticing is the fact that the motor is always operated in the generator
mode. When lifting without load in the first section, the counterweight drives the
motor, and when lowering in the second section, the load drives the motor by the
same absolute value.

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4.2 Selecting the geared motor

Open the "Drive systems" partial view and create a new drive system.
Fig. 4-7: Partial view drive systems
Assign a name to the drive system, e.g. lift drive. Select the drive system
corresponding to the path marked in red in the decision-making tree Fig. 3-1:
"Single drive", "SINAMICS G120" with PM250.
Fig. 4-8: Adding a drive system

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Then select "2KJ" motor type to select Siemens geared motors, "Vector" control
mode and "With Safety Integrated functionality". The geared motor should be
selected based on the mechanical system that has been created. Select the
created mechanical system "Lift". Confirm the selection with "OK" and the drive
dimensioning window opens.
Fig. 4-9: Selecting the mechanical system
Click on the button to dimension the motor.

Fig. 4-10: Dimensioning the geared motor

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Start with the step "Gearbox data". Here, helical gearing is already preassigned as
mounted gearbox. Keep the operation time at "24 [h/day]" to cover three-shift
operation.
Fig. 4-11: Gearbox data
Check the values in the steps load cycle and power data and keep the utilization
at 100%.

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In the Basic type specifications step, you make general statements regarding the
motor. The four-pole, self-ventilated motor should be operated with the 87 Hz
characteristic.
Note We recommend a force-ventilated motors, if during the pause, the drive should
remain in closed-loop control, and the motor holding brake should not be applied.
NOTICE Vertical axes should always be equipped with an integrated motor holding brake.
In order to minimize the load sagging/dropping in the case of a fault, the fastest
brake control should be selected using a function rectifier.
Note For safety reasons, the braking torque should as a minimum be dimensioned for
twice the rated motor torque ("M-brake/M-ref at least").
The remaining data can be left at the default settings.

Fig. 4-12: Basic type specifications
Click on the "Check all" button and filter according to the "SIMOGEAR" motor
series. Click on "Determine optimum motor" and select the displayed motor.
Fig. 4-13: Motor selection

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In this particular example, the braking torque must be 80 Nm; this must correspond
to more than twice the rated torque. The converter ensures low brake wear; as a
consequence, brake type L80 with a lower work capacity can be selected.
Fig. 4-14: Selecting a brake
Check the basic motor types and select the optimum motor according to the
service factor. In this case, the required service factor is calculated from the load
classification, switching frequency and the daily operation time. SIZER retrieves
this data from the motor and load cycle data.
If the customer specifies a service factor, then this can be entered using "Specify
required service factor".
Note In the attachment under 8.1.1, selecting a gearbox for a maximum velocity
equivalent to 70 Hz is described.
Fig. 4-15: Basic motor type

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In the next step, check the motor selection based on the motor characteristic, the
average operating point and under peak load conditions.
Fig. 4-16: Checking the motor
The selected geared motor is displayed in the last step. However, this must be
supplemented by several options before it can be ordered. To do this, open the
SIMOGEAR Configurator (here: online).
Fig. 4-17: Starting the SIMOGEAR Configurator
The SIMOGEAR Configurator retrieves the values from SIZER.

The KTY84-130 temperature sensor is selected as motor protection under
"Electrical design". This allows the motor temperature to be precisely monitored.
Fig. 4-18: Electrical design – motor protection

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The cable entry of terminal box 1B should be selected corresponding to Fig. 1-2.
Select terminal box position "[M56] 1B" and the Harting EMC shielded motor plug
"HAN10E" under "Mechanical design".
Fig. 4-19: Mechanical design in the SIMOGEAR Configurator
In Fig. 1-2 it can be seen that the geared motor has a manual release lever. Click
on the brake to select "[C02] manual release" in "[C27] 2" position.
NOTICE For lifts, do not use manual release with locking mechanism to avoid accidents
after service.
Fig. 4-20: Brake in the SIMOGEAR Configurator

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The motor encoder must now be selected. Make the selection corresponding to
Fig. 4-21. You can select the encoder cable in SIZER under accessories.
Fig. 4-21: Selecting encoder options
Finally, for the cast-iron series you must select a paint finish, which you can find
under "Additional options > Surface treatments / Conservation". Select "[L02]
Coating for normal environments C1" and the required color.
Fig. 4-22: Surface treatment/conservation
You have selected the geared motor options, and you can return to SIZER by
clicking on "Back to SIZER". The "2KJ31111HG229AX1-Z" geared motor is
displayed with the selected options.

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4.3 Selecting the drive

After you have selected the geared motor, you select the converter and additional
options. SIZER calculates the required rms current, the maximum current as well
as the maximum regenerative current that the converter can supply and/or draw.
Note The maximum power that the PM250 power unit can feed back is the rated
power. When lowering, the maximum regenerative current is the limiting variable.
The regenerative feedback current cannot be overloaded, as is it can be done
with output current. As a consequence, a 15 kW power unit is used.
Select the smallest power unit with 15 kW.

Fig. 4-23: Selecting the SINAMICS G120 power unit

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Complete the dimensioning with the output and system components, and select the
CU250S-2 PN Control Unit. The brake control module is used to control the brake
via the converter power unit. Select the "Brake Control Module 440V, standard"
and the shield connection kit. An operator panel (IOP or BOP) can be selected if
required.
Note To use the positioning functionality of the CU250S-2, a license must also be
ordered in the form of an SD card (Z option). The order number is:
6SL3054-4AG00-2AA0-Z E01.
Note Only the basic safety functions are used in this application example. The license
for the extended functions is not necessary.
Fig. 4-24: Selecting the control unit

You can export a parts list to Excel under "Tools -> Export parts list…". You can
find additional options under "Tools". Also export the project documentation under
"Tools -> Export project documentation…".
The project documentation serves as basis for commissioning the system. Ensure
that the commissioning engineer receives this project documentation.

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5 Installation and commissioning

This chapter focuses on the lift settings.
Note Please refer to this Application example for a detailed description of the
configuration of the SINAMICS G120 and the S7-300, the wiring, commissioning
and access to process data and parameters.
5.1 Connecting-up the hardware

Fig. 5-1 shows the connection of the HTL encoder to the CU250S-2 terminal and
the relevant pin of the plug connector at the encoder (take care to correctly identify
the male and female parts of the plug connector).
Fig. 5-1: Pin assignment and terminal connection of the HTL encoder
The SSI absolute encoder is connected at the X2100 interface (Sub-D) of the
CU250S-2, see Fig. 5-2 and Table 5-1.
Fig. 5-2: Pin assignment, Sub-D DA-15 (male) for SSI encoders
Table 5-1: Pin assignment X2100 interface of the CU250S-2 for SSI encoders
2 Clock +
3 Clock -
4 Power supply referred to pin 7
7 GND, reference potential for pins 4 and 5
14 Data -
15 Data +
Note The bottom (N201) and top (N202) emergency end positions must be wired to
the drive terminals. This means that the signals are not delayed by routing them
via the fieldbus. Connect cam N201 to DI4 at terminal 16, and cam N202 to DI5
of terminal 17.
The KTY84 motor temperature sensor is wired to terminal 14 (+) and to terminal 15 (-).

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The brake is controlled via digital output (DO 24) of the Control unit CU250S-2
connected to active brake rectifier and further to brake coil. Use of the active brake
rectifier allow switching of the brake with frequency up to 2,5Hz. It is recommended
to install the suppression directly at the brake.
Fig. 5-3: Brake control using the brake rectifier
Active Brake Rectifier

Murr Elektronik Art.No.:50003
To enable brake function it is necessary to set the control function of the digital
output. For the setting see chapter 5.2.2 Drive functions Fig. 5-23: Set digital output
“brake control” functionality
5.2 Basic commissioning

Commissioning the drive and its various functions is described in the following.
First, check that you have configured the correct hardware components.
Fig. 5-4: Control module and power unit
5.2.1 Commissioning Wizard (offline)
For positioning, the basic positioner function module is used in the drive in
conjunction with the CU250S-2.
Note Function modules can only be configured offline. The configuration must then be
loaded to the drive.
Start the commissioning Wizard under "Control_Unit > Configuration".

Fig. 5-5: Commissioning wizard

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Activate the "Basic positioner" function module and deactivate all other function
modules if they are not required in order that the performance of the CU250S-2 is
not unnecessarily used. Set the control mode "[21] Speed control (with encoder)".
Fig. 5-6: Closed-loop control structure
The default setting of the setpoint is left at "7.) Fieldbus with data set changeover",
as the setpoint is entered via Profinet.

Fig. 5-7: Default settings of the setpoints
The motor data is specified corresponding to an IEC motor, i.e. 50 Hz and SI units.
Load duty cycle with high overload for vector drives can be kept as power module
application.
Fig. 5-8: Drive settings

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Select the motor type: "[100] 1LE1 standard induction motor" and activate "Select
standard motor from list". Then select the main MLFB of the motor and select the
motor.
Fig. 5-9: Motor
If you cannot read the main MLFB of the induction motor from the rating plate, then
take the motor type designation from the SIZER project documentation Fig. 5-10.
You can find the main MLFB of the induction motor belonging to the SIMOGEAR
designation in the attachment, in Table 8-1.
Fig. 5-10: SIZER project documentation – SIMOGEAR motor type

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Change the motor connection type to "Delta"; the motor data will then be displayed
for a Delta connection (rated voltage = 230V etc.). Set the checkmark for the 87Hz
calculation.
Fig. 5-11: Motor data
Note If you are using a motor that is not included in the list, then from firmware 4.6 and
higher you can enter the motor data as described in this FAQ for the 87Hz
characteristic.
Select "[2] Identifying motor data (at standstill)" to precisely identify the motor data
using a stationary measurement.
Fig. 5-12: Drive functions
Potentially hazardous
Do not select a turning measurement for linear axes, such as the lift! The rotating
WARNING measurement attempts to determine the mass moment of inertia of the load and
to optimize the speed controller by accelerating the motor. To do this, the motor
must be coupled to the load. With these motion sequences, it is possible that the
mechanical limits of the machine are exceeded.

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The specified current limit (150% overload) and maximum speed already refer to
the motor in a delta connection and 87Hz characteristic.
Note When using the basic positioner, the ramp-up and ramp-down times have no
effect on the traversing profile. However, faults initiate a stop response with
OFF1 and OFF3, so that the lowest possible times should be selected here.
Fig. 5-13: Important parameters
Keep the setting "Complete calculation" for calculating the motor parameters.
Fig. 5-14: Calculating the motor data

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Note For SINAMICS drives, encoder_1 is interpreted as motor encoder, i.e. on the
motor shaft and encoder_2 as machine encoder, i.e. on load side.
For "Encoder_1", using "Select standard encoder from list" select the HTL encoder
with code number 3001 for the HTL encoder with A/B track, zero mark R and
1024 pulses per revolution. The encoder is evaluated via the terminal interface of
the CU250S-2.
Fig. 5-15: Encoder_1
Then connect encoder_2 to the D-Sub interface for the linear encoder, and enter
the encoder data.
Fig. 5-16: Encoder_2

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The linear encoder is parameterized in the following. The technical data of the
encoder are provided in the attachment2.
The SSI linear encoder has a 24 V power supply. Gray coding is used with a
resolution of 0.8 mm for a baud rate of 250 kHz. 19 bits are used with 3 filler bits
before the position and three diagnostic bits after the position. The alarm bits (bit
23) and the error bit (bit 24) are high-active. The 30 µs mono flop time is sufficient.
Fig. 5-17: User-defined linear encoder
The closed-loop position control is based on the linear encoder evaluation

(encoder_2).
Fig. 5-18: Measurement system
2
This data is based on the distance-coding system WCS3 from Pepperl+Fuchs. Other linear
encoders are possible.

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Note Calculating with the independent dimension LU (Length Units) gives users the
flexibility of converting one load revolution into any dimension. For linear axes,
generally a value of between 1 mm and 1 µm per LU is used, for rotary axes,
between 1° and 1 µ° per LU.
The conversion of the shaft height in LU is shown in Fig. 5-19. With a gear ratio of
62.48, the motor rotates 6248 revolutions for 100 load revolutions. With a drum
diameter of 0.32 m, a height of π * 0.32 m equal to 1.005309 m is traveled through
for each drum revolution.
Fig. 5-19: Converting the lift height into LU
For a linear measuring system, a spindle is assumed when entering mechanical

data. One spindle revolution corresponds to one drum revolution. The spindle pitch
is therefore 1005309 LU. As a consequence, one LU corresponds to 1 micrometer,

and therefore for each 10 mm 10000 LU is specified.
Fig. 5-20: Mechanical system

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NOTICE When the fine resolution Gx_XIST2 is configured, the encoder identifies a
maximum possible absolute position actual value (r0483) that can no
longer be represented within 32 bits.
A32915 encoder 2: Configuration error" with alarm value 419. To hide the alarm,
the monitoring in P0437[1].25 must be deactivated with a value of one.
Note The linear encoder only has a 0.8 mm resolution. Therefore, for a resolution of
1 µm equal to 1 LU, it is not possible to position with micrometer accuracy.
However, for the dynamic performance of the closed-loop position control, high
values for LU per load revolution (P2506) are better. As a consequence, the
repeatable or positioning accuracy is only in the range of millimeters and not
micrometers.
Complete the commissioning with "Finish". Check the motor data for the delta
connection under "Control_Unit->Configuration".
Fig. 5-21: Motor data in the configuration after basic commissioning
On the CU250S-2 go online, and load the data to the target device.
Fig. 5-22: Loading the configuration into the drive

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5.2.2 Drive functions
Brake control
To enable brake function it is necessary to set the control function of the digital
output.
Fig. 5-23: Set digital output “brake control” functionality
Potentially hazardous
Do not use for control of the brake the digital outputs DO 0 (as default “Fault
WARNING present”) or DO 1 (as default “Alarm present”). If assignment of the parameters
for DO 0, DO 1 would be not correct (due to first switching power on, parameter
download, reset to factory setting …), it could lead to the unwanted release of
the brake with the possibility of the lift falling down.

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Parameterize the Brake Control (P1215) under "Control Unit > Functions > Brake
control" to "[1] Motor holding brake acc. to sequence control". The brake relay is
not safe in the sense that it does not supply a feedback signal for brake closed.
Therefore, select "[1] Brake control without diagnostics evaluation". The brake
opening and closing times can be found in the SIZER (see chapter 4.2 Selecting
the geared motor – Fig. 4-14: Selecting a brake
) or in Catalog “SIMOGEAR Geared Motors MD50.1” (see chapter 11/36 Motor
options > Mounted components > Brake > Technical specifications > Brake control
- Definition of switching times).
Note Round off the brake closing time to above 100 ms so that the drive remains
somewhat longer in closed-loop control, and is not deactivated before the brake
has closed.
Fig. 5-24: Brake control

If the load sags after opening the brake, you should adjust a torque that is
generated when opening the brake. With P2900, enter a percentage of the rated
torque when opening the brake (e.g. enter 70% of the rated torque into parameter
P2900).

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Communication
Under "Control_Unit > Communication > Brake control", select standard telegram
"[111] SIEMENS telegram 111, PZD 12/12", which is generally used when
employing the basic positioner. In the transmit direction, you must still interconnect
current actual value r68 in PZD12 so that this can be read by the control system.
Fig. 5-25: PROFINET telegram selection

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Motor temperature monitoring

You can set the motor temperature monitoring under "Control_Unit > Messages
and monitoring > Motor temperature". Keep the response with overtemperature to
the preset value "[12] Messages, no reduction of I_max temperature storage".
Select "[2] KTY84" as temperature sensor. Set the ambient temperature.
Fig. 5-26: Motor temperature monitoring
5.2.3 Basic positioner (EPos)
When using direct setpoint input (MDI) via the fieldbus, it is not necessary to
parameterize the positioning as such. However, the absolute encoder must be
adjusted and the traversing range and traversing profile limiting, jog velocity – and
where relevant, the home position approach velocity (not necessary here) – must
be parameterized.

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Absolute encoder adjustment

For commissioning, the absolute encoder must be adjusted under "Control_Unit >
Technology > Basic positioner > Homing > Homing button". The position actual
value is set to the home position by calculating an offset between the actual
position and the home position. After the adjustment, save the converter data in the
non-volatile memory (RAM to ROM).
Fig. 5-27: Absolute encoder adjustment
Limitations
Software end positions can be activated under " Control_Unit > Technology >
Basic positioner > Limiting" in addition to the emergency end position cams. They
lie between the bottom position (B204) and bottom emergency end position (N201)
as well as top position (B205) and top emergency end position (N202). Here they
are set 10 cm behind the top or bottom position. The software limit switches are
activated via the fieldbus. The bottom emergency end position output cam, N201
(stop output cam minus) is connected to DI 4 (r722.4) and the top emergency end
position is connected to DI5 (r722.5).
Fig. 5-28: Traversing range limitation

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The velocity and acceleration are entered in the traversing profile limitation. The
maximum velocity for the 87Hz characteristic on the motor side is 2610 rpm,
i.e. equal to 41995000 LU/min.
Fig. 5-29: Traversing profile limitation – max. velocity
The configured acceleration and deceleration under 4.1 Configuring the

mechanical system was 0.5 m/s², which corresponds to 500000 LU/s².
Fig. 5-30: Traversing profile limitation – max. acceleration and deceleration
Note
As the brake control is realized the same as the sequence control, the ramp
down time of OFF1 (P1121) and OFF3 (P1135) should be as short as possible.
In addition, for the traversing profile limitation, jerk limiting can be activated.
Fig. 5-31: Activating jerk limiting

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Jogging
The jog velocity is saved under "Control_Unit > Technology > Basic positioner >
Jogging" in the drive, and must be specified as LU/min. The jog velocity should be
as low as possible so that positions can be precisely approached. Enter a velocity
of 5 m/min or 5,000,000 LU/min.
Fig. 5-32: Jogging – configuring jog setpoints

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5.2.4 Safe torque off (STO)
The safety functions are parameterized under "Control_Unit > Functions > Safety
Integrated". Click on "Change settings" to start safety commissioning. Select "Basic
functions via PROFIsafe" from the drop-down field. You must then specify the
F target address of the F-CPU – here, enter C7 hex.
Fig. 5-33: Basis functions via PROFIsafe
Click on "Copy parameters after download" and "Activate settings" one after the
other. You are prompted to assign or change a password. Copy from RAM to ROM
and switch off the power supply for the CU and on again to activate the safety
settings.
To verify safety-oriented parameters, an acceptance test must be performed

after the machine has been commissioned for the first time and also after
changes are made to safety-oriented parameters. The acceptance test must be
WARNING appropriately documented. You can find additional information in this Application
document.

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5.3 Optimizing the lift drive (optional)

Since the turning measurement can usually not be carried out, it might happen that
the dynamic performance is not adequate. Then the speed controller must be
manually optimized. To do this, proceed as follows:
1. Optimizing the speed controller
2. If required, adapt the limiting
3. Optimize the position controller
NOTICE Prior to optimizing

Before carrying out the optimization steps, ensure that all motor data have been
correctly entered. The basic commissioning must have been completed with
"Complete calculation" of the motor data (P340 is again zero).
5.3.1 Optimizing the speed controller
The speed controller under "Control_Unit > Open-loop/closed-loop control > Speed
controller" defines the speed at which the speed actual value tracks the speed setpoint.
Fig. 5-34: Parameterizing the speed controller
Coarse optimization
Using the following rule of thumb, Kp can be roughly determined using the
symmetrical optimum. You start at n equal to one. If the dynamic performance is
not adequate, then you continue with n equal to two etc.
𝑇𝑛 = 4 ∙ 𝑇𝑆 (𝑠𝑢𝑚 𝑜𝑓 𝑎𝑙𝑙 𝑑𝑒𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛𝑠) ≅ 90 − 120 𝑚𝑠
𝑟𝑎𝑡𝑒𝑑 𝑚𝑜𝑡𝑜𝑟 𝑠𝑡𝑎𝑟𝑡𝑖𝑛𝑔 𝑡𝑖𝑚𝑒 (𝑟0345)
𝐾𝑃 = 𝑛 ∙ 𝑤ℎ𝑒𝑟𝑒 𝑛 = 1, 2, …
integral time 𝑇𝑛 (𝑃1462)
Manual optimization
Alternatively, the speed controller can be manually optimized according to the
symmetrical optimum in the following steps:
1. Increase the P gain factor Kp (P1460) until the speed actual value overshoots
the setpoint step by 4.3%. Set Tn to zero or the maximum value.
2. Then reduce integration time Tn (integral time P1462) from approx. 120 ms
until the speed actual value overshoots the setpoint step by 43%.

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NOTICE Before optimizing the speed controller

1. Beforehand, ensure that the travel distance is sufficient for the setpoint
step.
2. At the control panel, operate in the closed-loop speed controlled mode
(f-setpoint input) so that the position controller is not active.
3. The speed setpoint step must be issued from a speed, where the friction
can be neglected. Therefore, enter a step of e.g. 500 to 700 rpm.
4. Set the integration time Tn (P1462), the torque precontrol (P1496) and
the ramp-up (P1120) and ramp-down time (P1121) to zero.
The system is optimized based on the step response using the control panel. Trace
the speed setpoint (r62) and the speed actual value (r61[0]). Fig. 5-35 shows the
resulting step response of the speed controller according to the symmetrical
optimum.
Fig. 5-35: Step response for various speed controller settings
Note During the step, ensure that the drive current, torque, voltage or power is not
limited (see the next Chapter 5.3.2).
Torque precontrol
The acceleration required is obtained based on the setpoint change. The drive can
calculate the torque required from the mass moment of inertia and the acceleration.
The torque precontrol controls the torque without involving the speed controller. As
a consequence, the speed controller only has to compensate disturbing quantities,
such as oscillations caused by the belt.

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As the turning measurement can usually not be carried out for the lift, the torque
precontrol must be manually parameterized. If you do not have a more precise
value, for the ratio between the total moment of inertia and the motor moment of
inertia, enter the value calculated by SIZER into P342; in this case the ratio of 3.2
(see Fig. 5-36).
Fig. 5-36: SIZER project documentation – moment of inertia ratio
Increase the scaling (P1496) of the precontrol from 50% step-by-step up to 100%.
Fig. 5-37: Torque precontrol in the speed controller
Ideally, trace the torque setpoint (r79) in a current controller clock cycle of 0.5 ms.
If, as a result of increasing the torque precontrol, the torque setpoint starts to
oscillate, increase the smoothing time constant of the torque setpoint in parameter
P1517, e.g. to 10 ms. Fig. 5-38 shows the influence of the precontrol and the
setpoint smoothing on the torque setpoint and the speed actual value.
Fig. 5-38: Torque setpoint and speed actual value with precontrol
5.3.2 Power and current limiting
During optimization the power, current or torque should not reach their limits, as
indicated by r56[13]. The limiting can be deactivated under "Control_Unit > Open-

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loop/closed-loop control > Torque limiting". Set the power limit motor mode in
P1530 to three times the motor power, in this case 16.5 kW. For power modules
with energy recovery, the power limit generator mode can at maximum be set to
the negative rated power of the power module, in this case -15 kW.
Fig. 5-39: Increasing the power limit
If necessary, increase the current limit (P640) up to a maximum of 200% of the

rated motor current (P305). Then set P340 to "[5] Calculate technological limits and
threshold values" in order to automatically adapt the torque limiting (you must be
connected online with the drive).
NOTICE In operation, the motor must be able to thermally withstand this load.
5.3.3 Position controller
The setting of the position controller under "Control_Unit > Technology > Position
control > Position controller" also defines the dynamic response. An optimized
position controller quickly reaches the setpoint position without any overshoot.
Change the P gain (Kv factor [servo gain factor] P2538) from one to approx. 0.3
and keep the integral time (P2539) at zero.
Fig. 5-40: Setting the position controller

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Trace the speed setpoint (EPos velocity setpoint r2666), the speed actual value
(r61.0), the torque setpoint (r79), the position actual value (r2521.0) and the
following error (r2563) analogous to Fig. 5-41. Observe as to whether the position
actual value is free of any overshoot, and whether the following error goes to zero
adequately fast.
Fig. 5-41: Position controller trace
Smooth the position setpoint by increasing the time constant of the position
setpoint filter (P2533) e.g. up to 20 – 50 ms. Increase the speed precontrol factor
(P2534) starting at 50%, as long as the speed setpoint does not start to oscillate.
Fig. 5-42: Optimizing the position controller setpoints

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6 Principle of operation of the application

Fig. 6-1 shows the program structure and the block calls of the lift application.
FB201 is responsible for the lift control and FC201 sending the position setpoints to
the drive. The setpoints of the positioning and the mechanical data for conversion
into the length dimension are remanently saved in DB202.
Fig. 6-1: Flow chart of the S7 program
6.1 Function description of the FC201

FC201 implements the direct setpoint specification of the SINAMICS EPos.
UDT30008 from the SINAMICS G/S Toolbox is used to read and write the standard
telegram 111 with SFC14 and SFC15.
Table 6-1: Input signals of the FC201
Input signal Type Default Meaning
DRIVE_IO_ADDRESS Int 256 I/O address of the drive device from HW Config
LU_PER_METER DInt 1000 Resolution of the LU per meter, 1000  1 LU = 1mm
LENGTH_PER_REVOLUTION Real 1.0 Distance moved on the output side for one load revolution
GEAR_RATION Real 1.0 Gearbox ratio i between load and motor revolution
INHIBIT Bool false Enables the drive (ON/OFF1)
ENABLE Bool True false = fast stop (reject traversing task)
RESET Bool false Acknowledge fault
DISABLE_SW_LIMIT_SWITCH Bool false true = deactivate software limit switch
JOG_PLUS_MODE Bool false Select jog, clockwise
JOG_MINUS_MODE Bool false Select jog, counterclockwise
REFERENCING_MODE Bool false Selects start of homing
POSITIONING_MODE Bool false Selects positioning operation
START_POSITIONING Bool false Starts the traversing task
POSITION_SETPOINT Real 0.0 Position setpoint in m
SPEED_SETPOINT Real 0.0 Velocity setpoint in m/min
ACCELERATION Int 0 Acceleration as a % of the maximum acceleration in P2572
DECELERATION Int 0 Deceleration as a % of the maximum deceleration in P2573

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Table 6-2: Output signals of the FC201

Output signal Type Default Meaning
COMMUNICATION_OK Bool false false = communication with SFC14/15 returns an error,
response: all outputs are set to zero.
AXIS_FAULT Bool false true = drive fault active
AXIS_WARNING Bool false true = alarm active
AXIS_READY Bool false true = drive ready to switch on
AXIS_ENABLED Bool false true = drive in closed-loop control
AXIS_REFERENCED Bool false true = home position (reference point) set
AXIS_IN_POSITION Bool false true = setpoint position reached
HW_LIMIT_SWITCH_TOP Bool false true = top HW limit switch reached
HW_LIMIT_SWITCH_BOTTOM Bool false true = bottom HW limit switch reached
AXIS_TURNING Bool false true = motor is rotating
FAULT_CODE Int 0 Drive fault code
ALARM_CODE Int 0 Drive alarm code
ACTUAL_POSITION Real 0.0 Position actual value in m
ACTUAL_SPEED Real 0.0 Velocity actual value in m/min
ACTUAL_CURRENT Int 0 Current actual value as a % of the reference current in P2002
Jogging
Fig. 6-2: Signal flow chart, FC201 jog mode

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Homing
Fig. 6-3: Signal flow chart, FC201 homing
Positioning
SINAMICS EPos communicates using the handshake technique. As a

consequence, the system must wait for EPos states before it moves into the next
state. For example, after the controller has been enabled using "INHIBIT", the
system first waits for the "AXIS_ENABLED" feedback signal before
"START_POSITIONING" can be issued. Otherwise, the drive misses the signal
edge of "START_POSITIONING".
Fig. 6-4: Signal flow chart, FC201 positioning

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6.2 Function description of the FB201

The FB201 controls the lift and calls the FC201.
Note Alternatively, the SICAR standard can be used, which among other things,
supplies technology blocks for the lift or roller conveyors and the associated
visualization and diagnostics.
Table 6-3: FB201 input signals

Input signal Type Default Meaning
IO_ADDRESS Int 256 I/O address of the drive device from HW Config
TARGET_POSITIONS Array Target positions for top and bottom, UDT202 includes
[1..2] of position, velocity, acceleration and deceleration
UDT202
LIFT_TYPE Int 0 1 = lowering, 2 = lifting, 3 = lifting and lowering
AUTOMATIC_MODE Bool false true = automatic mode selected
MANUAL_MODE Bool false true = manual mode selected
SETUP_MODE Bool false true = setting up mode selected
SLOW Bool false true = slow speed activated
MOVE_UP Bool false true = manual traversing to top position
MOVE_DOWN Bool false true = manual traversing to bottom position
SKID_IN_POSITION Bool false true = skid is in position
NO_SKID Bool false true = roller conveyor is free or no skid

IO_FC201 (IN_OUT) UDT201 Used for the HMI to access FC201 and to read out the drive
status
Table 6-4: Output signals of the FB201
Output signal Type Default Meaning
LIMIT_SWITCH_TOP Bool false true = top hardware limit switch actuated
LIMIT_SWITCH_BOTTOM Bool false true = bottom hardware limit switch actuated
IN_POSITION_TOP Bool false true = lift in the top position
IN_POSITION_BOTTOM Bool false true = lift in the bottom position
MOVING_UP Bool false true = lift is traversing to the top position
MOVING_DOWN Bool false true = lift is traversing to bottom position
FAILURE Bool false true = block error, illegal mode activated, drive or
communication fault/error
ACTUAL_POSITION Real 0.0 Actual position of the lift

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Automatic mode
Fig. 6-5 shows the signal flow chart for lowering operation only. For lifting only
applications "SKID_IN_POSITION" signal initiates the lifting and "NO_SKID" the
lowering.
Fig. 6-5: Signal flow chart FB201 for lowering
Fig. 6-6 shows the signal flow chart when a skid is lifted as well as lowered.
Fig. 6-6: Signal flow chart FB201 for lifting and lowering

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7 Operating the application

From the root screen, you can access the status, diagnostics, control and lift
screens via the menu bar. You can return to the root screen using the "House"
symbol. You can toggle between German and English using the flags.
Fig. 7-1: Navigation from the root screen
The lift control of the FB201 is not active in the status, diagnostic and control
screens. Instead of this, the HMI variables are written or read.

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Status screen
The status screen provides information about control variables (input signals of the
FC201) and state variables (output signals of the FC201). The positions are
specified in meters and the velocities in meters per minute. Acceleration and
deceleration are specified as a percentage of parameter P2572 or P2573. The
current actual value is displayed as a percentage of the reference current in
parameter P2002.
Fig. 7-2: Status screen
Diagnose screen
The diagnose screen provides information about active faults and alarms of the
drive connected with FC201. Fault and alarm numbers are output with the
associated text. It is also displayed if STO was initiated. Active faults can be
acknowledged using the "Acknowledge" button.
Fig. 7-3: Diagnostics screen

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Control screen
In the control screen, you can directly write to the FC201 interface block, i.e. the
control bypasses the lift control of FB201.
The drive is enabled using the "1" button (ON/OFF1); this is withdrawn using the
"0" button.
The motor can be jogged clockwise and counterclockwise using the "Jog Plus" and
"Jog Minus" buttons.
Homing is started by pressing the "Homing/Referencing" button. The reference
cams can be simulated using the "Cam" button. If homing was successful, then this
is displayed using the green circle next to "Homed".
Positioning is selected using the "Positioning" button. Setpoints can be entered
using the position, velocity, acceleration and deceleration input fields. The
traversing task is started by pressing the "Start" button. The "Stop" button initiates
a fast stop. The position actual value is displayed, and the green circle indicates
that the target position has been reached.
Fig. 7-4: Control screen

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Lift screen
FB201 can be operated in the lift screen. When selecting the lift type, the sequence
control in the automatic mode is defined. The automatic mode is selected using the
"Automatic" button.
"Lowering" waits in the top position for the signal SKID_ IN_POSITION", which can
be simulated using the "Loaded" button, and then starts to descend to the bottom
position. Ascent to the top position is started using the "NO_SKID" signal,
simulated using the "Empty" button.
"Lifting" evaluates the control commands ambivalently; i.e. if the skid is in position,
the lift ascends to the top position – and if the roller conveyor is free, to the bottom
position.
"Lifting and lowering" starts travel to the top or bottom position with the change
from "NO_SKID" to "SKID_IN_POSITION". If the lift is neither at the top or bottom
position after selecting the automatic mode, then "Lifting and lowering" waits for the
"MOVE_DOWN" or "MOVE_UP" signal.
In the manual mode, using the "Manual" button, the lift can be manually traversed
using the arrow buttons to either the top or bottom position. The velocity in the
manual mode is 50% (static variable SpeedFactorManual of FB201) of the velocity
in the automatic mode.
Using the "Slow" button, the velocity in the automatic and manual modes is set to
10% (static variable SpeedFactorSlow of FB201).
You can access the setting-up screen of the lift using the "Setting up" button.
The lift screen also visualizes the actual position of the lift – whether the lift is
ascending or descending and the signals "IN_POSITION_TOP",
"IN_POSITION_BOTTOM", "LIMIT_SWITCH_TOP" and
"LIMIT_SWITCH_BOTTOM".
If lift block FB201 outputs an error at its "FAILURE" output, the background of the
lift changes to red.
Fig. 7-5: Operation of the lift block

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Setting up screen
The lift can be traversed to the actual position for absolute encoder adjustment
using the "Jog Plus" and "Jog Minus" buttons in the setting up screen.
Encoder adjustment via the HMI is realized by directly accessing the drive from the
HMI; i.e. using cyclic communication between the HMI and drive.
Adjustment is still not initiated if the "Adjust" button has an orange background. The
button flashes if adjustment was initiated via the button. The button is green if the
adjustment was successful and red if it was unsuccessful.
After adjustment, the value must be written to the non-volatile memory (EEPROM)
of the drive. Click on the "Save" button. The button flashes, and turns gray as soon
as the data has been copied to the EEPROM.
If the lift is not at its future zero position, but is at a height of 1 m, for example, then
using the home position offset you can define that the actual position is not zero,
but 1,000,000 LU equal to 1 m.
The target positions as well as the associated velocity, acceleration and
deceleration must now be defined. The values are directly written to DB202, which
transfers the traversing blocks to the FB201.

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The mechanical data to convert from LU into a linear dimension include the
gearbox ratio, the length or the height per load or drum revolution and the number
of LU per meter. Fig. 7-6 describes how these values can be determined for a lift.
Fig. 7-6: Mechanical data of the lift
NOTICE After setting up, it is not permissible that data block DB202 is again loaded into
the control system. Otherwise, DB202 would be reinitialized, the data would be
lost and must be written again.
Fig. 7-7: Setting up the lift block


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8 Attachment for dimensioning and commissioning
8 Attachment for dimensioning and

commissioning
8.1 Notes for dimensioning
8.1.1 Dimensioning with a 70Hz operating speed
Some customers specify that the motor is operated with a maximum speed
corresponding to a frequency of 70Hz. For the 2KJ3211 motor that we have
selected, from the rated speed at 50Hz of 1465 rpm, a maximum speed of 2051
rpm at 70Hz (1465 * 70 / 50) is obtained. However, with the ratio of the Z129
gearbox, the speed is 2101 rpm. Select another gearbox, for example the D129.
Fig. 8-1: Select the next gearbox type
Check the maximum speed by clicking on the lightbulb in the motor check step.
Test the other gearbox by clicking on the gearbox plus symbol.
Fig. 8-2: Checking the gearbox data
In this case, you must select the D149 gearbox with the lowest ratio.
Fig. 8-3: Displaying the maximum speed
8.1.2 Project documentation from SIZER with parameters
In this section, the complete project engineering documentation generated by

SIZER is inserted. The values relevant for commissioning are shown in orange,
and supplemented by the corresponding parameters.

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1. Open-loop control/closed-loop control / 24V
2. Line supply
2.1. Technical data

Line supply data
Voltage 400 V
Frequency 50 Hz
Number of phases 3
Take into account a different line supply voltage No
Take into account brief line fluctuations Yes
Maximum brief undervoltage condition (with reference to the rated 15 %
voltage)
Undervoltage 340 V
2.2. Drive system "Drive system"
2.2.1. Technical data

SINAMICS G120 (PM250) - vector
Input options
Circuit breaker 3RV1031-4HA10
Fuse 3NA3814
CU250S-2 PN
Order designation 6SL3246-0BA22-1FA0 For the device configuration
Fail-safe version Yes
Communication system PROFINET IO
Encoder evaluation required HTL/TTL
Digital inputs 11
Digital outputs 3
PTC/KTY inputs 1
Analog Inputs 2
Analog outputs 2
Intelligent Operator Panel 6SL3255-0AA00-4JA1
Shield connection kit 6SL3264-1EA00-0LA0
Brake control module 440V, standard 6SL3252-0BB00-0AA0
Power unit
Order designation 6SL3225-0BE31-1AA0 For the device configuration
Degree of protection IP20
Internal filter A
Power unit/ambient conditions
Installation altitude 1000 m
Ambient temperature 40 °C
Power unit/catalog data
Rated power 15.00 kW
Rated current 32.00 A
Frame size C
Pulse frequency, factory setting 4000 Hz
Energy-efficiency class -
Power unit/data – load specific
Available current 32.00 A
Maximum current available 52.00 A

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Accessories and Options

Screening kit 6SL3262-1AC00-0DA0
Motor encoder
Encoder Rotary pulse encoder 1XP8 (HTL)
Signal cables
Order designation 6FX5002-2CA12-1BA0
Cable type MOTION CONNECT 500 (permanently routed)
Cable length 10.00 m
Power cable to motor
Cable type MOTION CONNECT 500 without brake cable, by the
meter (permanently routed)
Type of routing DIN EN 60204-1
Cable cross section 1 * 4x4 mm²
Order designation 6FX5008-1BB31-1BA0
Cable length 10.0 m
2.2.2. Motor
2.2.2.1. Technical data

Motor
Order designation 2KJ3111-1HG22-9AX1
Brake,L80 B22
Brake lining, low-wear brake lining C06
Control voltage, 380-440 AC C47

Function rectifier, overexcited +DC shutdown C60
voltage sensing
Voltage/frequency, 50 // 87 Hz 230V D // 400V D N6A
Special power P91
Motor / options from the Configurator
Manual release, manual release C02
Manual release position,2 C27
Mounting position,M1 D01
Degree of protection, IP65 K03
Gearbox oil, mineral oil CLP VG220 K06
Surface treatment, coating/paint for normal L02
environmental load C1
Color:, color RAL 7016 anthracite gray L75
Motor protection,KTY84-130 M16 Temperature sensor
P601=[2]KTY84
Terminal box position,1B M56
Motor plug, motor plug HAN10E (1 bar) (EMC) N06
Mating connector, mating connector HAN10E N18
Type,1XP8032-10 Q47 Encoder type P400=[3001] 1024
HTL A/B R
Note The brake closing time is not taken
into account.
Motor / environmental conditions
Installation altitude 1000 m
Ambient temperature 40 °C
Temperature class F/105K
Motor/catalog data
Motor power 5.50 kW
Output speed of the geared motor 23.45 rpm
Output torque 1999.98 Nm
Gearbox type Helical gearbox
Gearbox designation Z129

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Gear ratio 62.480 P2504 = 6248, P2505 = 100

Service factor of the geared motor 2.23
Motor type LE132SF4E Motor selection, see code
conversion to main MLFB
Frame size 132 S
Number of poles 4
Motor speed (gearbox input) 2575.00 rpm
Rated voltage 400 V
Moment of inertia of the motor (without brake) 0.027000 kg m²
Cooling method Self-ventilated, standard fan
Mounting position Standard
Version IE2
Efficiency at 50 Hz 0.877
Connection Delta
Brake Yes
Brake type L80
Braking torque 80.00 Nm
Moment of inertia of the brake 0.001500 kg m²
Brake control Function rectifier with voltage
sensing (C60)
Brake lining Low wear
Opening time 0.22000 s P1216 = 220
Closing time 0.05700 s P1217 = 100 ms (round off to

guarantee that the brake is
closed before the motor is
switched off)
Motor data referred to the specified drive
conditions
Connection Delta P133.0 = 1 delta
Motor frequency 87 Hz P133.1 = 1 (yes)
Rated voltage 348 V
Output power 7.60 kW
Output torque 1999.98 Nm
Output speed 35.86 rpm
Motor data/calculated data
rms motor current 18.04 A
Max. motor current 30.77 A
Relev. load torque for rms current 1910.50 Nm
Peak torque 3271.95 Nm
Speed at peak torque 33.63 rpm
Thermal utilization 95.9 %
Utilization of the max. possible torque 67.2 %
Ratio of external moment of inertia / motor 3.20 If optimization with motor
moment of inertia precontrol activated, this is
entered in P342
Load speed/rated speed 0.621
Gearbox input speed (maximum value) 2101.32 rpm Setpoint speed for FC201
Motor frequency (maximum value) 71.27 Hz
Service factor required 1.80
Braking torque/reference torque: minimum 2.00

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Load data at the motor output

Load type Travel drive / lift drive / conveyor
Version Hoisting gear
Average speed 25.58 rpm
Max. speed 33.63 rpm
Application Standard
Operating time 24 [h/day]
Load classification III (heavy shocks; mass
acceleration factor <= 10)
2.2.2.2. Characteristic
[Nm] Betrag des
Motormoments
80 Kippmoment
abzüglich
Sicherheitsabstand
60
Drehmoment
Spitzenlast
40
relev . Lastmoment
bei Ef f ektiv strom
20
0
0 1000 2000 3000 4000 [1/min]
2.2.2.3. Load characteristic at the motor shaft

[Nm] [1/min] Motormoment ohne

J-Motor
40 2000 (Anwendereingabe)
Motormoment unter
20 1000 Berücksichtigung v on
J-Motor und Haltemoment
0 0 Motordrehzahl
-20 -1000
-40 -2000
-60 -3000
0,0 5,0 10,0 15,0 20,0 25,0 [s]
The data in the table do not take into account any rounding off.
Traversing profile data as individual traversing segments:
Type Duration [s] n start n-end M start [Nm] M end [Nm] M start [Nm] M end [Nm] Holding brake
[rpm] [rpm] without J without J with J motor with J motor
motor motor
- 1.12702 0.00 2101.32 -20.41 -20.41 -15.14 -15.14 No
- 7.74597 2101.32 2101.32 -32.89 -32.89 -32.89 -32.89 No
- 1.12702 2101.32 0.00 -45.36 -45.36 -50.63 -50.63 No
- 5.00000 0.00 0.00 -41.86 -41.86 -41.86 -41.86 Yes
- 1.12702 0.00 -2101.32 17.06 17.06 11.78 11.78 No
- 7.74597 -2101.32 -2101.32 32.89 32.89 32.89 32.89 No
- 1.12702 -2101.32 0.00 48.72 48.72 53.99 53.99 No
- 5.00000 0.00 0.00 41.86 41.86 41.86 41.86 Yes
2.2.2.4. Application data

Mechanical data:
Travel drive / lift drive / conveyor
Version Hoisting gear
Continuous payload 0.000 kg
Intrinsic mass 4700.000 kg
Diameter of the drive wheel 320.000 mm Relevant for calculating LU per load revolution
in P2506  calculation of the lift height based

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on the circumference of the drive wheel (π*d)

Weight compensation 0.000 N
Counterweight 6200.000 kg
Frictional torque 0.00 Nm
Efficiency 0.900
Supplementary moment of inertia 0.000000 kg m²
(load)
Supplementary moment of inertia 0.000000 kg m²
(motor)
Reeving 1
Properties:
Take into account friction using control at standstill Yes
Take into account mechanical limit values No
Take into account rounding No
-Jerk limiting No
--Mech. use limit values as input values No
-Rounding time No
Cycle: 30.00000 s
Traversing profile data as trapezoidal/delta:
Section 1 Section 2
Inputs s,ab,av,t->v s,ab,av,t->v
Direction Forward, up Backward, down
Input values
Traversing distance m 5.000000 5.000000
Traversing time s 10.00000 10.00000
Accelerating time s
Deceleration time s
Pause time s 5.00000 5.00000
Velocity m/s
Acceleration m/s² 0.50000 0.50000
Deceleration m/s² 0.50000 0.50000
Load values
Additional force N
Additional mass kg 3000.000
Additional only for No No
constant-velocity travel
Brake during pause Yes Yes Brake must be closed
during pauses
Values reached
Max. velocity m/min 33.81 33.81 Setpoint speed for the
control module
Notice: Adapt the jog
and reference
velocities regarding
this
Max. acceleration m/s² 0.50000 0.50000 P2572 in LU/s²
Max.deceleration m/s² 0.50000 0.50000 P2573 in LU/s²
Traversing time s 10.00000 10.00000
~ Acceleration s 1.12702 1.12702
~ Constant velocity travel s 7.74597 7.74597
~ Deceleration s 1.12702 1.12702
Jerk limiting
Max. acceleration jerk m/s³
Max. deceleration jerk m/s³
Max. acceleration m/s²
Max.deceleration m/s²

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[m/s²] [m/s] Beschleunigungsv erlauf

Geschwindigkeitsv erlauf
0,40 0,40
0,20 0,20
0,00 0,00
-0,20 -0,20
-0,40 -0,40
-0,60 -0,60
0,0 5,0 10,0 15,0 20,0 25,0 [s]
[m] [m/s] Wegv erlauf
Geschwindigkeitsv erlauf
5,0 0,40
4,0 0,20
3,0 0,00
2,0 -0,20
1,0 -0,40
0,0 -0,60
[s]
0,0 5,0 10,0 15,0 20,0 25,0

[Nm] [1/min] Abtriebsdrehmoment
4000 30 Abtriebsdrehzahl
3000 20
2000 10
1000 0
0 -10
-1000 -20
-2000 -30
-3000 -40
0,0 5,0 10,0 15,0 20,0 25,0 [s]
Traversing profile data as individual traversing segments:

Type Duration [s] v end [m/s] s end [m] Supplementary Supplementary Holding
force [N] weight [kg] brake
Abschnitt 1, ab 1.12702 0.564 0.32 0.000 0.000 No
Segment 1, v 7.74597 0.564 4.68 0.000 0.000 No
Segment 1, av 1.12702 0.000 5.00 0.000 0.000 No
Segment 1, p 5.00000 0.000 5.00 0.000 0.000 Yes
Abschnitt 2, ab 1.12702 -0.564 4.68 0.000 3000.000 No
Segment 2, v 7.74597 -0.564 0.32 0.000 3000.000 No
Segment 2, av 1.12702 0.000 0.00 0.000 3000.000 No
Segment 2, p 5.00000 0.000 0.00 0.000 3000.000 Yes

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3. User comments - mechanical systems
3.1. Mechanical system
3.1.1. Lowering_2_positions_3000kg
4. User comments - additional components
5. Parts list
Item Quantity Order designation Product
• Drive system/line supply
10 1 6SL3203-0BD23-8SA0 Filter Class B
20 1 3RV1031-4HA10 Circuit breaker
30 3 3NA3814 Fuse
40 1 6SL3246-0BA22-1FA0 CU; CU250S-2 PN
50 1 6SL3255-0AA00-4JA1 Intelligent Operator Panel
60 1 6SL3264-1EA00-0LA0 Shield connection kit
70 1 6SL3252-0BB00-0AA0 Brake control module 440V, standard
80 1 6SL3225-0BE31-1AA0 Power unit; PM250; 15.00 kW; 32.00 A; -
90 1 6SL3262-1AC00-0DA0 Screening kit
100 1 6FX5002-2CA12-1BA0 Signal cable; MOTION CONNECT 500 (permanently routed);
10.00 m
110 1 6FX5008-1BB31-1BA0 Power cable to the motor MOTION CONNECT 500, by the meter
(permanently routed); 10.0 m
120 1 2KJ3111-1HG22-9AX1-Z Induction geared motor (2KJ)
B22 + C06 + C47 + C60 + N6A
+ P91 + C02 + C27 + D01 +
K03 + K06 + L02 + L75 + M16
+ M56 + N06 + N18 + Q47
Legend
► Please note:
The overload capability when dimensioning according to the load characteristic (e.g. load cycle with a
constant switch-on the duration), this refers to the brief overload at the motor that is required.
Configuring/engineering based on the actual application is required for longer or cyclic overload
conditions.
For "basic motor selection without configuring the load", depending on the selected drive and version
(DC link, control mode and modulation depth), the rated data referred to 400/460 V are not reached.
Please take this into account when selecting/using the motor.
For 2KJ motors, please note:

For drive speeds exceeding 1800 rpm, we recommend that the gearbox is thermally calculated.
The suitability of the brake for the specified application is not checked!
► Induction geared motor (2KJ)

B22: Brake,L80
C02: Manual release, manual release
C06: Brake lining, low-wear brake lining
C27: Manual release position,2
C47: Control voltage, 380-440 AC
C60: Function rectifier, overexcited +DC shutdown voltage sensing
D01: Mounting position,M1
K03: Degree of protection, IP65
K06: Gearbox oil, mineral oil CLP VG220
L02: Surface treatment, coating/paint for normal environmental load C1
L75: Color:, color RAL 7016 anthracite gray

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M56: Terminal box position,1B

N06: Motor plug, motor plug HAN10E (1 bar) (EMC)
N18: Mating connector, mating connector HAN10E
N6A: Voltage/frequency, 50 // 87 Hz 230V D // 400V D
P91: Special power
Q47: Type,1XP8032-10
6. General notes
The overload capability when dimensioning according to the load characteristic (e.g. load cycle with a
constant switch-on the duration), this refers to the brief overload at the motor that is required.
Configuring/engineering based on the actual application is required for longer or cyclic overload
conditions.
For "basic motor selection without configuring the load", depending on the selected drive and version
(DC link, control mode and modulation depth), the rated data referred to 400/460 V are not reached.
Please take this into account when selecting/using the motor.
8.2 Notes on commissioning

8.2.1 Converting the motor order number
If only the type designation of the geared motor is known, using the following table
the main MLFB of the standard induction motor can be determined. This can be
specified in STARTER.
Table 8-1: Converting the type designation of the geared motor (obtained from SIZER) to the main MLFB
(for commissioning in STARTER)

SIMOGEAR / 1LA / 1LE main SIMOGEAR / 1LA / 1LE main
MOTOX MLFB MOTOX MLFB
LA100L4 1LA71064AA.. LE132MF4E 1LE10011CB2.....

LA100L6 1LA71066AA.. LE132MJ6 1LE10021CC3.....
LA100L8 1LA71078AB.. LE132MJ6E 1LE10011CC3.....
LA100LA8 1LA71068AB.. LE132MJ6P 1LE10231CC2.....
LA100LB4 1LA71074AA.. LE132MJ8 1LE10021CD2.....
LA112M6 1LA71136AA.. LE132SB2E 1LE10011CA0.....
LA112M8 1LA71138AB.. LE132SB6 1LE10021CC0.....
LA112MB4 1LA71134AA.. LE132SC6E 1LE10011CC0.....
LA132M4 1LA71334AA.. LE132SF2E 1LE10011CA1.....
LA132MA6 1LA71336AA.. LE132SF2P 1LE10231CA0.....
LA132MA8 1LA71338AB.. LE132SF4 1LE10021CB0.....
LA132MB6 1LA71346AA.. LE132SF4E 1LE10011CB0.....
LA132S6 1LA71306AA.. LE132SH6P 1LE10231CC0.....
LA132S8 1LA71308AB.. LE132SL8 1LE10021CD0.....
LA132SB4 1LA71304AA.. LE132ZMS4P 1LE10231CB2.....
LA132ZMP4 1LA71374AA.. LE132ZMS6P 1LE10231CC3.....
LA160L4 1LA71664AA.. LE132ZSQB2P 1LE10231CA1.....
LA160LB6 1LA71666AA.. LE132ZST4P 1LE10231CB0.....
LA160LB8 1LA71668AB.. LE160LA4 1LE10021DB4.....
LA160M8 1LA71638AB.. LE160LB2E 1LE10011DA4.....
LA160MB4 1LA71634AA.. LE160LD4E 1LE10011DB2.....
LA160MB6 1LA71636AA.. LE160LL6E 1LE10011DC4.....
LA160MB8 1LA71648AB.. LE160LN6 1LE10021DC4.....
LA63MD4 1LA70604AB.. LE160LN8 1LE10021DD4.....

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LA63ME2 1LA70602AA.. LE160MB2E 1LE10011DA2.....

LA63ME4 1LA70604AB.. LE160MD4 1LE10021DB2.....
LA63MF2 1LA70632AA.. LE160MD8 1LE10021DD2.....
LA63MF4 1LA70634AB.. LE160MF4E 1LE10011DB2.....
LA71B4 1LA70754AB.. LE160MG2E 1LE10011DA3.....
LA71B6 1LA70766AA.. LE160MG2P 1LE10231DA2.....
LA71C4 1LA70764AB.. LE160ML6 1LE10021DC2.....
LA71C6 1LA70726AA.. LE160ML6E 1LE10011DC2.....
LA71M4 1LA70734AB.. LE160ML8 1LE10021DD3.....
LA71M6 1LA70736AA.. LE160MM2P 1LE10231DA3.....
LA71M8 1LA70708AB.. LE160MPB4P 1LE10231DB2.....
LA71MB8 1LA70738AB.. LE160MW6P 1LE10231DC2.....
LA71MG2 1LA70702AA.. LE160ZLJ2P 1LE10231DA4.....
LA71MG4 1LA70704AB.. LE160ZLL4P 1LE10231DB4.....
LA71MG6 1LA70706AA.. LE160ZLW6P 1LE10231DC4.....
LA71MH2 1LA70732AA.. LE80MA2E 1LE10010DA2.....
LA71MH4 1LA70734AB.. LE80MD4E 1LE10010DB2.....
LA71MH6 1LA70736AA.. LE80MD6E 1LE10010DC2.....
LA71S4 1LA70704AB.. LE80ME2E 1LE10010DA3.....

LA71S6 1LA70706AA.. LE80ME2P 1LE10030DA2.....
LA71ZMD4 1LA70784AB.. LE80MH4E 1LE10010DB3.....
LA71ZMP4 1LA70774AB.. LE80MK6E 1LE10010DC3.....
LA80M4 1LA70834AA.. LE80ZMJ2P 1LE10030DA3.....
LA80M6 1LA70836AA.. LE80ZMQ4P 1LE10030DB3.....
LA80M8 1LA70838AB.. LE90LH2E 1LE10010EA4.....
LA80S4 1LA70804AA.. LE90LH4E 1LE10010EB4.....
LA80S6 1LA70806AA.. LE90LLB6E 1LE10010EC4.....
LA80S8 1LA70808AB.. LE90SG2E 1LE10010EA0.....
LA90L4 1LA70964AA.. LE90SG4E 1LE10010EB0.....
LA90L6 1LA70966AA.. LE90SH6E 1LE10010EC0.....
LA90LA8 1LA70968AB.. LE90SM2P 1LE10030EA0.....
LA90S4 1LA70904AA.. LE90SM4P 1LE10030EB0.....
LA90S6 1LA70906AA.. LE90SQ6P 1LE10030EC0.....
LA90SA8 1LA70908AB.. LE90ZLR2P 1LE10030EA4.....
LA90ZLB4 1LA70974AA.. LE90ZLR4P 1LE10030EB4.....
LE100LA8 1LE10021AD4..... LES180LE6E 1LE1.011EC4.....
LE100LB4 1LE10021AB4..... LES180LJ6P 1LE1.031EC4.....
LE100LD2E 1LE10011AA4..... LES180MM4E 1LE1.011EB2.....
LE100LD6 1LE10021AC4..... LES180MQ4P 1LE1.031EB2.....
LE100LE4E 1LE10011AB4..... LES180ZLJ4E 1LE1.011EB4.....
LE100LH4 1LE10021AB5..... LES180ZLN4P 1LE1.031EB4.....
LE100LK4E 1LE10011AB5..... LES200LG6E 1LE1.012AC4.....
LE100LK8 1LE10021AD5..... LES200LM6P 1LE1.032AC4.....
LE100LLB6E 1LE10011AC4..... LES200LN4E 1LE1.012AB5.....

102950703, V 1.1, 05/2018 Unrestricted 69

LE100ZLK2P 1LE10231AA4..... LES200LP6E 1LE1.012AC5.....

LE100ZLSA4P 1LE10231AB4..... LES200ZLS6P 1LE1.032AC5.....
LE100ZLSB4P 1LE10231AB5..... LES200ZLU4P 1LE1.032AB5.....
LE112MA2E 1LE10011BA2..... LES225SD4E 1LE1.012BB0.....
LE112MB6 1LE10021BC2..... LES225SD4P 1LE1.032BB0.....
LE112ME4 1LE10021BB2..... LES225YMF4E 1LE1.012BB2.....
LE112ME4E 1LE10011BB2..... LES225YMF4P 1LE1.032BB2.....
LE112ME6E 1LE10011BC2..... LES225YMF6E 1LE1.012BC2.....
LE112MG8 1LE10021BD2..... LES225YMF6P 1LE1.032BC2.....
LE112ZMH2P 1LE10231BA2..... LES250MD4E 1LE1.012CB2.....
LE112ZMKB4P 1LE10231BB2..... LES250MD4P 1LE1.032CB2.....
LE132MA6 1LE10021CC2..... LES250MD6E 1LE1.012CC2.....
LE132MB6E 1LE10011CC2..... LES250MD6P 1LE1.032CC2.....
LE132ME4 1LE10021CB2.....
8.2.2 Technical data of the linear encoder and how to handle problems
Table 8-2: Technical data of the assumed linear encoder3

Resolution 1200 positions / m = 0.8 mm
Velocity Max. 12.5 m/s

Number of clock cycles n = 25
Number of revolutions 4096, 512 effective
Resolution per revolution 4986, 1024 effective
Position output 19 bit gray code
Pause time Tp = min. < 20 µs
Input frequency 100 … 1000 kHz
F07452 following error too high

If fault F07452 is output when traversing or at standstill, although the actual
following error lies within its limits, the absolute encoder supplies an incorrect
position actual value.
In the case that it is outside the mechanical tolerance, the WCS3B supplies the
position value 52287 (all position bits are equal to one, see Fig. 8-4). If this fault
occurs during positioning, and is reproducible, then the installation of the rail and
the reading head must be checked.
The EMC situation should be checked if position actual values are only sporadically
incorrect.
3
Based on Pepperl+Fuchs WCS3B distance-coding system

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Fig. 8-4: Position actual value steps (r497[1]) as a result of mechanical play of the read head

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9 Checklist
9 Checklist
The checklist serves as basis to pre-clarify the application with the customer or
internally in the relevant project phase.
Table 9-1: Checklist, drive concept
Question Answer
1. Distributed drive system in IP65 or central drive in IP20 for installation in a
cabinet?
2. Drive with energy recovery (regenerative operation) or with braking module
and braking resistor?
3. Positioning using proximity switches with rapid traverse/crawl switchover or
using position control?
3.1 Are the proximity switches evaluated in the drive or in the control system?
3.2 Position control in the drive (EPos) or in the control system (e.g. using a
technology object)?
3.2.1 Absolute encoder or incremental encoder for the position control?
3.2.2 Interface format of the position encoder? (SSI, EnDat, HTL, TTL, DRIVE
CLiQ, Profinet etc.)
3.2.3 Position encoder resolution? (increments per revolution, singleturn,

multiturn)
3.2.4 Is the encoder for the position control on the load side – or is it mounted
on the motor shaft?
3.2.5 Interface for the speed encoder?
3.2.6 Speed encoder resolution?
3.3 Closed-loop control mode, voltage-frequency characteristic (U/f), vector

control (with/without encoder)?
4. Communication via Profinet, Profibus or others?
5. No safety functions in the drive, basic functionality (STO, SS1) or extended

safety functions in the drive (SLS, SDI, SSM)?

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9 Checklist
Table 9-2: Checklist for the mechanical design

Question Answer
1. Just lifting, lowering – or lifting and lowering?
2. Intrinsic weight of the lift equipment?
3. Maximum payload?
4. Counterweight?
5. Diameter of the drum for the circulating belts?
6. Efficiency of the mechanical system (if not known, approx. 90%)?
7. Lifting height?
8. Traversing profile as trapezoidal/delta?
8.1. Max. cycle time?
8.1.1. Duration of the lifting or lowering operation?
8.1.2. Pause time?
8.1.2.1. Should the motor holding brake be applied during the pause?
8.2. Lifting/lowering velocity?
8.3. Acceleration?
8.4. Deceleration?

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9 Checklist
Table 9-3: Checklist for dimensioning the geared motor

Question Answer
1. Gearbox type (helical gearbox, parallel shaft gearbox, bevel gearbox, helical
worm gearbox)?
2. Is the service sector specified or calculated by SIZER based on the circuits?
2.1. Operating duration per day (8 hours, 16 hours or 24 hours)?
3. Line frequency 50 Hz or 60 Hz?
4. Dimensioned for a 87 Hz characteristic?
5. Maximum permissible frequency for the setpoint lifting velocity?
6. Are there special ambient/environmental conditions that supply, such as
increased installation altitude, operation outdoors, air humidity, explosion
protection, temperature etc.?
7. Mounting position (M1, M2, M3, M4, M5, M6)?
8. Terminal box position?
9. Mounting type – foot-mounting version, flange-mounting version, housing
flange or plug-on version?
10. Solid shaft with feather key, hollow shaft with feather key, shrunk-on disk,
splined connection or SIMOLOC mounting system
11. Diameter and length of the shaft?
12. Motor protection using PTC thermistor, winding thermostat, temperature
sensor KTY84-130 or resistance thermometer PT100?

13. Self-ventilated or force-ventilated? (Force ventilated is recommended, if, during
the pause, no brake is applied and the drive remains in closed-loop control at
zero speed)
14. Motor plug HAN 10E, HAN K4/4, HAN Q8, HANQ12?
15. With motor holding brake or operating brake on the load side?
15.1. Brake control using a function rectifier (this is recommended) or AC/DC?
15.2. Brake solenoid control voltage?
15.3. Brake with manual release lever?
15.3.1. Mounting position of the manual release lever?
16. Incremental encoder, absolute encoder, resolver or encoder mounting
prepared?
17. Surface protection, unpainted, C1, C2, C3, C4, C5, C3 with primer, C4 with
primer, RAL color?

102950703, V 1.1, 05/2018 Unrestricted 74
9 Checklist
Table 9-4: Checklist for dimensioning the drive (supplement to the drive concept)
Question Answer
1. With or without line filter, filter Class A, B or C2, C3?
2. Line reactor required and/or permissible?
3. Output reactor or sine-wave filter required?
4. Motor cable length? Shielding? Cable cross-section?
5. Brake control using the drive sequence control – and therefore using a brake
relay with control via the power unit?
6. Required I/O quantity structure?
7. Safety control via PROFIsafe or safety-related digital inputs?
8. Licensing for extended safety or positioning function?
9. With repair switch?
10. Combination encoder with HTL-SSI-Y adapter and combination encoder
cable?

102950703, V 1.1, 05/2018 Unrestricted 75
9 Checklist
Table 9-5 Basic commissioning checklist

Question Answer
Have the correct power unit and correct control module (Control Unit) been
configured?
Has the control module firmware the latest release (> 4.7)?
Basic positioner function module activated?
Are all function modules not required deactivated?
Closed-loop control mode (P1300) set to 21 Closed-loop speed control with encoder?
Has the motor been selected and/or specified corresponding to the rating plate?
Motor connection type (P133.0) set to delta?
87-Hz calculation selected?
Motor identification (P1900) identify 2 motor data at standstill selected?
Has the current limit been set to 150% of the 87 Hz delta current?
Has the maximum speed been set to 87Hz of the rated motor speed?
OFF3 ramp-down time set to zero?
Complete calculation of the motor parameters activated?
Encoder_1 selected at terminal interface with 1024 HTL encoder A/B R?
Encoder_2 parameterized via encoder data as linear encoder with absolute SSI
protocol corresponding to the technical data?
Encoder_2 selected for position control?

Gearbox ratio correctly parameterized?
LU load revolution parameterized on the drum circumference with 1LU equal to 1µm?
Monitoring multiturn representation deactivated in Gx_XIST2 in P0347.25 = 1?
Brake control (P1215) set on 1 motor holding brake just the same as sequence
control?
Brake opening (P1216) and closing time (P1217) entered, whereby the closing time
was increased?
Torque when opening the brake specified?
Under communication (P922) standard telegram 111
Current actual value (r68.0) logically combined with P2051 in the telegram?
Safety Integrated basic functions selected via PROFIsafe?
PROFIsafe address taken from the configuration?

102950703, V 1.1, 05/2018 Unrestricted 76
9 Checklist
Table 9-6 Basic positioner checklist

Question Answer
Has the absolute encoder been adjusted?
Traversing profile limitation – has the maximum velocity (P2571) been set to 87 Hz in
1000LU/min?
Have the maximum acceleration (P2572) and deceleration (P2573) been
parameterized corresponding to the drive dimensioning?
Jerk limiting activated?
Positive and negative software limit switches set?
Stop output cam plus and minus connected with the digital inputs?
EPos jog setpoint velocity adapted corresponding to the mechanical system?
Table 9-7 Drive optimization checklist

Question Answer
1. Optimization of the speed controller (position controller (P2538), speed
(P2534) and torque precontrol (P1496) have been set to zero)
a. Coarse optimization according to the symmetrical optimum:
𝑇𝑛 = 4 ∙ 𝑇𝑆 (𝑠𝑢𝑚 𝑜𝑓 𝑎𝑙𝑙 𝑑𝑒𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛𝑠) ≅ 90 − 120 𝑚𝑠
𝑟𝑎𝑡𝑒𝑑 𝑚𝑜𝑡𝑜𝑟 𝑠𝑡𝑎𝑟𝑡𝑖𝑛𝑔 𝑡𝑖𝑚𝑒 (𝑟0345)
𝐾𝑃 = 𝑛 ∙ 𝑤ℎ𝑒𝑟𝑒 𝑛 = 1, 2, …
integral time 𝑇𝑛 (𝑃1462)
b. Manual optimization via the control panel (f setpoint)

i.Set the integral time Tn (P1462) to zero or maximum
ii. Speed step higher than large frictional torques
iii. Increase the P gain factor (P1460) until the step response of
the speed actual value overshoots by approx. 4%
iv. Increase the integral time Tn (P1462) until the speed actual
value overshoots by approx. 43%
c. Activate the torque precontrol
i.Enter the moment of inertia ratio (P342).
ii. Increase the torque precontrol (P1496) step-by-step up to
100%
iii. Check the torque setpoint (r79.0), if it is not steady enough,
then set the smoothing time (P1517) to 10 ms
2. During optimization, ensure that the power (r82.0), current (r68.0) and torque
setpoint (r79.0) limits are not active, or increase the limits if the motor can
tolerate these increases.
3. Optimize the position controller (control panel for positioning)
a. Reduce the position controller P gain (P2538) from 1 to 0.3 and
increase as long as the position actual value does not overshoot.
b. Keep the position controller integral time (P2539) at zero.
c. Increase the speed precontrol (P2534) until the speed setpoint no
longer oscillates.
d. If required, filter the position setpoint by increasing the smoothing
time constant (P2533) to approx. 50 ms.

102950703, V 1.1, 05/2018 Unrestricted 77
10 References
10 References
Table 10-1
Topic Title
\1\ Siemens Industry http://support.automation.siemens.com
Online Support
\2\ Download page of https://support.industry.siemens.com/cs/ww/en/view/1029507
the article 03http://support.automation.siemens.com/WW/view/en/102950703
\3\ STARTER http://support.automation.siemens.com/WW/view/de/26233208

download
\4\ Download SIZER http://support.automation.siemens.com/WW/view/de/54992004
\5\ SICAR standard https://workspace.automation.siemens.com/content/10004325/sicar/d
efault.aspx
\6\ CU250S-2 http://support.automation.siemens.com/WW/view/de/68109071
standard
application
\7\ SINAMICS http://support.automation.siemens.com/WW/view/de/25166781
Toolbox
\8\ Application http://support.automation.siemens.com/WW/view/de/73102423
acceptance test
\9\ FAQ 87 Hz http://support.automation.siemens.com/WW/view/de/8896361
characteristic for 3
third-party motors
\10\ Information sheet, http://www.dguv.de/medien/fb-
axes subject to holzundmetall/publikationen/infoblaetter/infobl_deutsch/005_v
the force of ertikalachsen.pdf
gravity DGUV, Edition 09/2012, No. 005
11 Contact person
Siemens AG
Industry Sector
I DT MC PMA APC
Frauenauracher Strasse 80
D - 91056 Erlangen, Germany
E-mail: tech.team.motioncontrol@siemens.com
12 History
Table 12-1
Version Date Revision
V1.0 11/2014 First Edition
V1.1 04/2018 Corrected description of brake control wiring and
parametrization (chapters: 5.1, 5.2.2 )

102950703, V 1.1, 05/2018 Unrestricted 78

Belt - Lift - V1-1 - EN (1) مثال حزام ناقل مصنع سيارات يستعمل S300

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Belt lift for the

Warranty and liability

body or health, guarantee for the quality of a product, fraudulent concealment of a

Any form of duplication or distribution of these Application Examples or excerpts

Belt lift for the automotive industry

Danger for personnel as a result of unintentional lowering

Belt lift for the automotive industry

5.2.2 Drive functions................................................................................. 36

Belt lift for the automotive industry

1 Description of the belt lift application

1.1 Mechanical system

Belt lift for the automotive industry

1.2 Sensor technology

1.3 Drive train

Belt lift for the automotive industry

Belt lift for the automotive industry

Table 2-1: Mechanical data

3000 kg 4700 kg 6200 kg 320 mm

Table 2-2: Traversing profile data

1. Lifting unloaded 10 s 0.5 m/s² No

Belt lift for the automotive industry

Belt lift for the automotive industry

3.1 Overview of the solution

3.2 Software functionality

Belt lift for the automotive industry

3.3 Hardware and software components

CPU317F-2 PN/DP 1 6ES7317-2FK14-0AB0 Or another S7-300

Belt lift for the automotive industry

Table 3-3: Software components

Belt lift for the automotive industry

4.1 Configuring the mechanical system

You must first enter the mechanical data.

Belt lift for the automotive industry

Fig. 4-3: Entering the mechanical data

Then enter the traversing profile as "as trapez./triangular curves" with

Belt lift for the automotive industry

Belt lift for the automotive industry

4.2 Selecting the geared motor

Belt lift for the automotive industry

Click on the button to dimension the motor.

Fig. 4-10: Dimensioning the geared motor

Belt lift for the automotive industry

Belt lift for the automotive industry

The remaining data can be left at the default settings.

Belt lift for the automotive industry

Fig. 4-15: Basic motor type

Belt lift for the automotive industry

The SIMOGEAR Configurator retrieves the values from SIZER.

Belt lift for the automotive industry

Fig. 4-20: Brake in the SIMOGEAR Configurator

Belt lift for the automotive industry

Belt lift for the automotive industry

4.3 Selecting the drive

Select the smallest power unit with 15 kW.

Belt lift for the automotive industry

Fig. 4-24: Selecting the control unit

Belt lift for the automotive industry

5 Installation and commissioning

5.1 Connecting-up the hardware

Belt lift for the automotive industry

Active Brake Rectifier

5.2 Basic commissioning