INFORME DE SERVICIO TÉCNICO AUTOMATION & DRIVES.

FS
Revisión 02 15 de Agosto 2012

FOLIO 1
Fecha 11 de junio del 2012

CLIENTE CMPC SANTA FE II

RUT
CONTACTO Cristian otey
ORDEN DE Servicio de Emergencia.
TRABAJO Nº

CARACTERISTICAS DEL EQUIPO

MODELO Sinamics G150
MLFB 6SL3710-1GE32-6AA0-Z D60+L10+L26+L45+M13+M21+M78+T60+X30+Y09
SERIAL
TAG 267_VSD_013B
VOLTAJE 400Vac
ENTRADA VIN
CORRIENTE 260A
SALIDA IOUT

ANTECEDENTES

En día 06 de Marzo del año 2012 planta CMPC Santa Fe solicita la asistencia de emergencia por una
detención no programa/solicitada del VDF con tag: 267_VSD_013B. El log de fallas del VDF indica perdida
de comunicación con Maestro de red. Se realizan mejoras a la red y se realizan pruebas de operatividad
del equipo, no encontrándose problemas.

SERVICIO REALIZADO 11 JUNIO 2012: Ing. Michael Sourit

Cliente solicita la visita de un técnico de emergencia por aparente nueva detención no

programada/solicitada de VDF con tag: 267_VSD_013B.

Se revisa el histórico de eventos del equipo, encontrando varias indicaciones de detención de motor por
enclavamiento externo (falla externa 2). También existe indicación de caída de voltaje en el circuito
intermedio cuya causa podría deberse a una perdida de energía de alimentación.
No se observa ninguna indicación de fallas internas en el VDF y la inspección mecánica no presenta
detalles.
Se realiza el cambio de la unidad de control del VDF. Se sustituye la CU320 por su repuesto.
Se realizan pruebas con motor energizado con programa antiguo y nueva CU320.

SERVICIO REALIZADO 3 JULIO 2012 : Ing. José Berrios.

Cliente solicita la visita de un técnico de emergencia por aparente nueva detención no

programada/solicitada de VDF con tag: 267_VSD_013B.

Se revisa el histórico de eventos del equipo, encontrando varias indicaciones de detención de motor por
enclavamiento externo (falla externa 2).
Se realizan pruebas de operatividad de componentes. Se desconecta la AOP32 para probar respuesta del
VDF, no encontrándose problemas. Se prueban cables DRIVE-CLIQ, no encontrándose problemas. Se
miden tensiones de control de 24VDC, no encontrándose problemas.
Cliente revisa las conexiones de Puesta a Tierra de Gabinetes, no encontrándose problemas.
 INFORME DE SERVICIO TÉCNICO AUTOMATION & DRIVES.
FS
Revisión 02 15 de Agosto 2012

SERVICIO REALIZADO 20 JULIO 2012 : Ing. Dirk Kuhn.

Cliente solicita la visita de un técnico de emergencia por aparente nueva detención no

programada/solicitada de VDF con tag: 267_VSD_013B.

Se realiza mejora en acometida de cableado profibus en gabinete.

Se realiza upgrade de firmware a FW V2.6.
Se realiza cambio de AOP30 por nuevo repuesto.
Se realizan pruebas con motor energizado con programa migrado a versión de firmware 2.6.

Detalles del diagnóstico ver Anexo 1:

RECOMENDACIONES

1.-Revisar correcta acometida de cables de poder para cumplir con CEM(compatibilidad electromagnética).

2.-Revisar VDFs con firmware 2.3 en busca de registros de fallas con tiempos erróneo.

3.-Revisar correcta acometida de cables Profibus en gabinete.

CONCLUSIONES

1.-Todas las actividades realizadas con anterioridad al servicio del especialista de casa matriz( 20 julio 2012),
permitieron diseñar un plan de acción para solucionar detalles en VDF.

1.-Con los actividades realizadas por especialista de casa matriz, se logra normalizar funcionamiento de los
equipos(VDF) involucrados.

3.-Las acciones realizadas podrían ser aplicadas a otros equipos como acción preventiva.

ANEXO 1

Informe Ejecutivo:
SIEMENS
For internal use only

Service-Report

Distribution Details on author of Service-Report

Vucicevic, Miroslav (I CS LS LD ENG

SYS 4) Name Kuhn, Dirk
Loessel, Michael (I CS LS LD ENG SYS
2) Department I CS EH 3 1
Becker, Christine (I CS EH 3 3) Assignment from 20.07.2012
Assignment to 23.07.2012

Details on Service-Report

Network plan 1547487

Report No. INR_10102523
Composed on 24.07.2012

Details on Order

Org ID A4050523 I CS LS LD ENG SYS 4

Ordering customer
Order No. 2452221003 CMPC, Planta Santa Fe
End customer
Avenida J. Hemmelmann 670
SR No. no service request Location
Nacimiento
Switch No. 267-VSD23-013 Country CL | Chile
Plant Two Sinamics G150 for pump application inside cellulose/paper plant
designation

Investigation of strange behavior of Sinamics G150 VSD system

Activity
Exchange of AOP30 and CF card (upgrade of Firmware 2.3.0->2.6.2)

Mission completed, no further actions necessary

Follow-up activities
Long time observation necessary
no
Suggestions

Sierra Joel Ivan, Sourit Michael (Siemens Chile SCL)

Contact persons
Sourit Nelson (Siemens Chile, Concepcion)
Attendants, further no
employees

Summary

 Visual investigation of Sinamics G150 installation

 Discussion with CMPC end customer about history
 267-23-013A: Software Backup of VFD (Starter project and CF-card)
 267-23-013A: Exchange of AOP30 and CF card hardware
 267-23-013A: Firmware upgrade (2.3 to 2.6), testrun of drive successful
 267-23-013A: Optimization of Profibus cable connection (cable screen connected and cable shortened)
 267-23-013B: Software Backup of VFD (Starter project and CF-card)
 267-23-013B: Exchange of AOP30 and CF card hardware
 267-23-013B: Firmware upgrade (2.3 to 2.6), testrun of drive successful
 267-23-013B: Optimization of Profibus cable connection (cable screen connected and cable shortened)
1 Problem description and service history
1.1 Service request from Siemens Chile
Product: Sinamics G150, 6SL3710-1GE32-6AA0-Z; 380Vac; 294A
FN: N-TD5000753060002
Details:
Sinamics is failing randomly without failure recording in the DCS control system that is connected, the Sinamics G150
freezes in AOP variables are displayed with question marks (??) and the panel keys locked. The VDF stops operating
and displays message "no communication with drive." To de-energize the drive and power up again, the condition
remains ready to go, without saving alarms or faults.
Works:
A. - Review and certification of Profibus: OK.
2. - Review and improvement of grounding: OK.
3. - Change of CU320 with a new, without firmware update.
Additional Information:
1. - There are 2 Sinamics working and connected to DCS system, one in Automatic and the other one in Manual, was
detected that Automatic is working on which it freezes.
2. - Drive failure after 5 years.
Do you know a similar problem in another place?
Do you have some recommendation?
We need a specialist to support on this problem and if possible a Field Service Engineer ready to come to Chile.
This Drives are using in very critical process and customer are requesting all our attention, because he have a lot of
drives Sinamics and if we don't quickly answer they could change for another manufacturer

1.2 Service and problem history

There are two Sinamics G150 variable frequency converters (VFD) for a pump application at
CMPC Santa Fe cellulose site. The commissioning of the units was 2005. Since 2005 both
G150 operates without any problems. Since approx. March 2012 some strange problems
occurred with both units. The system stops without any stop command from DCS (Data
Control System) and the AOP30 panels was frozen and on the operation main screen there
were question marks “?” visible for the variables speed, frequency, current etc. The only
possibility to get the system back in operable situation was to switch the power off/on. It looks
like that the CU320 didn’t react. Also the Profibus values to the DCS were frozen so that the
operator didn’t saw the problem directly. In the DCS it looks like that the drive is running but it
wasn’t. For the CMPC plant these pumps are very important and a stop critical for the plant
process.
Siemens Chile tried to investigate the problems and exchanged a CU320 at system No: 267-
VSD-23-013B (03.07.2012). But this didn’t solve the problem. The strange behaviour occurs
again and the unit stops sporadic without any stop command. Due to the reason that this end
customer is very important for Siemens S.A. Chile they opened an escalation to Siemens
Germany. The assigned Siemens escalation manager is Mr. Miroslav Vucicevic (CS LS LD
ENG SYS 4).

2 Scope of work on site

2.1 End customer informations
After arrival on site at CMPC in Nacimiento/Chile the end customer reported to Mr. Kuhn that
the last action what the end customer did was some earth cable improvements. He installed
in both G150 cabinets some earth cable wires to the CU320 and TM31 modules. Also he
found out that there was an earth cable missing between the main potential equalization rails
and the cable racks. He reinstalled this earth cable during the last month but he didn’t
remember exactly when. Nobody of the end customer’s technicians could give any exactly

Service-Report INR_10102523 / Page 2 of 10

history how often and when and at which unit the problem occurs. The only thing what they
could find out was the beginning of the problems in march 2012 and that at both units the
problems occurs several times. The last problem occur “maybe” 17.07.2012.

2.2 Scope of work, problem presumptions, analyses and improvements

Due to the reason that after the problem occurs there was no communication of the AOP30
to the CU320 and also the Profibus to the DCS freezes it looks like that the CU320 hanged
up and didn’t react. This can be the reason of a corrupted CF storage card. Also it is possible
due to EMI problems (missing proper EMI installation) that the CF cards became corrupted in
some sections which will be accessed randomly and sporadic by the CU320 processor. Due
to the reason that Siemens Chile already exchanged the CU320 hardware without success
the next step is now to exchange the CF cards and also update the firmware to the latest
version 2.6.2.14 for CU320. This action will be done during the service visit of Mr. Kuhn
20.07.2012 & 23.07.2012.

2.2.1 267-VSD-23-013A, Bomba de Transferencia “A” de Licor de Quemado

G150: 6SL3710-1GE32-6AA0-Z (N-TD5000753060002), 132kW, 1000rpm
CF-card (old): 6SL3054-1CD00-1AA0, 12.10.2005, Firmware: V02030000
CF-card (new): Firmware: V02060214
AOP (old): 6SL3055-0AA0-4CA2, Version E, s Q6T9377892, V02.03.07
AOP (new): 6SL3055-0AA00-4CA4, s Q6A7401516, V02.06.38
CU320 (old): 6SL3040-0MA00-0AA1, Version E
No new CU320 installed
TM31 (old) Version E
No new TM31 installed

The following steps are performed:

 267-23-013A: Upload of Drive Software (Backup) (Starter V 4.3.1.0)
 267-23-013A: Convert Starter project from 2.3.0.0 to V2.6.2 (Starter V 4.3.1.0)
 267-23-013A: Spare CF-card with FW4.3 deleted and FW2.6.2.14 installed
 267-23-013A: Exchange of AOP30 and CF-card hardware
 267-23-013A: Firmware upgrade of CU320, AOP, TM31, CIB (2.3.0.0 to 2.6.2.14)
 267-23-013A: Testrun under load conditions of drive successful
 267-23-013A: Optimization of Profibus cable connection (cable screen connected and
cable shortened)

Due to the reason that the spare CF card which was taken by Mr. Kuhn from germany to the
site was not compatible with G150 (S120 CF card) a G150 CF-card with FW 4.3 was taken
from end customers stock. This CF-card was deleted and the G150 FW 2.6.2.14 (taken from
PridaNet) installed.
The Profibus cable inside the cabinet was not installed in a very good condition. It was very
long and also the cable screen of the Profibus cable was not connected directly at the
CU320. The distance between the CU320 Profibus connector and the cable screen
connection should be as short as possible to avoid EMI problems.

Service-Report INR_10102523 / Page 3 of 10

The motor cables screen connections is not made very good. The cables are connected only
with “pig tails” to the earth and not with a clamp around the cable screen for a flat 360°
connection. Pig tails can destroy the EMI effect of the cable screen and can cause EMI
problems!

Picture 2.2.1.a, FW version old, before FW upgrade

Picture 2.2.1.b, FW version new, after FW upgrade

Service-Report INR_10102523 / Page 4 of 10

Picture 2.2.1.d, motor cables without correct flat 360° cable screen connection (only with “pig tails”)

Picture 2.2.1.e, Alarm history of G150 unit no A before FW upgrade

Some alarm entries are very strange. It says that the alarm occurred at 0days and it was
reset at 1230days. This can not be. Maybe with the FW 2.3 there were some problems with
the alarm history?
If the alarm entries are correct there were no strange alarms during the last 1230days. Only a
profbus timeout and an undervoltage of the DC link happened at day 1222 & 1076. But this
will also occur if the end customer switches off the complete cabinet.
The alarm history didn’t show abnormal faults.

2.2.2 267-VSD-23-013B, Bomba de Transferencia “B” de Licor de Quemado

G150: 6SL3710-1GE32-6AA0-Z (N-TD5000753060001), 132kW, 1000rpm
CF-card (old): 6SL3054-1CD00-1AA0, 12.10.2005, Firmware: V02030000
CF-card (new): 6SL3054-1CD00-1AA0, Firmware: V02060214
AOP (old): 6SL3055-0AA0-4CA2, s Q6T9377876, FW V02.03.07
AOP (new): 6SL3055-0AA00-4CA4, s Q6A7401516, FW V02.06.38
CU320: 6SL3040-0MA00-0AA1, Version G
This CU was already exchanged by Siemens Chile 03.07.2012
TM31 (old) Version E

Service-Report INR_10102523 / Page 5 of 10

No new TM31 installed

Picture 2.2.2.a, FW version old, before FW upgrade

Picture 2.2.2.b, FW version new, after FW upgrade

Service-Report INR_10102523 / Page 6 of 10

Picture 2.2.2.c, Profibus cable inside G150 cabinet No. B

The following steps are performed:

 267-23-013A: Upload of Drive Software (Backup) (Starter V 4.3.1.0)
 267-23-013A: Convert Starter project from 2.3.0.0 to V2.6.2 (Starter V 4.3.1.0)
 267-23-013A: Spare CF-card with FW4.3 deleted and FW2.6.2.14 installed
 267-23-013A: Exchange of AOP30 and CF-card hardware
 267-23-013A: Firmware upgrade of CU320, AOP, TM31, CIB (2.3.0.0 to 2.6.2.14)
 267-23-013A: Testrun under load conditions of drive successful

An optimization of the Profibus cable was not permitted by the end customer. He was afraid
to open the Profibus loop. But it is strongly recommended to shorten the Profibus cable and
also connect the cable screen directly at the CU320 and PLC side to eliminate possible EMI
problems.

Picture 2.2.2.d, Alarm history of G150 unit no B

Since 03.07.2012 (new CU320 installed by Siemens Chile) there is no abnormal alarm entry.

Service-Report INR_10102523 / Page 7 of 10

2.3 Next steps and further recommendations
The reason for this problem couldn’t found out exactly during this service visit. Both G150
units operate without problems during the service visit 20.07.2012 – 23.07.2012.
Due to the reason that in the past suddenly both G150 makes problems it is most unlikely
that some parts are damaged inside both cabinets. Most likely something changed in the
installation. Mr. Nelson Sourit (Siemens Chile) told that he made a new commissioning of
some other converters which are also installed close to these G150. Maybe this cause now a
different EMI condition and makes an influence to the G150 cabinets.
Generally the complete Installation is not EMI proof. The motor cables and also the Profibus
cables are not installed in a way to eliminate EMI. Particular around and inside the G150 it is
very important to have a focus on a proper EMI installation. It can be that the Profibus
information gets corrupted due to EMI influence. This can produce exactly the effect that the
unit stops without any message and fault. If one of the “Off-command” bits inside the Profibus
telegram gets 0 for a short time the G150 will switch off without any fault (like a normal stop).
Also a high frequency noise current which flows through the electronic boards can interrupt
the CU320 processor and a restart is necessary. This theory explains also the
communication problems of the AOP30 because if the CU320 processor stucks the serial
communication to the AOP stops also and the “?-marks” at the AOP screen will appear.
Generally it is difficult to find the problem but first the installation should be correct and
improved.

For a better EMI installation the following steps are recommended:

-Shorten the Profibus communication cables (short as possible)
-No long ways and cable loops of Profibus cable inside the cabinet
-Prevent communication cable paths which are parallel or close to power rails or cables
-Connect the cable screens correctly (both ends also at the PLC side and connect the cable
screen close to the end of the cable, only some cm).
Note: At the CU320 there is a special clamp for Profibus underneath the plastic cover
-Connect all moveable metal parts (cabinet doors, cabinet roof, terminal box etc.) together
with a special EMI braided copper ribbon (see picture 2.3.a). Don’t use normal cable wires!

Picture 2.3.a braided copper ribbon

-Connect the motor cable screen correctly. Don’t make “pig tails”. Connect the cable screen
with special clamps 360° around the cable screen to the rail. Also connect the cable screen
at the motor side correctly.
- Make sure that all metal parts are connected with a braided copper ribbon.
Note in picture 2.3.b the G150 No. A.: The cable screens of the Profibus are connected but
there is a gap between the metal of the cabinet box and the earth rail. Such installations will
not give any positive EMI solution because the rail is not connected to the cabinet box! For
HF EMI currents normal cable wires are a big resistance. HF currents will only flow off over a
large metal surface (skin effect). This is also the reason why “pig tails” will not have any
positive effect against EMI problems.

Service-Report INR_10102523 / Page 8 of 10

Picture 2.3.b, metal gap in cabinet G150 No. A
The end customer has to observe the units again during the next few month. And also it is
recommended to write all problems exactly down with the date, time and what exactly
happened.
If the change of the CF-cards/AOP30 will not solve the problem and the problem occurs
again the next steps should be an improvement in the EMI installation by Siemens Chile or
end customer! If it is for sure that the installation is in a good condition it is possible to
analyse further things but generally, faults like that are most of the time the result of an EMI
problem and a bad EMI installation!

3 Spare parts
Material / spares
Materialbezeichnung MLFB Menge / davon Verbleib Rückgabemenge
(s. vorliegender Lieferschein) / Siemens-Materialnr. / amount: beim Kunden / (nicht benötigt) /
material Siemens material number: amount used not used material:
(according to dispatch note): at site:
ausgepackt / verpackt /
unpacked: still
packed:

Sinamics AOP30 6SL3055-0AA00-4CA4 2 2 0 0

CF-card Sinamics S120 6SL3054-0CG00-1AA0 2 2 0 0

Table 3.a Spare parts

The old AOP and CF cards are overhand to the end customer. Due to the reason that the
CF-cards which was taken by Mr. Kuhn to the site were the wrong one this cards couldn’t be
used. But Siemens Chile (Mr. Michael Sourit) asked to get it for another projects. Therefore
these 2 cards (S120 CF cards) are left in Siemens Santiago office.
Due to the reason that the spares were registered at the Chile customs office (after arrival at
the customs) Siemens Chile paid tax for the parts.

4 Tools and Instruments (Sirent)

No tools rented for this service.

Service-Report INR_10102523 / Page 9 of 10

5 Travel / working hours
5.1 Preparation time:
Date Hours Remarks
16/07/12 (5h) Service request, E-Mails, problem analyses, VISA
16/07/12 (4h) Travel preparation, flight, spare parts etc.
18/07/12 (5h) Meeting & discussions Siemens Santiago office
19/07/12 (9h) Travel preparations, Waiting for PET/VISA + spares
Table 5.1.a, preparation time

5.2 Travel- / Workinghours:

Date Time Remarks (Chile -6h)
17/07/12 15:00 – 17:00 (02h) Rental car and spares pick up
17/07/12 17:00 – 24:00 (07h) Travel time Germany – Chile (Santiago)
18/07/12 00:00 – 12:00 (18h) Travel time Germany – Chile (Santiago Siemens)
20/07/12 05:00 – 11:00 (06h) Travel time Chile (Santiago) - CMPC Nacimiento
20/07/12 11:00 – 16:00 (05h) Working time at CMPC Santa Fe Nacimiento
20/07/12 16:00 – 18:00 (02h) Travel time CMPC Nacimiento – Conception (Hotel)
23/07/12 06:30 – 08:30 (02h) Travel time Concepcion (Hotel) - CMPC Nacimiento
23/07/12 08:30 – 16:30 (07h) Working time at CMPC Santa Fe Nacimiento
23/07/12 16:30 – 24:00 (07h) Travel time CMPC Nacimiento – Santiago (Hotel)
25/07/12 10:00 – 19:00 (08h) Travel time Chile Hotel – Rio de Janeiro Hotel
26/07/12 18:00 – 24:00 (06h) Travel time Rio de Janeiro Hotel – Germany
27/07/12 00:00 – 19:00 (14h) Travel time Rio de Janeiro Hotel – Germany
Table 5.2.a, travel-, working hours

5.3 Final work:

Date Hours Remarks
24/07/12 (04h) Meeting, VISA issues at Santiago Siemens office
24/07/12 (05h) Siemens internal IN report
30/07/12 (03h) Siemens travelling expenses statement
Table 5.3.a, finishing work
sgd. D. Kuhn

Service-Report INR_10102523 / Page 10 of 10