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Application description  02/2015

SIMOCRANE Application
for
Drive-Based Technology
(based on CU320-2)
Siemens Cranes
Warranty and liability

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
to provide support for typical applications. You are responsible for ensuring that
the described products are used correctly. These application examples do not
relieve you of the responsibility to use safe practices in application, installation,
operation and maintenance. When using these Application Examples, you
recognize that we cannot be made liable for any damage/claims beyond the
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the examples, information, programs, engineering and performance data etc.,
described in this Application Example shall be excluded. Such an exclusion shall
not apply in the case of mandatory liability, e.g. under the German Product Liability
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Act (“Produkthaftungsgesetz”), in case of intent, gross negligence, or injury of life,


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Table of contents

Table of contents
Warranty and liability................................................................................................... 2
1 Task ..................................................................................................................... 4
1.1 Overview............................................................................................... 4
1.2 Function ................................................................................................ 5
2 Solution............................................................................................................... 6
2.1 Software structure ................................................................................ 6
2.2 Closed – loop structure in drive ............................................................ 7
2.3 Hardware and Software Components .................................................. 8
2.3.1 Validity .................................................................................................. 8
2.3.2 Used Components ................................................................................ 9
3 Communication interface................................................................................ 10
3.1 General information ............................................................................ 11
3.2 Configuring the PROFIBS connection ................................................ 12
3.2.1 Telegram definition SIMATIC  SINAMICS ...................................... 13
3.2.2 Telegram definition SINAMICS  SIMATIC ...................................... 14
4 Installation, Startup and Commissioning ...................................................... 16
4.1 Installation of the hardware ................................................................ 16
4.2 Startup and Commissioning ............................................................... 17
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4.3 Set sampling times for internal control loops ..................................... 17


4.4 Set Execution Groups for DCC blocks ............................................... 18
4.5 Fehler! Textmarke nicht definiert.
5 Related literature ............................................................................................. 20
6 Contact.............................................................................................................. 21
7 History............................................................................................................... 22

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1 Task

1 Task
1.1 Overview
Introduction
A sector solution based on the platform of SIMOTION / SINAMICS SIMOCRANE
Basic Technology was launched into the market in the middle of 2007. The new
platform based on SIMATIC + SIMOTION + SINAMICS is available for both harbor
and industrial cranes. The solution covers high-performance crane applications and
allows a modular, scalable closed – loop control system for all types of cranes by
adding the Advanced Technology (e.g. Sway Control).
However, in the meantime, the industrial crane market has developed further at a
fast rate. As a consequence, in recent years a broad range of applications for mid-
performance cranes has been opened up. With SIMOCRANE Drive-Based
Technology, Siemens Crane meets the challenges of this market.
The new mid-performance crane solution will not take market share from
SIMOCRANE Basic Technology. In fact, the SIMOCRANE Drive-Based
Technology perfectly adapts this high performance solution to the mid-performance
market.
SIMOCRANE Drive-Based Technology is drive-based and offers a compact
 Siemens AG Copyright year All rights reserved

functional scope within the SINAMICS environment. Highlights of Drive-Based


Technology are fast commissioning by using standard applications and a high
degree of flexibility through the appropriate adaptation possibilities.
SIMOCRANE Drive-Based Technology encompasses the following features:
• All of the functions that have been proven in practice and required for mid-
performance applications can be found on the new SINAMICS platform for
parameterization.
• Preconfigured standard applications for hoist and trolley/gantry with control
via I/O signals or PROFIBUS DP (ready-to-run, parameterization only,
selection using a script).
• Can be adapted for customer-specific requirements - "Ready-to-apply" (for
adaptation by the user).

The current SIMOCRANE Drive-Based Technology V1.0 SP1 HF1 is based on


SINAMICS CU310-2, whose focus is the AC/AC single axis application. The crane-
specific SINAMICS firmware makes the CU310-2 possible to operate the PM340
Power Modules, PM Chassis and PM250.
However there are some crane applications in mid-performance market which are
suitable for Simocrane Drive-Based Technology but need the larger power range
than Sinamics power module for AC/AC drives. To meet this challenge we add this
application to the Product. Its technology functionality is as same as the Simocrane
Drive-Based Technology but based on the Sinamics CU320-2 for multiaxes drive-
train.

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1 Task

1.2 Function
Overview of the function
The figure below provides an overview of the configuration of the application. This
OHBC has simply three main drives: hoist, short travel (Trolley) and long travel
(Gantry). Commands and setpoints are given by the PLC via Profibus DP. The
crane specified technology is embedded in drive controller CU320-2.

Figure 1-1: Overview crane configuration


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Note In the application a separate infeed (Active Line Module, Basic Line Module or
Smart Line Module) is necessary, when DC – AC motor modules are used. The
separate infeed is not necessary, when for the main drives AC – AC motor
modules are used.

Contact for download

Note For Simocrane Application of Dive-Based Technology (based on CU320-2)


please contact Siemens Cranes application support via E-mail:
(mailto:applications.cranes.aud@siemens.com)
Or contact your region Siemens for download
https://support.industry.siemens.com/cs/ww/de/ps/20087/man

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2 Solution

2 Solution
2.1 Software structure
Every main drive uses the standard speed setpoint channel in Sinamics. The crane
specified technology is generated in the graphic programming language "Drive
Control Charts" (DCC), and connected to the speed setpoint channel. It processes
the speed setpoint additionally and monitors various functions (e.g. current
distribution monitoring, overspeed). All crane-specific technologies are
implemented in a DCC chart. The number and functionality of the DCC blocks in
this chart are identical for all main drives. The not required DCC blocks must be
disabled in the execution system in the STARTER expert list in order to avoid any
unnecessary computational load.
When scripting is used, the connections among the DCC blocks depending on the main
Note
drive (Hoist, Short travel (Trolley) or Long travel (Gantry)), the main setpoint channel in
Sinamics and communication (PROFIBUS DP) are performed automatically.

Figure 2-1: Overview software architecture


Short travel (Trolley)
Long travel (Gantry)
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PROFIBUS - Communication between S7 and SINAMICS


Hoist

MasterSwitch MasterSwitch MasterSwitch


(DCC) (DCC) (DCC)

LoadDependingFW LoadDependingFW LoadDependingFW


(DCC) (DCC) (DCC)

PreLimitSwitch PreLimitSwitch PreLimitSwitch


(DCC) (DCC) (DCC)

StartPulse StartPulse StartPulse


(DCC) (DCC) (DCC)

OverSpeed OverSpeed OverSpeed


(DCC) (DCC) (DCC)

CurrentDistribution CurrentDistribution CurrentDistribution


(DCC) (DCC) (DCC)

DO DO DO
Hoist Trolley Gantry

Note The DCC blocks are described in detail in the documentation of the
SIMOCRANE Drive-Based Technology (Chapter 4 in Ref. 1).
The documentation can be found in the Internet here
https://support.industry.siemens.com/cs/ww/de/ps/20087/man

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2 Solution

2.2 Closed – loop structure in drive


A speed setpoint is read in from the S7 or from the Onboard Terminals. This speed
setpoint is connected to the input of the Crane DCC block MasterSwitch. The
setpoint is then transferred to the main setpoint channel of the SINAMICS basic
system after processing via the DCC blocks LoadDependingFieldWeak and
PreLimitSwitch; refer to the following diagrams.

Figure 2-2: Hoist setpoint channel using the example of control via PROFIBUS
Pulse Width
PLC / Terminal Interface Masterswitch LoadDependingFieldWeak PreLimitSwitch Rampfunction generator Speed controller Modulation

PLC via v v v
PROFIBUS /
Controlled by
Terminal Deflection
PWM
Interface M t

OverSpeed CurrentDistribution
v i

t t

StartPulse

T T 0
I

Crane Drive-Based Technology


SINAMICS Basic Unit HOIST
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Figure 2-3: Gantry/trolley setpoint channel using the example of the control via PROFIBUS
PLC / Terminal Rampfunction Pulse Width
Interface Masterswitch PreLimitSwitch generator Speed controller Modulation

PLC via v v
PROFIBUS /
Controlled by
Terminal Deflection
PWM
Interface t

OverSpeed CurrentDistribution
v i

t t

Crane Drive-Based Technology


SINAMICS Basic Unit GANTRY / TROLLEY

Speed path
The setpoint speed is first interconnected to the block MasterSwitch in the DCC. If
the master switch functionality is to be used, then the master switch curve must be
configured and enabled. Otherwise, the speed setpoint is directly connected from
the input to the block output without any change.
The speed setpoint is then connected to the LoadDependingFieldWeak block (only
for hoisting gear applications). When traveling at a constant speed in the rated
speed range, this block determines the load. The maximum speed is limited as a
function of the load.
The speed setpoint is further connected to the PreLimitSwitch block. Depending on
the operation, the setpoint speed can be reduced. Finally, the setpoint speed is
interconnected with the main setpoint of the SINAMICS basic system.

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2 Solution

Advantages

This application offers you the following advantages:


• Save time and costs
• Simple application solution
• Solution for the cranes in mid-performance market

Delimitation
This application does not include a description of
• SINAMICS functions, refer to (Ref.2-4)
• Cranes functions, refer to (Ref. 1)

Required knowledge
Basic knowledge on SINAMICS and CRANES technology is assumed.
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2.3 Hardware and Software Components


2.3.1 Validity

This application example is valid for


• STEP 7 V5.5 or newer
• STARTER V4.3 SP3 or higher
• SINAMICS CU320 – 2 DP
• Sinamics Firmware V4.5

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2.3.2 Used Components

The application was generated with the following components:

Hardware components
Table 2-1: Hardware components
Component No. Order number Note
e. g. plc is depending
on your project
SIMATIC S7-300,
1 6ES7318-3EL01-0AB0 requirements. Smaller
CPU 319-3 PN/DP
or bigger plc can also
be used
e. g. 8MByte card,
SIMATIC Micro size of the MMC is
1 6ES7953-8LP20-0AA0
Memory Card depending on your plc
program
SINAMICS Control
1 6SL3240-1MA00-0AA0 S120 Control Unit
Unit CU320 – 2DP
CF card with V4.5
SINAMICS Compact Firmware Version
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1 6SL3054-0EF00-1BA0
Flash card without Performance
extension

Standard software components


Table 2-2: Software components
Component No. Order number Note
STEP 7 V5.5 1 6ES7810-4CC10-0YA5 SIMATIC software
STARTER DVD 1 6SL3072-0AA00-0AG0 STARTER software
(current version)

Sample files and projects


The following list includes all files and projects that are used in this example.
Table 2-3: Sample files and projects
Component Note
This zip file includes the
SimocraneDBTAppl_0215.zip STARTER project for the CU320-
2 with the necessary script file.
SIMOCRANE_Drive_Based_Technology_Application This document.
_Sinamics_CU320_2_en.pdf

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3 Communication interface

3 Communication interface
In this application the drives are controlled via PROFIBUS DP. For PROFIBUS DP
communication between the higher-level SIMATIC S7 control and the drive, a
maximum of 16 process data for each axis are provided for the send and receive
directions.

Figure 3-1: Overview communication Simatic and Sinamics


PLC (e.g. S7)

SINAMICS
Profibus DP
max 16/16 PZD
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3 Communication interface

3.1 General information


The following list provides an overview of task distribution between SIMATIC S7
and SINAMICS.

SIMATIC S7
• Crane overview
• I/O signal processing
• Safety-related monitoring
• Setpoint and control commands for main drives
• Control commands for infeed

SINAMICS
• Crane technology in DCC
• Ramp-function generator
• Closed-loop speed control
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• Closed-loop current control


• Brake control (combined with StartPulse in the standard application)
• Safety Integrated function, if necessary

Prerequisites
In order to establish disturbance-free communication between the two parties, the
reference data in SIMATIC and SINAMICS modules must be identically configured.
The reference data must be normalized to the maximum data.

The following parameters are involved in the modules:


SIMATIC
• Reference speed
• Reference voltage
• Reference current
• Reference torque
SINAMICS
• p2000 = r2700 = reference speed reference frequency ( ≈ p1082 =
maximum speed)
• p2001 = r2701 = reference voltage
• p2002 = r2702 = reference current
• p2003 = r2703 = reference torque

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3 Communication interface

3.2 Configuring the PROFIBS connection

Note Parameter p0922 must be set to a free telegram (999) when configuring the
system. With the execution of the script from the selection screen, the
communication interconnection is automatically set to the correct values for the
telegram data words.

The type and baud rate of the communication between SIMATIC and SINAMICS is
configured in the HW-Configuration. The PROFIBUS communication is used.
The communication between SIMATIC and SINAMICS is implemented using a
telegram defined for Drive-Based Technology. The standard telegram is extended
to a free telegram (999) with 16 process data on the send and receive side,
separately.

The address ranges for communications between SIMATIC and SINAMICS should
be configured as follows. These addresses can be adapted in the HW-
Configuration.
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Table 3-1: Address areas of the main drives

Drives Address a range, I/O (peripherals) in bytes


Infeed (SLM) 256 … 275
Hoist 300 … 331
Short travel (Trolley) 400 … 431
Long travel(Gantry) 500 … 531
S Control Unit 600 … 631
S
cripts are available in the standard project. They can be used to automatically
execute all the communication interconnections in SINAMICS.
The script file is started with ‘Accept and execute’. After running the script file all
pre-defined communication connections are generated, refer to Chapter 3.2.1.

Note • The script file should be executed offline. The changes then have to be
downloaded to the drive.

• The script file to establish communication with the S7 control has the
same name for all main drives

• The reference data should be checked and adapted in every script file.

• All connections, which are established by the script, are listed in the
STARTER output window.

• Further, a report after running scripting can be generated. The report can
be saved on the hard disk.

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3 Communication interface

3.2.1 Telegram definition SIMATIC  SINAMICS

The communication from the SIMATIC plc to the SINAMICS drive is defined in the
following table:

Table 3-2: Telegram Simatic  Sinamics

PZD Signal name Remarks

1 See documentation of the SIMOCRANE Drive-Based


Control word_1
Technology
The speed setpoint is specified as normalized value as
a percentage (%).
2 Speed setpoint 4000hex = 16384dec = 100 %
The PZD2 must be connected with parameter p22000
“rInSpeedSetpointMS”.
3 See documentation of the SIMOCRANE Drive-Based
Control word_2
Technology
4 Application control See documentation of the SIMOCRANE Drive-Based
word_1 Technology
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Only for the hoist


The setpoint for the start pulse is specified as
normalized value as a percentage (%).
5 Setpoint for the start
pulse_S7 4000 hex = 16384 dec = 100 %
If the setpoint for the start pulse is to be specified by the
PLC control, then PZD 5 must be connected with
parameter p22075 “rTorqueValue”.
6– Application-related area
16 Free

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3 Communication interface

3.2.2 Telegram definition SINAMICS  SIMATIC

The communication from the SINAMICS drive to the SIMATIC plc is defined in the
following table:
Table 3-3: Telegram Sinamics  Simatic

PZD Signal name Remarks


See documentation of the SIMOCRANE Drive-Based
Technology
1 Status_word_1 Parameter r2089[0] “Send binector-connector converter
status word, Status word 1” must be connected with
parameter p2051[0].
The speed actual value (r0063) is sent, referred to the
reference value. The reference value is the maximum
value.
2 Speed actual value nmax = nreference = nrated + nFW = 100 %
4000 hex = 16384 dec = 100 %
Parameter r0063[0] “Actual speed value, unsmoothed”
must be connected with parameter p2051[1].
See documentation of the SIMOCRANE Drive-Based
Technology
 Siemens AG Copyright year All rights reserved

3 Status_word_2 Parameter r2089[1] “Send binector-connector converter


status word, Status word 2” must be connected with
parameter p2051[2].
See documentation of the SIMOCRANE Drive-Based
Technology
4 Application_status_word
_1 Parameter r2089[2] “Send binector-connector converter
status word, free Status word 3” must be connected
with parameter p2051[3].
The actual fault code is sent as word.
5 Fault numbers Parameter r2131 “Current fault code” must be
connected with parameter p2051[4].
The current actual value smoothed (r0068[1]) is sent,
referred to the reference value. The reference value is
the maximum value.
6 Smoothed total current Imax = Ireference = Irated + IOverload = 100 %
actual value 4000 hex = 16384 dec = 100 %
Parameter r0068[1] “Absolute current actual value”
must be connected with parameter p2051[5].

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3 Communication interface

PZD Signal name Remarks


The determined load actual value is sent (only for hoist,
e.g.: kg or tons).
The determined load value from 0 to 65,535 (UINT) is
7 Load actual value sent to the S7. The normalization factor for the load
current in physical units (tons) must be parameterized in
DCC block LoadDependingFieldWeak.
Parameter r22157 “rLoadWithNormFactor” must be
connected with parameter p2051[6].
The smoothed torque actual value (r0080[1]) is sent,
referred to the reference value.
The reference value is the maximum value.
8 Smoothed torque actual
Mmax = Mreference = Mrated + MOverload = 100 %
value
4000 hex = 16384 dec = 100 %
Parameter r0080[1] “Torque actual value” must be
connected with parameter p2051[7].
The actual alarm code is sent as word.
9 Alarm numbers Parameter r2132 “Current alarm code” must be
connected with parameter p2051[8].
10 – Application-related area
Free
16
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4 Installation, Startup and Commissioning

4 Installation, Startup and Commissioning


4.1 Installation of the hardware
The figure below shows the hardware configuration of the application:

Figure 4-1: Overview crane configuration


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Note The installation guidelines for SINAMICS S120 always have to be followed, refer
to Ref. 5 & 6.
In the application a separate infeed (Active Line Module, Basic Line Module or
Smart Line Module) is necessary, when DC – AC motor modules are used. The
separate infeed is not necessary, when for the main drives AC – AC motor
modules are used.

Drive – CliQ Topology


The ports on the Control Unit are used in the following way.
• At the port X100 the Smart Line Infeed is connected.
• At the port X101 the Hoist motor module is connected. The encoder of the
Hoist motor is connected to the port X402 of the Hoist motor module.
• At the port X102 the Trolley motor module is connected. The encoder of
the Trolley motor is connected to the port X402 of the Trolley motor
module.
• At the port X103 the Gantry motor module is connected. The encoder of
the Trolley motor is connected to the port X402 of the Gantry motor
module.
The below shows the topology of the application:

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4 Installation, Startup and Commissioning

Figure 4-2: Topology tree

4.2 Startup and Commissioning


Each main drive has a CraneDCC block, the name is different but the content is the
same. Also the script-files are almost the same for each main drive.
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Table 4-1: Name of script file for each main drive

Nr Main drive DCC blocks Script

1 Hoist_1 CraneDCCHoist Com_S7_Hoist

2 Trolley_1 CraneDCCTrolley Com_S7_Trolley

3 Gantry_1 CraneDCCGantry Com_S7_Gantry

Note The startup and the commissioning procedure are described in detail in the
documentation of the SIMOCRANE Drive-Based Technology (Chapter 6 in Ref.
1).

4.3 Set sampling times for internal control loops


Figure 4-3: standard sampling times for drives over 250kW

If with standard settings the system utilization is still too high (for example when
drives are used smaller than 250kW because of standard current controller
sampling time of 250us, speed controller 1000us) please change also the settings
for each drive in expert mode (p112 set to 0) like the following figure shows or the
figure 4-3.

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4 Installation, Startup and Commissioning

Figure 4-4: sampling times in expert settings

4.4 Set Execution Groups for DCC blocks


Figure 4-5: execution group for Hoist
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Default time for DCC Block is 8ms (1*r21003).

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4 Installation, Startup and Commissioning

Figure 4-6: execution group for Gantry and Trolley


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To take the original task settings shown in figure 4-5 and 4-6 please execute the
relevant script (set_run_time_group_XXX_dcc) in script folder for each drive.
Figure 4-7: Script file for execution group of Hoist and Trolley

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5 Related literature

5 Related literature
Table 5-1 Related literatures
Topic Title / Link
SIMOCRANE
1 https://support.industry.siemens.com/cs/ww/de/ps/20087/man
Drive-Based Technology
SINAMICS/SIMOTION
Programming and
2 Operating Manual Editor
Description
DCC, 02/2012
SINAMICS S120 Getting
Started for the STARTER
3 https://support.industry.siemens.com/cs/ww/en/ps/13231/man
Commissioning Tool,
01/2012
Equipment Manual for the
4
SINAMICS S120
Commissioning Manual
5
for the SINAMICS S120
List Manual for the
6
SINAMICS S120
 Siemens AG Copyright year All rights reserved

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6 Contact

6 Contact
Additional information
The latest information about SINAMICS products, product support, and FAQs can
be found on the Internet here
https://support.industry.siemens.com/cs/ww/de/ps/20087
You can find information about Crane Application Notes on the Internet here
https://support.industry.siemens.com/cs/ww/en/ps/20087/ae

Application support for cranes


E-mail: (mailto:applications.cranes.aud@siemens.com)

Additional support
We also offer training courses to help you familiarize yourself with SIMOCRANE.
You can find more information here (www.siemens.nl/training/cranes).
Under following link you can find a video for introduction and training of
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SIMOCRANE Drive-Based Technology


http://w3.siemens.com/mcms/mc-solutions/en/mechanical-engineering/crane-
solutions/video/Pages/cranes-videos.aspx

Product support for SIMOCRANE


Use the following addresses to receive support for your SIMOCRANE products:

• Support request in the Internet:


http://support.automation.siemens.com

• Europe hotline
Tel.: +49 (0) 911 895 7 222
Fax: +49 (0) 911 895 7 223
E-mail: support.automation@siemens.com

• America hotline
Tel.: +1 423 262 5710
Fax: +1 423 262 2231
E-mail: support.america.automation@siemens.com

• Asia/Pacific hotline
Tel.: +86 10 6475 7575
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7 History

7 History
Table 7-1 Changelog
Version Date Modifications
V1.0 03/2014 First version by T.T. & B.Ö.
V1.1 04/2014 modified by T.T. & B.Ö.
V1.3 04/2014 Modified by Q.C.
V1.4 02/2015 modified by T.T. & B.Ö.
 Siemens AG Copyright year All rights reserved

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