Page 1 SINAMICS G120 Frequency converter with the Control Units CU240B-2 CU240E-2 CU240B-2 DP CU240E-2 DP CU240E-2 F CU240E-2 DP-F Operating instructions · 01 2011 SINAMICS Answers for industry.
Page 3 ___________________ Inverter with CU240B-2 and CU240E-2 Change history Control Units ___________________ Introduction ___________________ Description SINAMICS ___________________ Installing SINAMICS G120 ___________________ Inverter with CU240B-2 and Commissioning CU240E-2 Control Units ___________________ Adapt terminal strip Operating Instructions ___________________ Configuring the fieldbus ___________________ Functions...
Page 4 Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.
Page 5: Change History
Change history Important changes with respect to the manual, edition 07/2010 New functions in firmware V4.4 In Chapter Predefined settings for the interfaces of the converter Installing Control Unit (Page 42) • Two- and three-wire control via terminal block Inverter control (Page 149) •...
Page 6 Change history Inverter with CU240B-2 and CU240E-2 Control Units Operating Instructions, 01/2011, FW 4.4, A5E02299792B AB...
Page 7: Table Of Contents
Table of contents Change history ............................3 Introduction.............................. 11 About this manual ........................11 Guide through this manual......................12 Adapting the inverter in line with the application................13 1.3.1 General basics ..........................13 1.3.2 Parameter ............................13 Frequently required parameters....................14 Extended scope for adaptation ....................16 1.5.1 BICO technology: basic principles ....................16 1.5.2...
Page 8 Table of contents 4.2.1 Collecting motor data ........................59 4.2.2 Inverter factory setting......................... 61 4.2.3 Defining requirements for the application ................... 62 Commissioning with factory settings................... 63 4.3.1 Wiring examples for the factory settings ..................64 Commissioning with the BOP-2 ....................66 4.4.1 Display of the BOP-2........................
Page 9 Table of contents 6.2.2.1 Setting the address ........................123 6.2.2.2 Basic settings for communication ....................124 6.2.2.3 Structure of a USS telegram ......................124 6.2.2.4 User data range of the USS telegram..................126 6.2.2.5 Data structure of the USS parameter channel................127 6.2.2.6 USS read request ........................132 6.2.2.7 USS write job ..........................133 6.2.2.8...
Page 10 Table of contents 7.7.4 Overcurrent protection ......................178 7.7.5 Limiting the maximum DC link voltage..................179 Status messages........................181 7.8.1 Overview, evaluating the inverter state..................181 7.8.2 System runtime ......................... 181 Application-specific functions ....................182 7.9.1 Unit changeover ........................182 7.9.1.1 Changing over the motor standard ...................
Page 11 Table of contents Replacing the Control Unit ......................242 Replacing the Power Module .....................244 Alarms, faults and system messages..................... 245 Operating states indicated on LEDs ..................246 Alarms ............................248 Faults ............................251 List of alarms and faults ......................256 Technical data ............................263 10.1 Technical data, CU240B-2 Control Unit..................263 10.2 Technical data, CU240E-2 Control Unit..................264...
Page 12 Table of contents Inverter with CU240B-2 and CU240E-2 Control Units Operating Instructions, 01/2011, FW 4.4, A5E02299792B AB...
Page 13: Introduction
Introduction About this manual Who requires the operating instructions and what for? These operating instructions primarily address fitters, commissioning engineers and machine operators. The operating instructions describe the devices and device components and enable the target groups being addressed to install, connect-up, parameterize, and commission the inverters safely and in the correct manner.
Page 14: Guide Through This Manual
Introduction 1.2 Guide through this manual Guide through this manual In this manual, you will find background information on your inverter, as well as a full description of the commissioning procedure: ① Should you be unfamiliar with assigning parameters to the inverter, background information can be found here: •...
Page 15: Adapting The Inverter In Line With The Application
Introduction 1.3 Adapting the inverter in line with the application Adapting the inverter in line with the application 1.3.1 General basics Inverters are used to improve and extend the starting and speed response of motors. Adapting the inverter to the drive task The inverter must match the motor that it is controlling and the drive task to be able to optimally operate and protect the motor.
Page 16: Frequently Required Parameters
Introduction 1.4 Frequently required parameters Frequently required parameters Parameters that in many cases help Table 1- 1 How to switch to commissioning mode or restore the factory setting Parameter Description p0010 Commissioning parameters 0: Ready (factory setting) 1: Carry out basic commissioning 3: Perform motor commissioning 5: Technological applications and units 15: Define number of data records...
Page 17 Introduction 1.4 Frequently required parameters Table 1- 5 This is how you set the closed-loop type Parameter Description p1300 0: V/f control with linear characteristic 1: V/f control with linear characteristic and FCC 2: V/f control with parabolic characteristic 3: V/f control with parameterizable characteristic 4: V/f control with linear characteristic and ECO 5: V/f control for drives requiring a precise frequency (textile area) 6: V/f control for drive requiring a precise frequency and FCC...
Page 18: Extended Scope For Adaptation
Introduction 1.5 Extended scope for adaptation Extended scope for adaptation 1.5.1 BICO technology: basic principles Principle of operation of BICO technology Open/closed-loop control functions, communication functions as well as diagnostic and operator functions are implemented in the inverter. Every function comprises one or several BICO blocks that are interconnected with one another.
Page 19 Introduction 1.5 Extended scope for adaptation Definition of BICO technology BICO technology represents a type of parameterization that can be used to disconnect all internal signal interconnections between BICO blocks or establish new connections. This is realized using Binectors and Connectors. Hence the name BICO technology. ( Binector Connector Technology) BICO parameters You can use the BICO parameters to define the sources of the input signals of a block.
Page 20: Bico Technology: Example
Introduction 1.5 Extended scope for adaptation What sources of information do you need to help you set parameters using BICO technology? ● This manual is sufficient for simple signal interconnections, e.g. assigning a different significance to the to digital inputs. ●...
Page 21 Introduction 1.5 Extended scope for adaptation Parameter Description P20032 = 5 The AND logic block is enabled by assigning to runtime group 5 (time slice of 128 ms) P20033 = 440 Run sequence of the AND logic block within runtime group 5 (processing after the time block) P20159 = 5000.00 Setting the delay time [ms] of the time module: 5 seconds...
Page 22 Introduction 1.5 Extended scope for adaptation Inverter with CU240B-2 and CU240E-2 Control Units Operating Instructions, 01/2011, FW 4.4, A5E02299792B AB...
Page 23: Description
The following overview describes the converter components, which you require for your application. Main components of the converter Each SINAMICS G120 converter comprises a Control Unit and Power Module. The Control Unit controls and monitors the Power •...
Page 24 Description 2.1 Modularity of the converter system Tools to commission the inverter Figure 2-1 Tools to commission the inverter Table 2- 1 Components and tools for commissioning and data backup Component or tool Order number Operator panel for BOP-2 - for snapping onto the frequency converter 6SL3255-0AA00-4CA1 commissioning, •...
Page 25 Description 2.1 Modularity of the converter system Component or tool Order number Drive ES Basic 6SW1700-5JA00-4AA0 To commission the frequency converter via the PROFIBUS interface. Includes STARTER Memory card to save and transfer the MMC card 6SL3254-0AM00-0AA0 frequency converter settings SD card 6ES7954-8LB00-0AA0 Components, which you require depending on your particular application...
Page 26: Overview Of Control Units
Description 2.2 Overview of Control Units Overview of Control Units The Control Units differ in relation to the integrated safety functions, the type of fieldbuses, and the number of inputs and outputs. CU240B-2 CU240B-2 DP CU240E-2 CU240E-2 F CU240E-2 DP CU240E-2 DP-F Fieldbus USS or PROFIBUS...
Page 27: Reactors And Filters
Description 2.4 Reactors and filters Frame size FSGX PM240, 3AC 400V - power units with integrated braking chopper Power range (LO) in kW 0.37 … 1.5 2.2 … 4 7.5 … 15 18.5 … 30 37 … 45 55 … 132 160 …...
Page 28 Description 2.4 Reactors and filters Inverter with CU240B-2 and CU240E-2 Control Units Operating Instructions, 01/2011, FW 4.4, A5E02299792B AB...
Page 29: Installing
③ Installing Control Unit (Page 42) You will find details on the installation in the Internet: Hardware Installation Manual (http://support.automation.siemens.com/WW/view/en/30563173/133300). You can start to commission the converter once installation has been completed. Inverter with CU240B-2 and CU240E-2 Control Units Operating Instructions, 01/2011, FW 4.4, A5E02299792B AB...
Page 30: Installing Reactors And Filters
Installing 3.2 Installing reactors and filters Installing reactors and filters Fitting inverter system components in space-saving manner Many inverter system components are designed as base components, that is, the component is mounted on the baseplate and the inverter mounted above it to save space. Up to two base components can be mounted above one another.
Page 31 Installing 3.2 Installing reactors and filters PM250 Line Line supply Line filter supply Power Line filter Output reactor or Power Modules sine-wave filter Module to the motor Basic layout of a PM250 Power Module with class Basic layout of a PM250 Power Module with a B line filter as a base component class B line filter as a base component and output reactor or sine-wave filter...
Page 32: Installing The Power Module
Installing 3.3 Installing the Power Module Installing the Power Module 3.3.1 Installing Power Modules Installing Power Modules with degree of protection IP20 ● Install the Power Module vertically on a mounting plate in a control cabinet. The smaller frame sizes of the converter (FSA and FSB) can also be mounted on DIN rails using an adapter.
Page 33 Installing 3.3 Installing the Power Module Dimensions and drilling patterns for the PM240 Power Modules Figure 3-1 PM240 drilling pattern Table 3- 1 PM240, IP20 dimensions Frame size Dimensions (mm) Clearances (mm) Height Width Depth bottom lateral 36.5 FSD without filter FSD with filter, Class A FSE without filter FSE with filter, Class A...
Page 34 Installing 3.3 Installing the Power Module Dimensions and drilling patterns for the PM250 Power Modules Figure 3-2 PM250 drilling pattern Table 3- 2 PM250, IP20 dimensions Frame size Dimensions (mm) Clearances (mm) Height Width Depth bottom lateral FSD without filter FSD with filter, Class A FSE without filter FSE with filter, Class A...
Page 35 Installing 3.3 Installing the Power Module Dimensions and drilling patterns for the PM260 Power Modules Figure 3-3 PM260 drilling pattern Table 3- 3 PM260, IP20 dimensions Frame size Dimensions (mm) Clearances (mm) Height Width Depth bottom lateral FSD without / with filter FSF without / with filter Fixing: FSD: M6 screws, 6 Nm/53 lbf.in...
Page 36: Connection Overview For Power Module
Installing 3.3 Installing the Power Module 3.3.3 Connection overview for Power Module Figure 3-4 Connections for PM240 and PM250 Power Modules In addition to the Power Modules shown above, you can also combine Control Units with a PM260 Power Module. The PM260 connection corresponds to that of a PM250, however, a sine-wave filter is integrated in the PM260.
Page 37: Connecting The Line Supply And Motor
Installing 3.3 Installing the Power Module 3.3.4 Connecting the line supply and motor Preconditions Once the inverter has been properly installed, the line and motor connections can now be established. The following warning information must be observed here. WARNING Line and motor connections The inverter must be grounded on the line supply and motor side.
Page 38 Ensure that the appropriate circuit breakers / fuses for the inverter's rated current are fitted between the line and inverter (see catalog D11.1). Connecting the motor: Star connection and delta connection With SIEMENS motors, you will see a diagram of both connection methods on the inside of the cover of the terminal box: •...
Page 39 Installing 3.3 Installing the Power Module Connecting the inverter Motor connection ● If available, open the terminal covers of the inverter. ● Connect the motor to terminals U2, V2 and W2. Carefully observe the regulations for EMC-compliant wiring: EMC-compliant connection (Page 38) ●...
Page 40: Emc-Compliant Connection
Installing 3.3 Installing the Power Module 3.3.5 EMC-compliant connection The inverters are designed for operation in industrial environments where high values of electromagnetic interference are expected. Safe, reliable and disturbance-free operation is only guaranteed if the devices are professionally installed. Inverters with degree of protection IP20 must be installed and operated in an enclosed control cabinet.
Page 41 Installing 3.3 Installing the Power Module ● All cables should be kept as short as possible ● Signal and data cables and the associated equipotential bonding cables must always be routed in parallel with the smallest possible clearance between them ●...
Page 42 Installing 3.3 Installing the Power Module EMC-compliant installation of Power Modules in degree of protection IP20 The EMC-compliant installation of power modules is shown in the following diagram using two examples. Example for a connection without a shield plate via an external filter Example for a connection with a shield plate, directly to the line supply ①...
Page 43 Installing 3.3 Installing the Power Module Shielding with shield plate: Shield connection kits are available for all Power Module frame sizes (you will find more information in Catalog D11.1). The cable shields must be connected to the shield plate through the greatest possible surface area using shield clamps.
Page 44: Installing Control Unit
Installing 3.4 Installing Control Unit Installing Control Unit 3.4.1 Snapping the Control Unit onto the Power Module Installing the Control Unit on an IP20 Power Module Plugging on the CU Removing the CU To gain access to the terminal strips, open the top and bottom front doors to the right. The terminal strips use spring-loaded terminals.
Page 45: Interfaces, Connectors, Switches, Terminal Blocks And Leds Of The Cu
Installing 3.4 Installing Control Unit 3.4.2 Interfaces, connectors, switches, terminal blocks and LEDs of the CU 31 31 +24V IN 32 32 GND IN 34 34 DI COM2 10 10 AI 1+ 11 11 AI 1- 26 26 AO 1+ 27 27 +10V OUT AI 0+...
Page 46: Terminal Strips On Cu240B-2 Control Units
Installing 3.4 Installing Control Unit 3.4.3 Terminal strips on CU240B-2 Control Units If you require more than four digital inputs, use terminals 3 and 4 (AI 0) as additional digital input DI 11. ① Wiring when using the internal power supplies. DI = high, if the switch is closed.
Page 47: Terminal Strips On Cu240E-2 Control Units
Installing 3.4 Installing Control Unit 3.4.4 Terminal strips on CU240E-2 Control Units The terminal strip wiring is not completely shown, only as example for each type of input and output. If you require more than six digital inputs, use terminals 3 and 4 (AI 0) or terminals 10 and 11 (AI 1) as additional digital inputs DI 11 or DI 12.
Page 48: Select Interface Assignments
Installing 3.4 Installing Control Unit For a fail-safe digital input, use two "standard" digital inputs. Terminals Designation Fail-safe digital input with Basic Safety F-DI0 If you wish to use several fail-safe digital inputs of the converter, this is described in the Safety Integrated Function Manual.
Page 49: Inverter With Cu240B-2 Control Units
Installing 3.4 Installing Control Unit 3.4.5.1 Inverter with CU240B-2 Control Units The converter with CU240B-2 and CU240B-2 DP Control Units offers the following default settings for its interfaces: Automatic/local - Changeover between fieldbus and jog mode Factory setting for converter with CU240B-2 DP Control Unit. Refer to the following Section on how you can obtain the GSD file: Configuring communication to the control (Page 102).
Page 50 Installing 3.4 Installing Control Unit Communication with higher-level control via USS Inverter with CU240B-2 and CU240E-2 Control Units Operating Instructions, 01/2011, FW 4.4, A5E02299792B AB...
Page 51: Inverter With Cu240E-2 Control Units
Installing 3.4 Installing Control Unit 3.4.5.2 Inverter with CU240E-2 Control Units The converter with CU240E-2, CU240E-2 F, CU240E-2 DP, and CU240E-2 DP F Control Units offers the following default settings for its interfaces: Fixed speeds You must enable the safety function, see Section: Safe Torque Off (STO) safety function (Page 220).
Page 52 Installing 3.4 Installing Control Unit You must enable the safety function, see Section: Safe Torque Off (STO) safety function (Page 220). Refer to the following Section on how you can obtain the GSD file: Configuring communication to the control (Page 102). Two safety functions This default setting can only be used for CU240E-2 F and CU240E-2 DP F Control Units.
Page 53 Installing 3.4 Installing Control Unit Automatic/local - Changeover between fieldbus and jog mode Factory setting for converters with PROFIBUS interface: Refer to the following Section on how you can obtain the GSD file: Configuring communication to the control (Page 102). Motorized potentiometer You must enable the safety function, see Section: Safe Torque Off (STO) safety function (Page 220).
Page 54 Installing 3.4 Installing Control Unit Applications with analog setpoint You must enable the safety function, see Section: Safe Torque Off (STO) safety function (Page 220). Process industry Refer to the following Section on how you can obtain the GSD file: Configuring communication to the control (Page 102).
Page 55 Installing 3.4 Installing Control Unit Two- or three-wire control Macro 12 is the factory setting for converters with the Control Units CU240E-2 and CU240E- 2 F. Communication with a higher-level control via USS Inverter with CU240B-2 and CU240E-2 Control Units Operating Instructions, 01/2011, FW 4.4, A5E02299792B AB...
Page 56: Wiring Terminal Strips
Installing 3.4 Installing Control Unit 3.4.6 Wiring terminal strips Solid or flexible cables are permitted as signal lines. Wire end ferrules must not be used for the spring-loaded terminals. The permissible cable cross-section ranges between 0.5 mm² (21 AWG) and 1.5 mm² (16 AWG).
Page 57: Commissioning
Commissioning You must commission the inverter after installation has been completed. To do this, using Section "Collecting motor data (Page 59)" you must clarify whether the motor can be operated with the inverter factory settings or an additional adaptation of the inverter is required.
Page 58 Commissioning NOTICE For the basic commissioning, you determine the function of the interfaces for your inverter via predefined settings (p0015). If you subsequently select a different predefined setting for the function of the interfaces, then all BICO interconnections that you changed will be lost. Inverter with CU240B-2 and CU240E-2 Control Units Operating Instructions, 01/2011, FW 4.4, A5E02299792B AB...
Page 59: Restoring The Factory Setting
Commissioning 4.1 Restoring the factory setting Restoring the factory setting There are cases where something goes wrong when commissioning a drive system e.g.: ● The line voltage was interrupted during commissioning and you were not able to complete commissioning. ● You got confused when setting the parameters and you can no longer understand the individual settings that you made.
Page 60 Commissioning 4.1 Restoring the factory setting Restoring the factory setting with STARTER or BOP-2 This function resets the settings in the inverter to the factory settings. Note The communication settings and the settings of the motor standard (IEC/NEMA) are retained even after restoring the factory setting.
Page 61: Preparing For Commissioning
TICI F 1325 IP 55 IM B3 commissioning tool and a 230/400 V Δ/Υ 50 Hz 60 Hz 460 V SIEMENS motor, you 5.5kW 19.7/11.A 6.5kW 10.9 A P0307 only have to specify the motor Order No. In all Cos ϕ 0.81 1455/min Cos ϕ...
Page 62 Commissioning 4.2 Preparing for commissioning NOTICE Information about installation The rating plate data that you enter must correspond to the connection type of the motor (star connection [Y]/delta connection [Δ]), i.e. for a delta motor connection, the delta rating plate data must be entered. In which region of the world is the motor used? - Motor standard [P0100] ●...
Page 63: Inverter Factory Setting
Commissioning 4.2 Preparing for commissioning 4.2.2 Inverter factory setting Factory settings of additional important parameters Parameter Factory setting Meaning of the factory Name of the parameter and comments setting p0010 Ready to be entered Drive, commissioning parameter filter p0100 Europe [50 Hz] IEC/NEMA motor standard IEC, Europe •...
Page 64: Defining Requirements For The Application
Commissioning 4.2 Preparing for commissioning 4.2.3 Defining requirements for the application What type of control is needed for the application? [P1300] A distinction is made between V/f open-loop control and vector closed-loop control. ● The V/f open-loop control is the simplest operating mode for an inverter. For example, it is used for applications involving pumps, fans or motors with belt drives.
Page 65: Commissioning With Factory Settings
Commissioning 4.3 Commissioning with factory settings Commissioning with factory settings Prerequisites for using the factory settings In simple applications, commissioning can be carried out just using the factory settings. Check which factory settings can be used and which functions need to be changed. During this check you will probably find that the factory settings only require slight adjustment: 1.
Page 66: Wiring Examples For The Factory Settings
Commissioning 4.3 Commissioning with factory settings 4.3.1 Wiring examples for the factory settings To ensure that the factory setting can be used, you must wire the terminal strip of your inverter as shown in the following examples. Pre-assignment of the terminal strip for the CU240B-2 Figure 4-2 Wiring example to use the factory settings Pre-assignment of the terminal strip for the CU240B-2 DP...
Page 67 Commissioning 4.3 Commissioning with factory settings Pre-assignment of the terminal strip for the CU240E-2 and CU240E-2 F Figure 4-4 Wiring example to use the factory settings Pre-assignment of the terminal strip for the CU240E-2 DP and CU240E-2 DP-F Figure 4-5 Wiring example to use the factory settings Inverter with CU240B-2 and CU240E-2 Control Units Operating Instructions, 01/2011, FW 4.4, A5E02299792B AB...
Page 68: Commissioning With The Bop-2
Commissioning 4.4 Commissioning with the BOP-2 Commissioning with the BOP-2 The "Basic Operator Panel-2" (BOP-2) is an operation and display instrument of the converter. For commissioning, it is directly plugged onto the converter Control Unit. Plugging on the BOP- Removing the BOP-2 4.4.1 Display of the BOP-2 Figure 4-6...
Page 69: Menu Structure
Commissioning 4.4 Commissioning with the BOP-2 4.4.2 Menu structure OK ESC OK ESC OK ESC OK ESC OK ESC OK ESC OK ESC Changing parameter values: ① Parameter number freely selectable ② Basic commissioning Inverter with CU240B-2 and CU240E-2 Control Units Operating Instructions, 01/2011, FW 4.4, A5E02299792B AB...
Page 70: Freely Selecting And Changing Parameters
Commissioning 4.4 Commissioning with the BOP-2 4.4.3 Freely selecting and changing parameters Use BOP-2 to change your inverter settings, by selecting the appropriate parameter number and changing the parameter value. Parameter values can be changed in the "PARAMS" menu and the "SETUP" menu. >2 sec >2 sec Select the parameter number...
Page 71: Basic Commissioning
Commissioning 4.4 Commissioning with the BOP-2 4.4.4 Basic commissioning Menu Remark Set all of the parameters of the menu "SETUP". In the BOP-2, select the menu "SETUP". Select reset if you wish to reset all parameters to the factory setting before the basic commissioning.
Page 72: Additional Settings
Commissioning 4.4 Commissioning with the BOP-2 Identifying motor data If you select the MOT ID (p1900) during basic commissioning, alarm A07991 will be issued once basic commissioning has been completed. To enable the converter to identify the data for the connected motor, you must switch on the motor (e.g. via the BOP-2). The converter switches off the motor after the motor data identification has been completed.
Page 73: Commissioning With Starter
USB cable and on which STARTER V4.2 or higher has been installed. You can find updates for STARTER in the Internet under: Update download path for STARTER (http://support.automation.siemens.com/WW/view/en/10804985/133100) Commissioning steps Commissioning with STARTER is subdivided into the following steps: 1.
Page 74: Adapting The Usb Interface
Commissioning 4.5 Commissioning with STARTER 4.5.1 Adapting the USB interface Switch on the converter supply voltage and start the STARTER commissioning software. If you are using STARTER for the first time, you must check whether the USB interface is correctly set. To do this, click in STARTER on (accessible participants).
Page 75: Generating A Starter Project
Commissioning 4.5 Commissioning with STARTER 4.5.2 Generating a STARTER project Creating a STARTER project using project wizards • Using "Project / New with wizard" create a new project. • To start the wizard, click on "Search online for drive units ...". •...
Page 76 • In the next step, enter the motor data according to the rating plate of your motor. The motor data for SIEMENS standard motors can be called in STARTER based on their order number. • In the next step, we recommend the setting "Identify motor data at...
Page 77 Commissioning 4.5 Commissioning with STARTER • In the next step, we recommend the setting "Calculate motor data only". ① In the next step, set the • check mark for "RAM to ROM (save data in drive)" in order to save your data in the converter so that it is not lost when the power fails.
Page 78 Commissioning 4.5 Commissioning with STARTER Switch on motor for motor data identification CAUTION Motor data identification for dangerous loads Secure dangerous plant and system parts before starting the motor data identification, e.g. by fencing off the dangerous location or lowering a suspended load to the floor. ①...
Page 79: Making Additional Settings
Commissioning 4.5 Commissioning with STARTER 4.5.4 Making additional settings After the basic commissioning, you can adapt the inverter to your application as described in the Commissioning (Page 55). STARTER offers two options: 1. Change the settings using the appropriate screen forms - our recommendation. ①...
Page 80: Trace Function For Optimizing The Drive
Commissioning 4.5 Commissioning with STARTER 4.5.5 Trace function for optimizing the drive Description The trace function is used for converter diagnostics and helps to optimize the behavior of the drive. Start the function in the navigation bar using "... Control_Unit/Commissioning/Device trace".
Page 81 Commissioning 4.5 Commissioning with STARTER Trigger You can create your own start condition (trigger) for the trace. With the factory setting (default setting) the trace starts as soon as you press the button (Start Trace). Using the button , you can define another trigger to start the measurement. Using pretrigger, set the time for the recording before the trigger is set.
Page 82 Commissioning 4.5 Commissioning with STARTER Display options In this area, you can set how the measurement results are displayed. ● Repeat measurement: This means that you place the measurements, which you wish to perform at different times, one above one another ●...
Page 83: Data Backup And Standard Commissioning
Commissioning 4.6 Data backup and standard commissioning Data backup and standard commissioning External data backup After commissioning, your settings are saved in the inverter so that they are protected against power failure. Further, we recommend that you externally save the parameter settings so that in the case of a defect, you can simply replace the Power Module or Control Unit (see also Replacing the Control Unit (Page 242)).
Page 84: Backing Up And Transferring Settings Using A Memory Card
Commissioning 4.6 Data backup and standard commissioning 4.6.1 Backing up and transferring settings using a memory card What memory cards do we recommend? The memory card is a removable flash memory, that offers you the following options ● Automatically or manually write parameter settings from the card into the inverter (automatic or manual download) ●...
Page 85 Commissioning 4.6 Data backup and standard commissioning Automatic upload The inverter power supply has been switched off. 1. Insert an empty memory card into the inverter. 2. Then switch-on the inverter power supply again. After it has been switched-on, the inverter copies the modified parameters to the memory card Transfer the setting to the empty memory card...
Page 86: Transferring The Setting From The Memory Card
Commissioning 4.6 Data backup and standard commissioning 4.6.1.2 Transferring the setting from the memory card If you wish to transfer the parameter setting from a memory card into the inverter (download), you have two options: Automatic download The inverter power supply has been switched off. 1.
Page 87: Safely Remove The Memory Card
Commissioning 4.6 Data backup and standard commissioning Inverter with enabled safety functions You must confirm the settings of the safety functions. Table 4- 3 Procedure STARTER BOP-2 Set the following parameters: 1. Go online with STARTER 2. Call the safety functions screen form p9761 = …...
Page 88: Backing Up And Transferring Settings Using Starter
Commissioning 4.6 Data backup and standard commissioning 4.6.2 Backing up and transferring settings using STARTER Backing up the inverter settings on PC/PG (upload) 1. Go online with STARTER: 2. Click on the button "Load project to PG": 3. To save data in the PG (computer), click on Transferring settings from the PC/PG into the inverter (download) 1.
Page 89: Saving Settings And Transferring Them Using An Operator Panel
Commissioning 4.6 Data backup and standard commissioning 4.6.3 Saving settings and transferring them using an operator panel You start the download or upload in the "TOOLS" menu. Download for inverters with enabled safety functions You must confirm the settings of the safety functions. Table 4- 4 Procedure Set the following parameters...
Page 90 Commissioning 4.6 Data backup and standard commissioning Inverter with CU240B-2 and CU240E-2 Control Units Operating Instructions, 01/2011, FW 4.4, A5E02299792B AB...
Page 91: Adapt Terminal Strip
Adapt terminal strip Before you adapt the inputs and outputs of the inverter, you should have completed the basic commissioning, see Chapter Commissioning (Page 55) . In the basic commissioning, select an assignment of the inverter interfaces from several predefined configurations, see Section Select interface assignments (Page 46). If none of the predefined configurations completely matches your application, then you must adapt the assignment of the individual inputs and outputs.
Page 92: Digital Inputs
Adapt terminal strip 5.1 Digital inputs Digital inputs Digital input terminals Changing the function of the digital input Interconnect the status parameter of the digital input with a BI: pxxxx binector input of your choice. r0722.0 Binector inputs are marked with "BI" in the parameter list of the List r0722.1 Manual.
Page 93 Adapt terminal strip 5.1 Digital inputs Advanced settings You can debounce the digital input signal using parameter p0724. For more information, see the parameter list and the function block diagrams 2220 ff of the List Manual. Analog inputs as digital inputs When required, you can use analog inputs as additional digital inputs.
Page 94: Fail-Safe Digital Input
Adapt terminal strip 5.2 Fail-safe digital input Fail-safe digital input This manual describes the STO safety function with control via a fail-safe input. Additional safety functions, additional fail-safe digital inputs of the inverter and the control of the safety functions via PROFIsafe are described in the Safety Integrated Function Manual. Defining a fail-safe digital input If you use the STO safety function, then you must configure the terminal strip during the basic commissioning for a fail-safe digital input, e.g.
Page 95: Digital Outputs
Adapt terminal strip 5.3 Digital outputs Digital outputs Digital output terminals Changing the function of the digital output Interconnect the digital output with a binector output of your p0730 choice. BO: ryyxx.n Binector outputs are marked with "BO" in the parameter list of the List Manual.
Page 96: Analog Inputs
Adapt terminal strip 5.4 Analog inputs Analog inputs Analog input terminals Changing the function of the analog input 1. Define the analog input type using p0756[0] parameter p0756 and the switch on the CI: pyyyy inverter (e.g. voltage input -10 V … 10 V or r0755[0] current input 4 mA …...
Page 97 Adapt terminal strip 5.4 Analog inputs Figure 5-2 Examples for scaling characteristics Table 5- 5 Parameters for the scaling characteristic and wire break monitoring Parameter Description p0757 x-coordinate of 1st characteristic point [V or mA] p0758 y coordinate of the 1st characteristic point [% of p200x] p200x are the parameters of the reference variables, e.g.
Page 98 Adapt terminal strip 5.4 Analog inputs Parameter Description p0756[0] = 3 Analog input type Set DIP switch for AI 0 to current input Define analog input 0 as current input ("I"): with wire break monitoring. After changing p0756 to the value 3, the inverter sets the scaling characteristic parameters to the following values: p0757[0] = 4,0;...
Page 99: Analog Outputs
Adapt terminal strip 5.5 Analog outputs Analog outputs Analog output terminals Changing the function of the analog output 1. Define the analog output type using parameter p0776[0] p0776 (e.g. voltage output -10 V … 10 V or p0771[0] current output 4 mA … 20 mA). CO: rxxyy 2.
Page 100 Adapt terminal strip 5.5 Analog outputs Parameters p0777 … p0780 are assigned to an analog output via their index, e.g. parameters p0777[0] … p0770[0] belong to analog output 0. Table 5- 8 Parameters for the scaling characteristic Parameter Description p0777 X coordinate of the 1st characteristic point [% of P200x] P200x are the parameters of the reference variables, e.g.
Page 101 Adapt terminal strip 5.5 Analog outputs Defining the analog output function You define the analog output function by interconnecting parameter p0771 with a connector output of your choice. Parameter p0771 is assigned to the particular analog input via its index, e.g. parameter p0771[0] is assigned to analog output 0. Table 5- 9 Connector outputs (CO) of the inverter (selection) Significance...
Page 102 Adapt terminal strip 5.5 Analog outputs Inverter with CU240B-2 and CU240E-2 Control Units Operating Instructions, 01/2011, FW 4.4, A5E02299792B AB...
Page 103: Configuring The Fieldbus
Configuring the fieldbus Before you connect the inverter to the field bus, you should have completed the basic commissioning, see Chapter Commissioning (Page 55) Fieldbus interfaces of the Control Units The Control Units are available in different versions for communication with higher-level controls with the subsequently listed fieldbus interfaces: Fieldbus Profile...
Page 104: Communication Via Profibus
We recommend connectors with the following order numbers for connecting the PROFIBUS cable: ● 6GK1500-0FC00 ● 6GK1500-0EA02 Both connectors are suitable for all SINAMICS G120 inverters with respect to the angle of the outgoing cable. Note Communication with the controller, even when the supply voltage on the Power Module is...
Page 105: Setting The Address
Configuring the fieldbus 6.1 Communication via PROFIBUS 6.1.2 Setting the address You can set the inverter's PROFIBUS address using either DIP switches on the Control Unit or parameter p0918. Valid PROFIBUS addresses: 1 … 125 Invalid PROFIBUS addresses: 0, 126, 127 If you have specified a valid address using DIP switches, this address will always be the one that takes effect and p0918 cannot be changed.
Page 106: Basic Settings For Communication
Standard telegram 20, PZD-2/6 350: SIEMENS telegram 350, PZD-4/4 SIEMENS telegram 352, PZD-6/6 353: SIEMENS telegram 353, PZD-2/2, PKW-4/4 354: SIEMENS telegram 354, PZD-6/6, PKW-4/4 999: Free telegram configuring with BICO Using parameter p0922, you automatically interconnect the corresponding signals of the converter to the telegram.
Page 107: Cyclic Communication
Configuring the fieldbus 6.1 Communication via PROFIBUS 6.1.4 Cyclic communication The PROFIdrive profile defines different telegram types. Telegrams contain the data for cyclic communication with a defined meaning and sequence. The inverter has the telegram types listed in the table below. Table 6- 3 Inverter telegram types Telegram type (p0922)
Page 108: Control And Status Word 1
Configuring the fieldbus 6.1 Communication via PROFIBUS Table 6- 5 Telegram status in the inverter Process data Control ⇒ inverter Inverter ⇒ control item Status of the received Bits 0…15 in the Defining the word to be Status of the sent word word received word sent...
Page 109 Configuring the fieldbus 6.1 Communication via PROFIBUS Control word 1 (STW1) Control word 1 (bits 0 … 10 in accordance with PROFIdrive profile and VIK/NAMUR, bits 11 … 15 specific to inverter). Table 6- 6 Control word 1 and interconnection with parameters in the inverter Bit Value Significance Comments...
Page 110 6.1 Communication via PROFIBUS Status word 1 (ZSW1) Status word 1 (bits 0 to 10 in accordance with PROFIdrive profile and VIK/NAMUR, bits 11 to 15 for SINAMICS G120 only). Table 6- 7 Status word 1 and interconnection with parameters in the inverter...
Page 111: Control And Status Word 3
Configuring the fieldbus 6.1 Communication via PROFIBUS 6.1.4.2 Control and status word 3 The control and status words fulfill the specifications of PROFIdrive profile version 4.1 for "speed control" mode. Control word 3 (STW3) Control word 3 has the following default assignment. You can change the assignment with BICO technology.
Page 112 Configuring the fieldbus 6.1 Communication via PROFIBUS Status word 3 (ZSW3) Status word 3 has the following standard assignment. You can change the assignment with BICO technology. Table 6- 9 Status word 3 and interconnection with parameters in the converter Bit Value Meaning Description...
Page 113: Data Structure Of The Parameter Channel
Configuring the fieldbus 6.1 Communication via PROFIBUS 6.1.4.3 Data structure of the parameter channel Parameter channel You can write and read parameter values via the parameter channel, e.g. in order to monitor process data. The parameter channel always comprises four words. Figure 6-1 Structure of the parameter channel Parameter identifier (PKE), 1st word...
Page 114 Configuring the fieldbus 6.1 Communication via PROFIBUS The meaning of the request identifier for request telegrams (control → inverter) is explained in the following table. Table 6- 10 Request identifier (control → inverter) Request Description Response identifier identifier positive negative No request 7 / 8 Request parameter value...
Page 115 Configuring the fieldbus 6.1 Communication via PROFIBUS If the response identifier is 7 (request cannot be processed), one of the error numbers listed in the following table will be saved in parameter value 2 (PWE2). Table 6- 12 Error numbers for the response "Request cannot be processed" Description Comments Impermissible parameter number (PNU)
Page 116 Configuring the fieldbus 6.1 Communication via PROFIBUS Parameter index (IND) Figure 6-3 Structure of the parameter index (IND) ● For indexed parameters, select the index of the parameter by transferring the appropriate value between 0 and 254 to the subindex within a job. ●...
Page 117 Configuring the fieldbus 6.1 Communication via PROFIBUS Example of read request for parameter P7841[2] To obtain the value of the indexed parameter P7841, you must fill the telegram of the parameter channel with the following data: ● Request parameter value (field): Bits 15 … 12 in the PKE word: Request identifier = 6 ●...
Page 118: Slave-To-Slave Communication
Configuring the fieldbus 6.1 Communication via PROFIBUS 6.1.4.4 Slave-to-slave communication With "Slave-slave communication" ( also called "Data Exchange Broadcast") it is possible to quickly exchange data between inverters (slaves) without the master being directly involved, for instance to use the actual value of one inverter as setpoint for other inverters. For slave-to-slave communication, in the control system you must define which inverter acts as publisher (sender) or subscriber (receiver) - and which data or data areas (access points) you wish to use for slave-to-slave communication.
Page 119: Acyclic Communication
Configuring the fieldbus 6.1 Communication via PROFIBUS 6.1.5 Acyclic communication As from performance level DP-V1, PROFIBUS communications offer acyclic data communications apart from cyclic communications. You can parameterize and troubleshoot (diagnostics) the inverter via acyclic data transfer. Acyclic data is transferred in parallel with cyclic data transfer but with a lower priority.
Page 120 Configuring the fieldbus 6.1 Communication via PROFIBUS Table 6- 16 Converter response to a read request Data block Byte n Bytes n + 1 Header Reference (identical to a read request) 01 hex: Converter has executed the read request. 81 hex: Converter was not able to completely execute the read request.
Page 121 Configuring the fieldbus 6.1 Communication via PROFIBUS Changing parameter values Table 6- 17 Request to change parameters Data block Byte n Bytes n + 1 01 hex ... FF hex Header Reference 02 hex: Change request 01 hex ... 27 hex 01 hex Number of parameters (m) Address, parameter 1...
Page 122 Configuring the fieldbus 6.1 Communication via PROFIBUS Table 6- 19 Response, if the converter was not able to completely execute the change request Data block Byte n Bytes n + 1 Header Reference (identical to a change request) 82 hex 01 hex Number of parameters (identical to a change request)
Page 123 Configuring the fieldbus 6.1 Communication via PROFIBUS Error Meaning value 1 (illegal or unsupported value for attribute, number of elements, parameter number, 16 hex Illegal parameter address subindex or a combination of these) 17 hex Illegal format (change request for an illegal or unsupported format) (number of values of the parameter data to not match the number of elements 18 hex Number of values not consistent...
Page 124: Communication Via Rs485
Configuring the fieldbus 6.2 Communication via RS485 Communication via RS485 6.2.1 Integrating inverters into a bus system via the RS485 interface Connecting to a network via RS485 Connect the inverter to your fieldbus via the RS485 interface. Position and assignment of the RS485 interface can be found in section Interfaces, connectors, switches, terminal blocks and LEDs of the CU (Page 43).
Page 125: Communication Via Uss
Configuring the fieldbus 6.2 Communication via RS485 6.2.2 Communication via USS Using the USS protocol (protocol of the universal serial interface), users can set up a serial data connection between a higher-level master system and several slave systems (RS 485 interface).
Page 126: Basic Settings For Communication
Configuring the fieldbus 6.2 Communication via RS485 6.2.2.2 Basic settings for communication Parameter Description P0015 = 21 Macro drive unit Selecting the I/O configuration p2020 Value Baud rate 2400 4800 9600 19200 38400 57600 76800 93750 115200 187500 p2022 Fieldbus interface, USS PZD count Setting the number of 16-bit words in the PZD part of the USS telegram p2023 Fieldbus interface, USS PKW count...
Page 127 Configuring the fieldbus 6.2 Communication via RS485 Description Telegrams with both a variable and fixed length can be used. This can be selected using parameters p2022 and p2023 to define the length of the PZD and the PKW within the net data.
Page 128: User Data Range Of The Uss Telegram
● Bit 5 broadcast bit Bit 5 = 0: normal data exchange. Bit 5 = 1: Address (bits 0 … 4) is not evaluated (is not supported in SINAMICS G120!). ● Bit 6 mirror telegram Bit 6 = 0: normal data exchange. Bit 6 = 1: The slave returns the telegram unchanged to the master.
Page 129: Data Structure Of The Uss Parameter Channel
Configuring the fieldbus 6.2 Communication via RS485 The length for the parameter channel is determined by parameter p2023 and the length for the process data is specified by parameter p2022. If the parameter channel or the PZD is not required, the appropriate parameters can be set to zero ("PKW only" or "PZD only"). It is not possible to transfer "PKW only"...
Page 130 Configuring the fieldbus 6.2 Communication via RS485 The following table includes the request ID for telegrams between the master → inverter. Table 6- 21 Request identifier (master → inverter) Request Description Response identifier identifier Positive Negative No request Request parameter value 1 / 2 Change parameter value (word) Change parameter value (double word)
Page 131 Configuring the fieldbus 6.2 Communication via RS485 If the response ID = 7, then the inverter sends one of the error numbers listed in the following table in parameter value 2 (PWE2). Table 6- 23 Error numbers for the response "Request cannot be processed" Description Comments Impermissible parameter number (PNU)
Page 132 Configuring the fieldbus 6.2 Communication via RS485 Parameter index (IND) Figure 6-8 Structure of the parameter index (IND) ● For indexed parameters, select the index of the parameter by transferring the appropriate value between 0 and 254 to the subindex within a job. ●...
Page 133 Configuring the fieldbus 6.2 Communication via RS485 Parameter value (PWE) You can vary the number of PWEs using parameter p2023. Parameter channel with fixed length Parameter channel with variable length P2023 = 4 P2023 = 127 A parameter channel with fixed length should For a variable length of parameter channel, the contain 4 words as this setting is sufficient for all master will only send the number of PWEs...
Page 134: Uss Read Request
Configuring the fieldbus 6.2 Communication via RS485 6.2.2.6 USS read request Example: Reading out alarm messages from the inverter. The parameter channel comprises four words (p2023 = 4). In order to obtain the values of the indexed parameter r2122, you must fill the telegram of the parameter channel with the following data: ●...
Page 135: Uss Write Job
722 = 2D2H. ● Drive Object: Enter bit 10 … 15 in PWE2 (4th word): for SINAMICS G120, always 63 = 3FH ● Index of the parameter: Enter bit 0 … 9 in PWE2 (word4): in example 2.
Page 136: Uss Process Data Channel (Pzd)
Configuring the fieldbus 6.2 Communication via RS485 6.2.2.8 USS process data channel (PZD) Description Process data (PZD) is exchanged between the master and slave in this telegram range. Depending on the direction of transfer, the process data channel contains request data for the slave or response data to the master.
Page 137 Configuring the fieldbus 6.2 Communication via RS485 The telegram runtime is longer than just purely adding all of the character runtimes (=residual runtime). You must also take into consideration the character delay time between the individual characters of the telegram. Residual runtime 50% of compressed (compressed telegram)
Page 138 Configuring the fieldbus 6.2 Communication via RS485 Telegram monitoring of the master With your USS master, we recommend that the following times are monitored: Response time of the slave to a request from the master • Response delay: The response delay must be < 20 ms, but longer than the start delay •...
Page 139: Communication Over Modbus Rtu
Configuring the fieldbus 6.2 Communication via RS485 6.2.3 Communication over Modbus RTU Overview of communication using Modbus The Modbus protocol is a communication protocol with linear topology based on a master/slave architecture. Modbus offers three transmission modes: ● Modbus ASCII Data is transferred in ASCII code.
Page 140: Setting The Address
Configuring the fieldbus 6.2 Communication via RS485 6.2.3.1 Setting the address You can set the inverter's Modbus RTU address using either DIP switches on the Control Unit or parameter p2021. Valid Modbus RTU addresses: 1 … 247 Invalid Modbus RTU addresses: If you have specified a valid address using DIP switches, this address will always be the one that takes effect and p2021 cannot be changed.
Page 141: Modbus Rtu Telegram
Configuring the fieldbus 6.2 Communication via RS485 6.2.3.3 Modbus RTU telegram Description For Modbus, there is precisely one master and up to 247 slaves. Communication is always triggered by the master. The slaves can only transfer data at the request of the master. Slave-to-slave communication is not possible.
Page 142: Baud Rates And Mapping Tables
Configuring the fieldbus 6.2 Communication via RS485 6.2.3.4 Baud rates and mapping tables Permissible baud rates and telegram delay The Modbus RTU telegram requires a pause for the following cases: ● Start detection ● Between the individual frames ● End detection Minimum duration: Processing time for 3.5 bytes (can be set via p2024[2]).
Page 143 Configuring the fieldbus 6.2 Communication via RS485 The valid holding register addressing range extends from 40001 to 40522. Access to other holding registers generates the fault "Exception Code". The registers 40100 to 40111 are described as process data. A telegram monitoring time can be activated in p2040 for these registers.
Page 144 Configuring the fieldbus 6.2 Communication via RS485 Modbus Description Modbus Unit Scaling On/Off text Data / parameter Reg. access factor or value range 40300 Powerstack number 0 … 32767 r0200 40301 Converter firmware 0.0001 0.00 … 327.67 r0018 Converter data 40320 Rated power of the power unit 0 …...
Page 145: Write And Read Access Via Fc 3 And Fc 6
Configuring the fieldbus 6.2 Communication via RS485 Modbus Description Modbus Unit Scaling On/Off text Data / parameter Reg. access factor or value range Technology controller adjustment 40510 Time constant for actual value filter of 0.00 … 60.0 p2265 the technology controller 40511 Scaling factor for actual value of the 0.00 …...
Page 146 Configuring the fieldbus 6.2 Communication via RS485 Table 6- 31 Structure of a read request for slave number 17 Example Byte Description 11 h Slave address 03 h Function code 00 h Register start address "High" (register 40110) Register start address "Low" 6D h 00 h No.
Page 147: Communication Procedure
Configuring the fieldbus 6.2 Communication via RS485 Table 6- 33 Structure of a write request for slave number 17 Example Byte Description 11 h Slave address 06 h Function code 00 h Register start address "High" (write register 40100) Register start address "Low" 63 h 55 h Register data "High"...
Page 148 Configuring the fieldbus 6.2 Communication via RS485 Logical error If the slave detects a logical error within a request, it responds to the master with an "exception response". In the response, the highest bit in the function code is set to 1. If the slave receives, for example, an unsupported function code from the master, the slave responds with an "exception response"...
Page 149: Functions
Functions Before you set the inverter functions, you should have completed the following commissioning steps: ● Commissioning (Page 55) ● If necessary: Adapt terminal strip (Page 89) ● If necessary: Configuring the fieldbus (Page 101) Overview of the inverter functions Figure 7-1 Overview of inverter functions Inverter with CU240B-2 and CU240E-2 Control Units...
Page 150 Functions 7.1 Overview of the inverter functions Functions relevant to all applications Functions required in special applications only The functions that you require in each application are shown The functions whose parameters you only need to adapt in a dark color in the function overview above. when actually required are shown in white in the function overview above.
Page 151: Inverter Control
Functions 7.2 Inverter control Inverter control If you are controlling the inverter using digital inputs, you use parameter p0015 during basic commissioning to define how the motor is switched on and off and how it is changed over from clockwise to counter-clockwise rotation. Five different methods are available for controlling the motor.
Page 152: Two-Wire Control: Method 1
Functions 7.2 Inverter control 7.2.1 Two-wire control: method 1 You switch the motor on and off using a control command (ON/OFF1). while the other control command reverses the motor direction of rotation. Figure 7-2 Two-wire control, method 1 Table 7- 2 Function table ON/OFF1 Reversing...
Page 153: Two-Wire Control, Method 2
Functions 7.2 Inverter control 7.2.2 Two-wire control, method 2 You switch the motor on and off using a control command (ON/OFF1) and at the same time select clockwise motor rotation. You also use the other control command to switch the motor on and off, but in this case you select counter-clockwise rotation for the motor.
Page 154: Two-Wire Control, Method 3
Functions 7.2 Inverter control 7.2.3 Two-wire control, method 3 You switch the motor on and off using a control command (ON/OFF1) and at the same time select clockwise motor rotation. You also use the other control command to switch the motor on and off, but in this case you select counter-clockwise rotation for the motor.
Page 155: Three-Wire Control, Method 1
Functions 7.2 Inverter control 7.2.4 Three-wire control, method 1 With one control command, you enable the two other control commands. You switch the motor off by canceling the enable (OFF1). You switch the motor's direction of rotation to clockwise rotation with the positive edge of the second control command.
Page 156: Three-Wire Control, Method 2
Functions 7.2 Inverter control 7.2.5 Three-wire control, method 2 With one control command, you enable the two other control commands. You switch the motor off by canceling the enable (OFF1). You switch on the motor with the positive edge of the second control command (ON). The third control command defines the motor's direction of rotation (reversing).
Page 157: Switching Over The Inverter Control (Command Data Set)
Functions 7.2 Inverter control 7.2.6 Switching over the inverter control (command data set) In several applications, the inverter must be able to be operated from different, higher-level control systems. Example: Switchover from automatic to manual operation A motor is switched on and off and its speed varied either from a central control system via a fieldbus or from a local control box.
Page 158 Functions 7.2 Inverter control You select the command data set using parameter p0810. To do this, you must interconnect parameter p0810 with a control command of your choice, e.g. a digital input. p0840[0] r2090.0 p2103[0] r2090.7 p0854[0] r2090.10 p1036[0] r2090.14 p1055[1] r722.0 p1056[1]...
Page 159 Functions 7.2 Inverter control Advanced settings If you require more than two command data sets, then define the number of command data sets (2, 3 or 4) using parameter p0170. Table 7- 12 Defining the number of command data sets Parameter Description p0010 = 15...
Page 160: Command Sources
Functions 7.3 Command sources Command sources The command source is the interface via which the inverter receives its control commands. When commissioning, you define this using macro 15 (p0015). Note The "Get master control" or "Manual/Auto changeover" function can also be used to specify commands and setpoints via STARTER or the Operator Panel.
Page 161: Setpoint Sources
Functions 7.4 Setpoint sources Setpoint sources The setpoint source is the interface via which the inverter receives its setpoint. The following options are available: ● Motorized potentiometer simulated in the inverter. ● Inverter analog input. ● Setpoints saved in the inverter: –...
Page 162: Motorized Potentiometer As Setpoint Source
Functions 7.4 Setpoint sources 7.4.2 Motorized potentiometer as setpoint source The 'motorized potentiometer' (MOP) function simulates an electromechanical potentiometer for entering setpoints. You can continuously adjust the motorized potentiometer (MOP) using the control signals "raise" and "lower". The control signals are received via the digital inputs of the inverter or from the operator panel that has been inserted.
Page 163 Functions 7.4 Setpoint sources Table 7- 17 Extended setup of motorized potentiometer Parameter Description p1030 Configuration of the MOP, parameter value with four independently adjustable bits 00 to 03 (factory setting 00110 bin) Bit 00: Save setpoint after switching off motor 0: After the motor is switched on, p1040 is specified as the setpoint 1: Setpoint is saved after the motor is switched off and set to the saved value once it is switched on...
Page 164: Fixed Speed As Setpoint Source
Functions 7.4 Setpoint sources Example of parameterization of the motorized potentiometer Table 7- 18 Implementing a motorized potentiometer using digital inputs Parameter Description p0015 = 9 Macro drive unit: Configure inverter on MOP as the setpoint source The motor is switched on and off via digital input 0. •...
Page 165 Functions 7.4 Setpoint sources The various fixed setpoints can be selected in two ways: 1. Direct selection: Precisely one fixed speed setpoint is assigned to each selection signal (e.g. a digital input). As several selection signals are selected, the associated fixed speed setpoints are added together to from a total setpoint.
Page 166: Running The Motor In Jog Mode (Jog Function)
Functions 7.4 Setpoint sources Example: Selecting two fixed speed setpoints using digital input 2 and digital input 3 The motor is to run at two different speeds: ● The motor is switched on with digital input 0 ● When digital input 2 is selected, the motor is to run at a speed of 300 rpm. ●...
Page 167: Specifying The Motor Speed Via The Fieldbus
Functions 7.4 Setpoint sources Table 7- 22 Parameters for the "Jog" function Parameter Description p1055 Signal source for jogging 1 - jog bit 0 (factory setting: 0) If you wish to jog via a digital input, then set p1055 = 722.x p1056 Signal source for jogging 2 - jog bit 1 (factory setting: 0) If you wish to jog via a digital input, then set p1056 = 722.x...
Page 168: Setpoint Calculation
Functions 7.5 Setpoint calculation Setpoint calculation The setpoint processing modifies the speed setpoint, e.g. it limits the setpoint to a maximum and minimum value and using the ramp-function generator prevents the motor from executing speed steps. Figure 7-10 Setpoint processing in the inverter 7.5.1 Minimum speed and maximum speed The speed setpoint is limited by both the minimum and maximum speed.
Page 169: Ramp-Function Generator
Functions 7.5 Setpoint calculation 7.5.2 Ramp-function generator The ramp-function generator in the setpoint channel limits the speed of changes to the speed setpoint. The ramp-function generator does the following: ● The soft acceleration and braking of the motor reduces the stress on the mechanical system of the driven machine.
Page 170: Motor Control
Functions 7.6 Motor control Motor control For induction motors, there are two different open-loop control or closed-loop control techniques: ● Open-loop control with V/f-characteristic (V/f control) ● Field-oriented control (vector control) Criteria for selecting either V/f control or vector control V/f control is perfectly suitable for almost any application in which the speed of induction motors is to be changed.
Page 171: V/F Control
Functions 7.6 Motor control 7.6.1 V/f control V/f control sets the voltage at the motor terminals on the basis of the specified speed setpoint. The relationship between the speed setpoint and stator voltage is calculated using characteristic curves. The required output frequency is calculated on the basis of the speed setpoint and the number of pole pairs of the motor (f = n * number of pole pairs / 60, in particular: f = p1082 * number of pole pairs / 60).
Page 172: Additional Characteristics For The V/F Control
Functions 7.6 Motor control 7.6.1.2 Additional characteristics for the V/f control In addition to linear and square-law characteristics, there are the following additional versions of the V/f control that are suitable for special applications. Linear V/f characteristic with Flux Current Control (FCC) (P1300 = 1) Voltage losses across the stator resistance are automatically compensated.
Page 173: Optimizing With A High Break Loose Torque And Brief Overload
Functions 7.6 Motor control V/f control for drives requiring a precise frequency (textile industry) (p1300 = 5), V/f control for drives requiring a precise frequency and FCC (p1300 = 6) These characteristics require the motor speed to remain constant under all circumstances. This setting has the following effects: ●...
Page 174 Functions 7.6 Motor control Note Only increase the voltage boost in small steps until satisfactory motor behavior is reached. Excessively high values in p1310 ... p1312 can cause the motor to overheat and switch off (trip) the inverter due to overcurrent . Table 7- 25 Optimizing the starting characteristics for a linear characteristic Parameter Description...
Page 175: Vector Control
Additional information about this function is provided in the parameter list and in function diagrams 6030 onwards in the List Manual. You will find more information On the Internet: (http://support.automation.siemens.com/WW/view/en/7494205): Inverter with CU240B-2 and CU240E-2 Control Units Operating Instructions, 01/2011, FW 4.4, A5E02299792B AB...
Page 176: Torque Control
Functions 7.6 Motor control 7.6.2.3 Torque control Torque control is part of the vector control and normally receives its setpoint from the speed controller output. By deactivating the speed controller and directly entering the torque setpoint, the closed-loop speed control becomes closed-loop torque control. The inverter then no longer controls the motor speed, but the torque that the motor generates.
Page 177: Protection Functions
Description P0290 Power unit overload response (factory setting for SINAMICS G120 inverters with Power Module PM260: 0; factory setting for all of the inverters: 2) Setting the reaction to a thermal overload of the power unit: 0: Reduce output current (in vector control mode) or speed (in V/f mode)
Page 178: Motor Temperature Monitoring Using A Temperature Sensor
Functions 7.7 Protection functions 7.7.2 Motor temperature monitoring using a temperature sensor You can use one of the following sensors to protect the motor against overtemperature: ● PTC sensor ● KTY 84 sensor ● ThermoClick sensor The motor's temperature sensor is connected to the Control Unit. Temperature measurement via PTC The PTC sensor is connected to terminals 14 and 15.
Page 179 Functions 7.7 Protection functions Parameters to set the motor temperature monitoring with sensor Table 7- 28 Parameters for detecting the motor temperature via a temperature sensor Parameter Description P0335 Specify the motor cooling 0: Self-ventilated - with fan on the motor shaft (IC410* or IC411*) - (factory setting) 1: Forced ventilation - with a separately driven fan (IC416*) 2: Self-ventilated and inner cooling* (open-circuit air cooled) 3: Forced ventilated and inner cooling* (open-circuit air cooled)
Page 180: Protecting The Motor By Calculating The Motor Temperature
Functions 7.7 Protection functions 7.7.3 Protecting the motor by calculating the motor temperature The temperature calculation is only possible in the vector control mode (P1300 ≥ 20) and functions by calculating a thermal motor model. Table 7- 29 Parameter to sense the temperature without using a temperature sensor Parameters Description P0621 = 1...
Page 181: Limiting The Maximum Dc Link Voltage
Functions 7.7 Protection functions Settings You only have to change the factory settings of the I controller if the drive tends to oscillate when it reaches the current limit or it is shut down due to overcurrent. Table 7- 30 controller parameters Parameter Description...
Page 182 Functions 7.7 Protection functions There are two different groups of parameters for the V controller, depending on whether DCmax the motor is being operated with U/f control or vector control. Table 7- 31 controller parameters DCmax Parameter for Parameter for Description V/f control vector control...
Page 183: Status Messages
Functions 7.8 Status messages Status messages 7.8.1 Overview, evaluating the inverter state Information about the inverter state (alarms, faults, actual values) can be output via inputs and outputs and also via the communication interface. Details on evaluating the inverter state via inputs and outputs are provided in Section Adapt terminal strip (Page 89).
Page 184: Application-Specific Functions
Functions 7.9 Application-specific functions Application-specific functions The inverter offers a series of functions that you can use depending on your particular application, e.g.: ● Unit changeover ● Braking functions ● Automatic restart and flying restart ● Basic process control functions ●...
Page 185: Changing Over The Motor Standard
Functions 7.9 Application-specific functions Note Restrictions for the unit changeover function • The values on the rating plate of the inverter or motor cannot be displayed as percentage values. • Using the unit changeover function a multiple times (for example, percent → physical unit 1 →...
Page 186: Changing Over The Unit System
Functions 7.9 Application-specific functions The parameters listed below are affected by the changeover. Table 7- 32 Variables affected by changing over the motor standard P no. Designation Unit for p0100 = r0206 Power Module rated power p0307 Rated motor power p0316 Motor torque constant Nm/A...
Page 187: Changing Over Process Variables For The Technology Controller
Functions 7.9 Application-specific functions 7.9.1.3 Changing over process variables for the technology controller Note We recommend that the units and reference values of the technology controller are coordinated and harmonized with one another during commissioning. Subsequent modification in the reference variable or the unit can result in incorrect calculations or displays.
Page 188 Functions 7.9 Application-specific functions Procedure ● Go to the "Units" tab in the configuration screen form to change over the units. ③ Changing over the unit system ④ Selecting process variables of the technology controller ⑤ adapting to the line supply Figure 7-11 Unit changeover ●...
Page 189: Braking Functions Of The Inverter
Functions 7.9 Application-specific functions 7.9.2 Braking functions of the inverter A differentiation is made between mechanically braking and electrically braking a motor: ● Mechanical brakes are generally motor holding brakes that are closed when the motor is at a standstill. Mechanical operating brakes, that are closed while the motor is rotating are subject to a high wear and are therefore often only used as an emergency brake.
Page 190 Functions 7.9 Application-specific functions Main features of the braking functions DC braking The motor converts the regenerative power into heat. Advantage: The motor brakes without the • inverter having to process the regenerative energy Disadvantages: significant increase in the • motor temperature;...
Page 191 Functions 7.9 Application-specific functions Braking with regenerative feedback into the line supply The inverter feeds the regenerative power back into the line supply. Advantages: Constant braking torque; the • regenerative power is not converted into heat, but is regenerated into the line supply; can be used in all applications;...
Page 192: Dc Braking
Functions 7.9 Application-specific functions 7.9.2.2 DC braking DC braking is used for applications without regenerative feedback into the line supply, where the motor can be more quickly braked by impressing a DC current than along a braking ramp. Typical applications for DC braking include: ●...
Page 193 Functions 7.9 Application-specific functions DC braking when the start speed for DC braking is fallen below DC braking is automatically activated as soon as the motor speed falls below the start speed for DC braking. However, the motor speed must have first exceeded the start speed for DC braking.
Page 194 Functions 7.9 Application-specific functions DC braking parameters Table 7- 34 Parameters for configuring DC braking Parameter Description p1230 Activate DC braking (BICO parameter) The value for this parameter (0 or 1) can be either entered directly or specified by means of an interconnection with a control command. p1231 Configure DC braking p1231 = 0, no DC braking...
Page 195: Compound Braking
Functions 7.9 Application-specific functions 7.9.2.3 Compound braking Compound braking is typically used for applications in which the motor is normally operated at a constant speed and is only braked down to standstill in longer time intervals, e.g.: ● Centrifuges ● Saws ●...
Page 196 Functions 7.9 Application-specific functions Parameterizing compound braking Table 7- 37 Parameters to enable and set compound braking Parameter Description P3856 Compound braking current (%) With the compound braking current, the magnitude of the DC current is defined, which is additionally generated when stopping the motor for operation with V/f control to increase the braking effect.
Page 197: Dynamic Braking
Functions 7.9 Application-specific functions 7.9.2.4 Dynamic braking Dynamic braking is typically used in applications in which dynamic motor behavior is required at different speeds or continuous direction changes, e.g.: ● Horizontal conveyors ● Vertical and inclined conveyors ● Hoisting gear Principle of operation The inverter controls the braking chopper depending on its DC link voltage.
Page 198 Braking resistor connection (example: Temperature monitoring via DI 3) You will find more information about the braking resistor in the installation instructions for Power Module PM240 (http://support.automation.siemens.com/WW/view/en/30563173/133300). WARNING If an unsuitable braking resistor is used, this could result in a fire and severely damage the converter.
Page 199: Braking With Regenerative Feedback To The Line
Functions 7.9 Application-specific functions 7.9.2.5 Braking with regenerative feedback to the line Regenerative braking is typically used in applications where braking energy is generated either frequently or for longer periods of time, e.g.: ● Centrifuges ● Unwinders ● Cranes and hoisting gear Pre-requisite for regenerative braking is the Power Module PM250 or PM260.
Page 200: Motor Holding Brake
The Brake Relay can be mounted on a mounting plate, the cabinet wall or the inverter's shield connection kit. For more information, refer to Installation instructions for the Brake Relay (http://support.automation.siemens.com/WW/view/en/23623179). Connect the Brake Relay to the Power Module using the cable form provided.
Page 201 Functions 7.9 Application-specific functions Connect the motor holding brake to the terminals of the Brake Relay. Figure 7-15 Connecting the motor holding brake Further information can be found in the Hardware Installation Manual for your Power Module. Inverter with CU240B-2 and CU240E-2 Control Units Operating Instructions, 01/2011, FW 4.4, A5E02299792B AB...
Page 202 Functions 7.9 Application-specific functions Principle of operation after OFF1 and OFF3 command Figure 7-16 Controlling the motor holding brake when the motor is switched on and off The motor brake is controlled as shown in the following diagram: 1. After the ON command (switch on motor), the inverter magnetizes the motor. At the end of the magnetizing time (p0346), the inverter issues the command to open the brake.
Page 203 Functions 7.9 Application-specific functions Principle of operation after OFF2 or STO command For the following signals, the brake closing time is not taken into account: ● OFF2 command ● For fail-safe applications, in addition, after "Safe Torque Off" (STO) After these control commands, the signal to close the motor holding brake is immediately output independent of the motor speed.
Page 204 Functions 7.9 Application-specific functions Commissioning WARNING The following applications require special settings of the motor holding brake. In these cases, the motor holding brake control may only be commissioned by experienced personnel: • All applications that involve moving and transporting people •...
Page 205 Functions 7.9 Application-specific functions Table 7- 40 Control logic parameters of the motor holding brake Parameter Description p1215 = 1 Enable motor holding brake 0 Motor holding brake locked (factory setting) 1 Motor holding brake just like the sequence control 2: Motor holding brake permanently open 3: Motor holding brake just like the sequential control, connected via BICO p1216...
Page 206: Automatic Restart And Flying Restart
Functions 7.9 Application-specific functions 7.9.3 Automatic restart and flying restart 7.9.3.1 Flying restart – switching on while the motor is running If you switch on the motor while it is still running, then with a high degree of probability, a fault will occur due to overcurrent (overcurrent fault F07801).
Page 207 Functions 7.9 Application-specific functions Table 7- 43 Advanced settings Parameter Description P1201 Flying restart enable signal source (factory setting: 1) Defines a control command, e.g. a digital input, through which the flying restart function is enabled. P1202 Flying restart search current (factory setting 100 %) Defines the search current with respect to the motor magnetizing current (r0331), which flows in the motor while the flying restart function is being used.
Page 208: Automatic Switch-On
Functions 7.9 Application-specific functions 7.9.3.2 Automatic switch-on The automatic restart includes two different functions: 1. The inverter automatically acknowledges faults. 2. After a fault occurs or after a power failure, the inverter automatically switches-on the motor again. This automatic restart function is primarily used in applications where the motor is controlled locally via the inverter's inputs.
Page 209 Functions 7.9 Application-specific functions ● Set the parameters of the automatic restart function. The method of operation of the parameters is explained in the following diagram and in the table. The inverter automatically acknowledges faults under the following conditions: p1210 = 1 or 26: always. •...
Page 210 Functions 7.9 Application-specific functions Table 7- 44 Setting the automatic restart Parameter Explanation p1210 Automatic restart mode (factory setting: 0) Disable automatic restart Acknowledge all faults without restarting Restart after power failure without further restart attempts Restart after fault with further restart attempts Restart after power failure after manual fault acknowledgement Restart after fault after manual fault acknowledgement Acknowledgement of all faults and restart with ON command...
Page 211 Functions 7.9 Application-specific functions Parameter Explanation p1213[0] Automatic restart monitoring time for restart (factory setting: 60 s) This parameter is only effective for the settings p1210 = 4, 6, 14, 16, 26. With this monitoring function, you limit the time in which the inverter may attempt to automatically switch-on the motor again.
Page 212: Pid Technology Controller
Functions 7.9 Application-specific functions 7.9.4 PID technology controller The technology controller permits all types of simple process controls to be implemented. You can use the technology controller for e.g. pressure controllers, level controls or flow controls. Figure 7-20 Example: technology controller as a level controller Principle of operation The technology controller specifies the speed setpoint of the motor in such a way that the process variable to be controlled corresponds to its setpoint.
Page 213: Load Torque Monitoring (System Protection)
Functions 7.9 Application-specific functions 7.9.5 Load torque monitoring (system protection) In many applications, it is advisable to monitor the motor torque: ● Applications where the load speed can be indirectly monitored by means of the load torque. For example, in fans and conveyor belts too low a torque indicates that the drive belt is torn.
Page 214 Functions 7.9 Application-specific functions Table 7- 46 Parameterizing the monitoring functions Parameter Description No-load monitoring P2179 Current limit for no-load detection If the converter current is below this value, the message "no load" is output. P2180 Delay time for the "no load" message Blocking protection P2177 Delay time for the "motor locked"...
Page 215: Speed And Load Failure Via Digital Input
Functions 7.9 Application-specific functions 7.9.6 Speed and load failure via digital input With this function you can directly monitor not only the motor speed but also the speed of the driven load. Examples include: ● Gearbox monitoring, e.g. in traction drives or hoisting gear ●...
Page 216 Functions 7.9 Application-specific functions Speed deviation monitoring This function is only available for Control Units CU240E-2, CU240E-2 DP, CU240E-2 F and CU240E-2 DP-F. The monitoring sensor is connected to digital input 3. The inverter can process a pulse sequence of up to 32 kHz. Figure 7-22 Speed deviation monitoring by means of digital input DI3 The speed is calculated from the pulse signal of the digital input in the "probe".
Page 217 Functions 7.9 Application-specific functions Table 7- 48 Setting speed deviation monitoring Parameter Description P2193 = 2 Load monitoring configuration (factory setting: 1) 2: Speed and load failure monitoring. P2192 Load monitoring delay time (factory setting 10 s) Setting of the delay time for evaluating load monitoring. P2181 Load monitoring response (factory setting 0) Setting of the response for evaluating load monitoring.
Page 218: Logical And Arithmetic Functions Using Function Blocks
Functions 7.9 Application-specific functions 7.9.7 Logical and arithmetic functions using function blocks Additional signal interconnections in the inverter can be established by means of free function blocks. Every digital and analog signal available via BICO technology can be routed to the appropriate inputs of the free function blocks. The outputs of the free function blocks are also interconnected to other functions using BICO technology.
Page 219 Functions 7.9 Application-specific functions Table 7- 49 Runtime groups and possible assignments of the free function blocks Runtime groups 1 … 6 with associated time slices Free function blocks 8 ms 16 ms 32 ms 64 ms 128 ms 256 ms Logic modules ✓...
Page 220 Functions 7.9 Application-specific functions Scaling examples ● Speed: Reference speed p2000 = 3000 rpm, actual speed 2100 rpm. As a consequence, the following applies to the scaled input quantity: 2,100 / 3,000 = 0.7. ● Temperature: Reference quantity is 100 °C. For an actual temperature of 120 °C, the input value is obtained from 120 °C / 100 °C = 1.2.
Page 221 BICO technology: example (Page 18)chapter. You can find additional information in the following manuals: ● Function Manual "Description of the Standard DCC Blocks" (http://support.automation.siemens.com/WW/view/en/29193002) ● Function Manual "Free Function Blocks" (http://support.automation.siemens.com/WW/view/en/35125827) Inverter with CU240B-2 and CU240E-2 Control Units...
Page 222: Safe Torque Off (Sto) Safety Function
Functions 7.10 Safe Torque Off (STO) safety function 7.10 Safe Torque Off (STO) safety function These operating instructions describe the commissioning of the STO safety function when it is controlled via a fail-safe digital input. You will find a detailed description of all safety functions and control using PROFIsafe in the Safety Integrated Function Manual, see Section Additional information on the inverter (Page 292).
Page 223: Connecting Fail-Safe Digital Inputs
Functions 7.10 Safe Torque Off (STO) safety function 7.10.3 Connecting fail-safe digital inputs On the following pages, you will find examples of connecting the fail-safe digital input from "Basic safety", in accordance with PL d according to EN 13849-1 and SIL2 according to IEC 61508 for the case that all of the components are installed in a control cabinet.
Page 224 Functions 7.10 Safe Torque Off (STO) safety function Figure 7-26 Connecting an F digital output module, e.g. SIMATIC F digital output module You can find additional connection options and connections in separate control cabinets in the Safety Integrated Function Manual, see Section Additional information on the inverter (Page 292).
Page 225: F-Di Signal Filtering
Functions 7.10 Safe Torque Off (STO) safety function 7.10.4 F-DI signal filtering The inverter checks the signals of the fail-safe digital input for consistency. Consistent signals at both inputs always assume the same signal state (high or low). Discrepancy With electromechanical sensors (e.g. emergency stop buttons or door switches), the two sensor contacts never switch at exactly the same time and are therefore temporarily inconsistent (discrepancy).
Page 226 Functions 7.10 Safe Torque Off (STO) safety function 2. Several control modules test their fail-safe outputs using bit pattern tests (on/off tests), in order to identify faults due to either short or cross circuiting. When you interconnect the fail-safe input of the inverter with a fail-safe output of a control module, the inverter responds to these test signals.
Page 227 Functions 7.10 Safe Torque Off (STO) safety function An adjustable signal filter in the inverter suppresses temporary signal changes using bit pattern test or contact bounce. Figure 7-29 Filter for suppressing temporary signal changes Note The filter increases the inverter response time. The inverter only activates its safety function after the debounce time has elapsed (parameters p9651 and p9851).
Page 228: Forced Dormant Error Detection
Functions 7.10 Safe Torque Off (STO) safety function 7.10.5 Forced dormant error detection To fulfill the requirements of standards EN 954-1, ISO 13849-1 and IEC 61508 regarding timely error detection, the inverter must regularly test its safety-relevant circuits to ensure that they function correctly - this must be performed at least once every year.
Page 229: Commissioning The Sto
Table 7- 51 STARTER commissioning tool (PC software) Download Order number STARTER PC Connection Kit (http://support.automation.siemens.com/WW/view The kit contains a STARTER DVD and USB /en/10804985/130000) cable 6SL3255-0AA00-2CA0 7.10.7.2 Resetting the safety function parameters to the factory setting Proceed as follows if you wish to reset the safety function parameters to the factory setting, without influencing the standard parameters: ●...
Page 230: Defining Commissioning Method
Functions 7.10 Safe Torque Off (STO) safety function Procedure ● Go online with STARTER. ● In STARTER, call up the screens displaying the fail-safe functions and click on "Change settings": 7.10.7.3 Defining commissioning method ● Select "STO via terminal". ● If you require the status signal "STO active" in your higher-level controller, interconnect it accordingly.
Page 231: Setting Sto
Functions 7.10 Safe Torque Off (STO) safety function 7.10.7.4 Setting STO ● You can adapt the STO function according to your requirements in the following screen. ● Set the following in the above screen: – ① ② F-DI input filter (debounce time) and monitoring for simultaneous operation (discrepancy): The method of functioning of the two filters is described in the section entitled F-DI signal filtering (Page 223).
Page 232: Multiple Assignment Of The Di
Functions 7.10 Safe Torque Off (STO) safety function ● Switch off the inverter supply voltage. ● Wait until all LEDs on the inverter go dark. Now switch on the inverter supply voltage again. Your settings only become effective after this power-on reset. 7.10.7.6 Multiple assignment of the DI ●...
Page 233 Functions 7.10 Safe Torque Off (STO) safety function Figure 7-32 Remove pre-assignment of digital inputs DI 4 and DI 5 ● When you use the data set changeover CDS, you must delete the multiple assignment of the digital inputs for all CDS. Inverter with CU240B-2 and CU240E-2 Control Units Operating Instructions, 01/2011, FW 4.4, A5E02299792B AB...
Page 234: Acceptance Test - Following Completion Of Commissioning
Functions 7.10 Safe Torque Off (STO) safety function 7.10.8 Acceptance test - following completion of commissioning 7.10.8.1 Prerequisites and authorized persons Requirements for acceptance tests are derived from the EC Machinery Directive and ISO 13849-1. ● Check the safety-related functions and machine parts following commissioning. ●...
Page 235: Reduced Acceptance Test (Only Sto)
Functions 7.10 Safe Torque Off (STO) safety function 7.10.8.3 Reduced acceptance test (only STO) A complete acceptance test is only necessary following first commissioning. An acceptance test with a reduced scope is sufficient for expansions of safety functions. The reduced acceptance tests must be carried out separately for each individual drive, as far as the machine allows.
Page 236: Documentation
Functions 7.10 Safe Torque Off (STO) safety function 7.10.8.4 Documentation Machine overview Enter your machine's data into the following table. Designation … Type … Serial number … Manufacturer … End customer … Overview image of the machine: … … … …...
Page 237 Functions 7.10 Safe Torque Off (STO) safety function Function table Fill in the following table for your machine. Mode of operation Safety device Drive Controlling the safety Status of the safety function function … … … … … … … …...
Page 238: Function Test
Functions 7.10 Safe Torque Off (STO) safety function 7.10.8.5 Function test The following is checked during the function test: ● The hardware is functioning properly. ● The digital inputs of the inverter are assigned correctly to the safety function. ● The PROFIsafe address of the inverter has been set correctly. ●...
Page 239: Completion Of The Certificate
Functions 7.10 Safe Torque Off (STO) safety function 7.10.8.6 Completion of the certificate Document your machine's data for each drive based on the following specifications. Parameters of the safety functions The function test does not detect all faults in the parameter assignment of safety functions, e.g.
Page 240 Functions 7.10 Safe Torque Off (STO) safety function Data backup Storage medium Holding area Type Designation Date Parameter PLC program Circuit diagrams Countersignatures Commissioning engineer This confirms that the tests and checks have been carried out properly. Date Name Company/dept. Signature Machine manufacturer This confirms that the parameters recorded above are correct.
Page 241: Switchover Between Different Settings
Functions 7.11 Switchover between different settings 7.11 Switchover between different settings In several applications, the inverter must be able to be operated with different settings. Example: You connect different motors to one inverter. Depending on the particular motor, the inverter must operate with the associated motor data and the appropriate ramp-function generator.
Page 242 Functions 7.11 Switchover between different settings Using parameter p0180 you can define the number of command data sets (2, 3 or 4). Table 7- 55 Selecting the number of command data sets Parameter Description p0010 = 15 Drive commissioning: Data sets p0180 Drive data sets (DDS) number(factory setting: 1) p0010 = 0...
Page 243: Service And Maintenance
Service and maintenance Overview of replacing converter components In the event of a permanent function fault, you can replace the converter's Power Module or Control Unit independently of one another. In the following cases, you may immediately switch on the motor again after the replacement. Replacing the Power Module Replacing the Control Unit with external backup of the settings, e.g.
Page 244: Replacing The Control Unit
Service and maintenance 8.2 Replacing the Control Unit Replacing the Control Unit After commissioning has been completed, we recommend that you back up your settings on an external storage medium, e.g.: on a memory card or the operator panel. If you do not back up your data, you have to recommission the drive when you replace the Control Unit.
Page 245 Service and maintenance 8.2 Replacing the Control Unit Procedure for replacing a Control Unit without a memory card ● Disconnect the line voltage of the Power Module and (if installed) the external 24 V supply or the voltage for the relay outputs DO 0 and DO 2 of the Control Unit. ●...
Page 246: Replacing The Power Module
Service and maintenance 8.3 Replacing the Power Module Replacing the Power Module Procedure for replacing a Power Module ● Disconnect the Power Module from the line supply. ● If being used, switch off the 24 V supply of the Control Unit. DANGER Risk of electrical shock! Hazardous voltage is still present for up to 5 minutes after the power supply has been...
Page 247: Alarms, Faults And System Messages
Alarms, faults and system messages The converter has the following diagnostic types: ● LED The LED at the front of the converter immediately informs you about the most important converter states right at the converter. ● Alarms and faults The converter signals alarms and faults via the fieldbus, the terminal strip (when appropriately set), on a connected operator panel or STARTER.
Page 248: Operating States Indicated On Leds
Alarms, faults and system messages 9.1 Operating states indicated on LEDs Operating states indicated on LEDs The LED RDY (Ready) is temporarily orange after the power supply voltage is switched-on. As soon as the color of the LED RDY changes to either red or green, the LEDs signal the inverter state.
Page 249 Alarms, faults and system messages 9.1 Operating states indicated on LEDs Table 9- 4 Diagnostics of the safety functions SAFE LED Meaning YELLOW - on One or more safety functions are enabled, but not active. YELLOW - slow One or more safety functions are active; no safety function faults have occurred.
Page 250: Alarms
Alarms, faults and system messages 9.2 Alarms Alarms Alarms have the following properties: ● They do not have a direct effect in the inverter and disappear once the cause has been removed ● They do not need have to be acknowledged ●...
Page 251 Alarms, faults and system messages 9.2 Alarms Figure 9-3 Complete alarm buffer Emptying the alarm buffer: Alarm history The alarm history traces up to 56 alarms. The alarm history only takes alarms that have been removed from the alarm buffer. If the alarm buffer is completely filled - and an additional alarm occurs - then the inverter shifts all alarms that have been removed from the alarm buffer into the alarm history.
Page 252 Alarms, faults and system messages 9.2 Alarms If the alarm history is filled up to index 63, each time a new alarm is accepted in the alarm history, the oldest alarm is deleted. Parameters of the alarm buffer and the alarm history Table 9- 5 Important parameters for alarms Parameter...
Page 253: Faults
Alarms, faults and system messages 9.3 Faults Faults A fault displays a severe fault during operation of the inverter. The inverter signals a fault as follows: ● at the Operator Panel with Fxxxxx ● at the Control Unit using the red LED RDY ●...
Page 254 Alarms, faults and system messages 9.3 Faults The fault buffer can accept up to eight actual faults. The next to last fault is overwritten if an additional fault occurs after the eighth fault. Figure 9-7 Complete fault buffer Fault acknowledgement In most cases, you have the following options to acknowledge a fault: ●...
Page 255 Alarms, faults and system messages 9.3 Faults Figure 9-8 Fault history after acknowledging the faults After acknowledgement, the faults that have not been removed are located in the fault buffer as well as in the fault history. For these faults, the "fault time coming" remains unchanged and the "fault time removed"...
Page 256 Alarms, faults and system messages 9.3 Faults Parameters of the fault buffer and the fault history Table 9- 7 Important parameters for faults Parameter Description r0945 Fault code Displays the numbers of faults that have occurred r0948 Fault time received in milliseconds Displays the time in milliseconds when the fault occurred r0949 Fault value...
Page 257 Alarms, faults and system messages 9.3 Faults Extended settings for faults Table 9- 8 Advanced settings Parameter Description You can change the fault response of the motor for up to 20 different fault codes: p2100 Setting the fault number for fault response Selecting the faults for which the fault response should be changed p2101 Setting, fault response...
Page 258: List Of Alarms And Faults
Alarms, faults and system messages 9.4 List of alarms and faults List of alarms and faults Axxxxx Alarm Fyyyyy: Fault Table 9- 9 The most important alarms and faults of the safety functions Number Cause Remedy F01600 STOP A initiated Select STO and then deselect again F01650 Acceptance test required...
Page 259 Alarms, faults and system messages 9.4 List of alarms and faults Number Cause Remedy F30053 Error in FPGA data Replace the Power Module. F30662 CU hardware fault Switch CU off and on again, upgrade firmware, or contact technical support. F30664 CU power up aborted Switch CU off and on again, upgrade firmware, or contact technical support.
Page 260 Alarms, faults and system messages 9.4 List of alarms and faults Number Cause Remedy F06310 Supply voltage (p0210) incorrectly Check the parameterized supply voltage and if required change (p0210). parameterized Check the line voltage. F07011 Motor overtemperature Reduce the motor load. Check ambient temperature.
Page 261 Alarms, faults and system messages 9.4 List of alarms and faults Number Cause Remedy F07801 Motor overcurrent Check current limits (p0640). Vector control: Check current controller (p1715, p1717). U/f control: Check the current limiting controller (p1340 … p1346). Increase acceleration ramp (p1120) or reduce load. Check motor and motor cables for short circuit and ground fault.
Page 262 Alarms, faults and system messages 9.4 List of alarms and faults Number Cause Remedy A07922 Torque/speed out of tolerance Check the connection between the motor and the load. • Adapt the parameterization corresponding to the load. • F07923 Torque/speed too low •...
Page 263 Alarms, faults and system messages 9.4 List of alarms and faults Number Cause Remedy F30021 Ground fault Check the power cable connections. • Check the motor. • Check the current transformer. • Check the cables and contacts of the brake connection (a wire might •...
Page 264 Alarms, faults and system messages 9.4 List of alarms and faults Inverter with CU240B-2 and CU240E-2 Control Units Operating Instructions, 01/2011, FW 4.4, A5E02299792B AB...
Page 265: Technical Data
Technical data 10.1 Technical data, CU240B-2 Control Unit Feature Data Operating voltage Supply from the Power Module or an external 24 V DC supply (20.4 V ... 28.8 V, 1 A) via control terminals 31 and 32 Heat loss 5.0 W plus power loss of output voltages Output voltages 18 V to 30 V (max.
Page 266: Technical Data, Cu240E-2 Control Unit
Technical data 10.2 Technical data, CU240E-2 Control Unit 10.2 Technical data, CU240E-2 Control Unit Feature Data Operating voltage Supply from the Power Module or an external 24 V DC supply (20.4 V … 28.8 V, 0.5 A) via control terminals 31 and 32 Heat loss 5.0 W plus power loss of output voltages Output voltages...
Page 267 Technical data 10.2 Technical data, CU240E-2 Control Unit Feature Data Memory cards MMC (we recommend a card with Order No. 6SL3254-0AM00-0AA0). SD (Secure Digital Memory Card, we recommend the card with Order No. 6ES7954-8LB00-0AA0). SDHC (SD High Capacity) cannot be used. Operating temperature 0 °C …...
Page 268: Technical Data, Power Modules
Technical data 10.3 Technical data, Power Modules 10.3 Technical data, Power Modules Permissible converter overload There are two different power data specifications for the Power Modules: "Low Overload" (LO) and "High Overload" (HO), depending on the expected load. Figure 10-1 Duty cycles, "High Overload"...
Page 269 Technical data 10.3 Technical data, Power Modules Definitions 100 % of the permissible input current for a load cycle according to • LO input current Low Overload (LO base load input current). 100 % of the permissible output current for a load cycle according •...
Page 270: Technical Data, Pm240
Technical data 10.3 Technical data, Power Modules 10.3.1 Technical data, PM240 Note The given input currents are valid for operation without a line reactor for a line voltage of 400 V with Vk = 1 % referred to the rated power of the inverter. If a line reactor is used, the specified values are reduced by a few percent.
Page 271 Technical data 10.3 Technical data, Power Modules Power-dependent data, PM240 - IP20 Table 10- 1 PM240 frame size A, 3-ph. 380 V AC… 480 V, ± 10 % Order number Without filter 6SL3224-0BE13-7UA0 6SL3224-0BE15-5UA0 6SL3224-0BE17-5UA0 Values based on Low Overload ●...
Page 272 Technical data 10.3 Technical data, Power Modules Table 10- 3 PM240 frame size B, 3-ph. 380 V AC… 480 V, ± 10 % Order number with filter 6SL3224-0BE22-2AA0 6SL3224-0BE23-0AA0 6SL3224-0BE24-0AA0 without filter 6SL3224-0BE22-2UA0 6SL3224-0BE23-0UA0 6SL3224-0BE24-0UA0 Values based on Low Overload ●...
Page 273 Technical data 10.3 Technical data, Power Modules Table 10- 5 PM240 frame size D, 3-ph. 380 V AC… 480 V, ± 10 % Order number with filter 6SL3224-0BE31-5AA0 6SL3224-0BE31-8AA0 6SL3224-0BE32-2AA0 without filter 6SL3224-0BE31-5UA0 6SL3224-0BE31-8UA0 6SL3224-0BE32-2UA0 Values based on Low Overload ●...
Page 274 Technical data 10.3 Technical data, Power Modules Table 10- 7 PM240 frame size F, 3-ph. 380 V AC… 480 V, ± 10 % Order number with filter 6SL3224-0BE34-5AA0 6SL3224-0BE35-5AA0 6SL3224-0BE37-5AA0 without filter 6SL3224-0BE34-5UA0 6SL3224-0BE35-5UA0 6SL3224-0BE37-5UA0 Values based on Low Overload ●...
Page 275 Technical data 10.3 Technical data, Power Modules Table 10- 9 PM240 frame size GX, 3-ph. 380 V AC… 480 V, ± 10 % Order number Without filter 6SL3224-0BE41-3UA0 6SL3224-0BE41-6UA0 6SL3224-0BE42-0UA0 Values based on Low Overload ● LO power 160 kW 200 kW 250 kW ●...
Page 276: Technical Data, Pm250
Technical data 10.3 Technical data, Power Modules 10.3.2 Technical data, PM250 General data, PM250 - IP20 Feature Version Line voltage 3-ph. 380 V … 480 V AC ± 10 % The actual permissible line voltage depends on the installation altitude Input frequency 47 Hz …...
Page 277 Technical data 10.3 Technical data, Power Modules Power-dependent data, PM250 - IP20 Table 10- 10 PM250 frame size C, 3-ph. 380 V AC… 480 V, ± 10 % Order number 6SL3225-0BE25-5AA0 6SL3225-0BE27-5AA0 6SL3225-0BE31-1AA0 Values based on Low Overload ● LO power 7.5 kW 11.0 kW 15 kW...
Page 278 Technical data 10.3 Technical data, Power Modules Table 10- 12 PM250 frame size E, 3-ph. 380 V AC… 480 V, ± 10 % Order number 6SL3225-0BE33-0AA0 6SL3225-0BE33-7AA0 Values based on Low Overload ● LO power 37 kW 45 kW ● LO input current 70 A 84 A ●...
Page 279: Technical Data, Pm260
Technical data 10.3 Technical data, Power Modules 10.3.3 Technical data, PM260 General data, PM260 - IP20 Feature Version Line voltage 3-ph. 660 V … 690 V AC ± 10% The permissible line voltage depends on the installation altitude The power units can also be operated with a minimum voltage of 500 V –10 %. In this case, the power is linearly reduced as required.
Page 280 Technical data 10.3 Technical data, Power Modules Power-dependent data, PM260 - IP20 Table 10- 14 PM260 frame size D, 3-ph. 660 V AC… 690 V, ± 10% (500 V - 10%) Order number with filter 6SL3225- 0BH27-5AA1 6SL3225- 0BH31-1AA1 6SL3225- 0BH31-5AA1 without filter 6SL3225- 0BH27-5UA1 6SL3225- 0BH31-1UA1...
Page 281: Appendix
6ES7390-1AE80-0AA0 PROFIBUS connector PROFIBUS connector 6ES7972-0BB50-0XA0 PROFIBUS cable PROFIBUS cable 6XV1830-3BH10 Converter SINAMICS G120 Control Unit CU240E-2 DP 6SL3244-0BB12-1PA1 SINAMICS G120 Power Module PROFIBUS connector PROFIBUS connector 6GK1500-0FC00 Inverter with CU240B-2 and CU240E-2 Control Units Operating Instructions, 01/2011, FW 4.4, A5E02299792B AB...
Page 282: Creating A Step 7 Project
Appendix A.1 Application Examples In order to configure communication you also require the following software packages: Table A- 2 Software components Component Type (or higher) Order no. SIMATIC STEP 7 V5.3 + SP3 6ES7810-4CC07-0YA5 STARTER V4.2 6SL3072-0AA00-0AG0 A.1.1.3 Creating a STEP 7 project PROFIBUS communication between the inverter and a SIMATIC control is configured using the SIMATIC STEP 7 and HW Config software tools.
Page 283: Configuring Communications To A Simatic Control
Appendix A.1 Application Examples When you add the SIMATIC 300, a window is displayed in which you can define the network. ● Create a PROFIBUS DP network. Figure A-2 Inserting a SIMATIC 300 station with PROFIBUS DP network A.1.1.4 Configuring communications to a SIMATIC control The inverter can be connected to a SIMATIC control in two ways: 1.
Page 284: Insert The Frequency Converter Into The Step 7 Project
Integrated Function Manual". 2. PKW channel (if one is used) 3. Standard, SIEMENS or free telegram (if one is used) 4. Slave-to-slave module If you do not use one or several of the modules 1, 2 or 3, configure the remaining modules starting with the 1st slot.
Page 285 Appendix A.1 Application Examples Note regarding the universal module It is not permissible to configure the universal module with the following properties: ● PZD length 4/4 words ● Consistent over the complete length With these properties, the universal module has the same DP identifier (4AX) as the "PKW channel 4 words"...
Page 286: Step 7 Program Examples
Appendix A.1 Application Examples A.1.2 STEP 7 program examples A.1.2.1 STEP 7 program example for cyclic communication The control and inverter communicate via standard telegram 1. The control specifies control word 1 (STW1) and the speed setpoint, while the inverter responds with status word 1 (ZSW1) and its actual speed.
Page 287 Appendix A.1 Application Examples Table A- 3 Assignment of the control bits in the inverter to the SIMATIC flags and inputs Bit in Significance Bit in Bit in Bit in Inputs STW1 ON/OFF1 E0.0 ON/OFF2 ON/OFF3 Operation enable Ramp-function generator enable Start ramp-function generator Setpoint enable Acknowledge fault...
Page 288: Step 7 Program Example For Acyclic Communication
The number of simultaneous requests for acyclic communication is limited. More detailed information can be found in the Data set communication (http://support.automation.siemens.com/WW/vie w/en/15364459). Inverter with CU240B-2 and CU240E-2 Control Units Operating Instructions, 01/2011, FW 4.4, A5E02299792B AB...
Page 289 Appendix A.1 Application Examples Figure A-3 Reading parameters Inverter with CU240B-2 and CU240E-2 Control Units Operating Instructions, 01/2011, FW 4.4, A5E02299792B AB...
Page 290 Appendix A.1 Application Examples Explanation of FC 1 Table A- 4 Request to read parameters Data block DB 1 Byte n Bytes n + 1 MB 40 Header Reference 01 hex: Read request MB 62 01 hex Numberof parameters (m) 10 hex: Parameter value MB 58 Address,...
Page 291 Appendix A.1 Application Examples Figure A-4 Writing parameters Explanation of FC 3 Table A- 5 Request to change parameters Data block DB 3 Byte n Bytes n + 1 MB 42 Header Reference 02 hex: Change request MB 44 01 hex Number of parameters 00 hex Address,...
Page 292: Configuring Slave-To-Slave Communication In Step 7
Appendix A.1 Application Examples A.1.3 Configuring slave-to-slave communication in STEP 7 Two drives communicate via standard telegram 1 with the higher-level control. In addition, drive 2 receives its speed setpoint directly from drive 1 (actual speed). Figure A-5 Communication with the higher-level control and between the drives with slave-to-slave communication Settings in the control In HW Config in drive 2 (Subscriber), insert a slave-to-...
Page 293 Appendix A.1 Application Examples ① Activate the tab "Address configuration". ② Select line 1. ③ Open the dialog box in which you define the Publisher and the address area to be transferred. ① Select DX for direct data exchange ② Select the PROFIBUS address of drive 1 (publisher).
Page 294: Additional Information On The Inverter
German, (http://support.automation.sie CU240B-2; CU240E-2 Italian, mens.com/WW/view/en/2233 French, 9653/133300) Getting Started Installing the Power Module Spanish SINAMICS G120 Power Order numbers: Module SD Manual Collection (DVD) Operating instructions (this manual) • 6SL3298-0CA00-0MG0 Function Manual for Safety Configuring PROFIsafe. English,...
Page 295 Support when configuring and selecting the converter Manual or tool Contents Languages Download or order number Catalog D 11.1 Ordering data and technical English, Everything about SINAMICS G120 information for the standard German, (www.siemens.en/sinamics-g120) SINAMICS G converters Italian, French, Spanish...
Page 296: Mistakes And Improvements
If you come across any mistakes when reading this manual or if you have any suggestions for how it can be improved, then please send your suggestions to the following address or by E-mail: Siemens AG Drive Technologies Motion Control Systems...
Page 297: Index
Index Binectors, 16 Bit pattern test, 223 Block, 16 Blocking protection, 211, 212 Boost parameter, 171 87 Hz characteristic, 36 BOP-2 Display, 66 Menu, 67 Brake Relay, 198 Braking Acceptance test, 232 Regenerative, 197 Authorized person, 232 Braking chopper, 195 Complete, 243 Braking method, 189 Preconditions, 232...
Page 298 Index Consistency, 223 Filter, 223 Consistent signals, 223 Tolerance time, 223 Contact bounce, 223 Display parameters, 13 Control Data Set, CDS, 155 Down ramp, 14 Control mode, 15, 62 Download, 23, 84, 86, 87 Control terminals, 64, 65 DP-V1 (PROFIBUS), 117 Control Unit Drive Data Set, DDS, 239 Updating, 233...
Page 299 Index Updating, 233 Inverter control, 148 Firmware version, 14, 234 Fixed speed, 49 Flow control, 210 Flying restart, 204, 205 JOG function, 164 Forced dormant error detection, 226 Jogging, 47, 51 Formatting, 82 Frame size, 24 Frame sizes, 24 FS (Frame Size), 24 Function blocks KTY 84 temperature sensor, 176 Free, 216, 218...
Page 300 Index Mode of operation, 235 PC Connection Kit, 22, 227 MOP (motorized potentiometer), 47, 160 Permitted sensors, 220 MotID (motor data identification), 69 PID controller, 210 Motor connection, 37 PKE, 111, 127 Motor control, 148 PKW (parameter, ID, value), 105 Motor holding brake, 187, 200, 201, 202 PLC functionality, 18 Motor standard, 183...
Page 301 Index Sensor Electromechanical, 221 Technical data Serial number, 234 Power Module, 268, 274, 277 Series commissioning, 233 Technology controller, 109, 210 Setpoint calculation, 148 Telegram 20, 52 Setpoint processing, 166 Telegram 352, 49 Setpoint source, 148 Telegram types, 105, 282 Selecting, 159, 161, 16514 Temperature calculation, 178 Selecting, 159, 161, 16514...
Page 302 Index Version Firmware, 234 Hardware, 234 Safety function, 234 Vertical conveyors, 168, 195, 198 Voltage boost, 15, 172 voltage input, 94 Winders, 168, 197 Wire break, 223 Wire-break monitoring, 95, 176 ZSW (status word), 105 ZSW1 (status word 1), 108 ZSW3 (status word 3), 110 Inverter with CU240B-2 and CU240E-2 Control Units Operating Instructions, 01/2011, FW 4.4, A5E02299792B AB...
Page 304 Siemens AG We reserve the right to make technical Industry Sector changes. Drive Technologies © Siemens AG 2011 Motion Control Systems Postfach 3180 91050 ERLANGEN GERMANY www.siemens.com/sinamics-g120...

Siemens SINAMICS G120 Operating Instructions Manual

1 Introduction

2 Description

3 Installing

4 Commissioning

5 Adapt Terminal Strip

6 Configuring the Fieldbus

7 Functions

8 Service and Maintenance

9 Alarms, Faults and System Messages

10 Technical Data

Appendix

Quick Links

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Summary of Contents for Siemens SINAMICS G120