Siemens SINAMICS G120 Operating Instructions Manual

Operating instructions

Low voltage converters

Chassis devices with CU240B-2 and CU240E-2

Control Units

SINAMICS G120

01/2017Edition

SINAMICS

www.siemens.com/drives

SINAMICS

SINAMICS G120

Converter with the CU240B-2 and

CU240E-2 Control Units

Operating Instructions

Edition 01/2017, Firmware V4.7 SP6

01/2017, FW V4.7 SP6

A5E34259001B AD

Changes in the current

manual

Fundamental safety

instructions

1

Introduction

2

Description

3

Installing

4

Commissioning

5

Advanced commissioning

6

Saving the settings and

series commissioning

7

Alarms, faults and system

messages

8

Corrective maintenance

9

Technical data

10

Appendix

A

Legal information

Warning notice system

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent

damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert

symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are

graded according to the degree of danger.

DANGER

indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING

indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION

indicates that minor personal injury can result if proper precautions are not taken.

NOTICE

indicates that property damage can result if proper precautions are not taken.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will be

used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property

damage.

Qualified Personnel

The product/system described in this documentation may be operated only by personnel qualified for the specific

task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified

personnel are those who, based on their training and experience, are capable of identifying risks and avoiding

potential hazards when working with these products/systems.

Proper use of Siemens products

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. The permissible

ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks

All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication

may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and software described.

Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in

this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AG

Division Digital Factory

Postfach 48 48

90026 NÜRNBERG

GERMANY

A5E34259001B AD

Ⓟ 01/2017 Subject to change

Changes in the current manual

Notable changes since the 01/2016 edition of the manual

New hardware

● New PM240P‑2 Power Modules, FSD … FSF

Power Module (Page 33)

● New version of the PM230 Power Modules, FSA … FSC, with article numbers

6SL32 . . ‑ . . . . ‑ . . G .

Detailed technical data, PM230 (Page 461)

Hardware that is no longer described in the manual

The following Power Modules are no longer described in the current edition of the manual:

● PM240 Power Module

● PM340 Power Module

● PM260 Power Module

Additional information is provided on the Internet:

PM240 Power Modules mounting instructions (https://support.industry.siemens.com/cs/ww/

en/view/109738501)

Installation Guide for the PM260 Power Module (https://support.industry.siemens.com/cs/ww/

en/view/79109730)

Corrections

● The 1PH8 induction motor may no longer be operated with the PM230 Power Module.

The encoderless permanently-excited SIMOTICS S 1FK7 synchronous motor and the

SIMOTICS 1FG1 may by operated on the inverter only on request.

Motors and multi-motor drives that can be operated (Page 49)

● We recommend that you also activate the friction characteristic when you use the "moment

of inertia estimator" function.

An appropriate note has been added to the description of the "moment of inertia estimator"

function.

Moment of inertia estimator (Page 293)

● After selecting the "Standard Drive Control" application class, the inverter activates the slip

compensation.

An appropriate note has been added to the description of the "U/f control" function.

V/f control (Page 276)

Converter with the CU240B-2 and CU240E-2 Control Units

Operating Instructions, 01/2017, FW V4.7 SP6, A5E34259001B AD 5

● After selecting the "Standard Drive Control" application class, only the settings p1900 = 0

or 2 are possible for the motor data identification. The settings p1900 = 1, 3, 11 and 12

have been removed.

Standard Drive Control (Page 158)

Standard Drive Control (Page 138)

● For an inverter replacement, the permissible minimum ratio of the motor/inverter rated

power is changed from 1/8 to 1/4.

Replacing inverter components (Page 396)

Further revised chapters

● Summary of the directives and standards relevant for the inverter

Directives and standards (Page 29)

● Description of the differences for star and delta connection of an induction motor augmented

Connecting the motor to the inverter in a star or delta connection (Page 84)

● New designations -X… of the terminals on the Control Unit augmented

Overview of the interfaces (Page 91)

● Sorting of the inverter functions changed, new "Energy saving" and "Availability" categories

Overview of the inverter functions (Page 173)

● Graphic augmented

Motor and inverter protection by limiting the voltage (Page 322)

● LED symbols augmented, tables revised

Operating states indicated on LEDs (Page 374)

● Descriptions shortened and graphics simplified

Alarms, alarm buffer, and alarm history (Page 379)

Faults, alarm buffer and alarm history (Page 382)

● Fault and alarm lists combined to form a common list

List of alarms and faults (Page 386)

● The description for the firmware upgrade or downgrade extended, graphics revised

Firmware upgrade and downgrade (Page 409)

● The description for the setting of the resistance braking revised

Dynamic braking (Page 309)

● The description for the "Calculating the energy saving for fluid flow machines" function

revised

Calculating the energy saving for fluid flow machines (Page 343)

● The description for the know-how protection revised

Know-how protection (Page 366)

● The special requirements placed on the EMC-conform installation for use of fail-safe digital

inputs are augmented.

Connecting a fail-safe digital input (Page 496)

Changes in the current manual

Converter with the CU240B-2 and CU240E-2 Control Units

6 Operating Instructions, 01/2017, FW V4.7 SP6, A5E34259001B AD

Table of contents

Changes in the current manual....................................................................................................................5

1 Fundamental safety instructions.................................................................................................................15

1.1 General safety instructions.....................................................................................................15

1.2 Handling electrostatic sensitive devices (ESD)......................................................................20

1.3 Industrial security...................................................................................................................21

1.4 Residual risks of power drive systems...................................................................................22

2 Introduction.................................................................................................................................................23

2.1 About the Manual...................................................................................................................23

2.2 Guide through the manual......................................................................................................24

3 Description..................................................................................................................................................27

3.1 Identifying the converter.........................................................................................................28

3.2 Directives and standards........................................................................................................29

3.3 Overview of Control Units......................................................................................................31

3.4 Power Module........................................................................................................................33

3.4.1 Power Module with IP20 degree of protection.......................................................................34

3.4.2 Power Module with Push-Through technology.......................................................................36

3.4.3 Power Module in IP55 degree of protection / UL Type 12.....................................................37

3.5 Components for the Power Modules......................................................................................38

3.5.1 Accessories for shielding.......................................................................................................38

3.5.2 Line filter.................................................................................................................................39

3.5.3 Line reactor............................................................................................................................40

3.5.4 Output reactor........................................................................................................................42

3.5.5 Sine-wave filter.......................................................................................................................45

3.5.6 Braking resistor......................................................................................................................46

3.5.7 Brake Relay............................................................................................................................48

3.5.8 Safe Brake Relay...................................................................................................................48

3.6 Motors and multi-motor drives that can be operated..............................................................49

4 Installing.....................................................................................................................................................51

4.1 EMC-compliant setup of the machine or plant.......................................................................51

4.1.1 Control cabinet.......................................................................................................................52

4.1.2 Cables....................................................................................................................................53

4.1.3 Electromechanical components.............................................................................................56

4.2 Installing reactors, filters and braking resistors......................................................................57

4.3 Installing Power Modules.......................................................................................................58

4.3.1 Basic installation rules............................................................................................................58

4.3.2 Dimensioned drawings, drilling dimensions for the PM240-2 Power Module, IP20...............59

4.3.3 Dimension drawings, drilling dimensions for PM240P-2, IP20...............................................61

Converter with the CU240B-2 and CU240E-2 Control Units

Operating Instructions, 01/2017, FW V4.7 SP6, A5E34259001B AD 7

4.3.4 Dimension drawings, drilling dimensions for the PM230 Power Module, IP20......................63

4.3.5 Dimension drawings, drilling dimensions for PM230 and PM240-2 Power Modules

utilizing push-through technology...........................................................................................65

4.3.6 Dimensioned drawings, drilling dimensions for the PM250 Power Module............................67

4.4 Connecting the line supply, motor, and inverter components................................................69

4.4.1 TN line system.......................................................................................................................69

4.4.2 TT line system........................................................................................................................71

4.4.3 IT system................................................................................................................................72

4.4.4 Protective conductor..............................................................................................................72

4.4.5 Connecting an inverter with the PM240-2 Power Module......................................................74

4.4.6 Connecting the inverter with the PM230 Power Module........................................................78

4.4.7 Connecting the inverter with the PM240P-2 Power Module...................................................80

4.4.8 Connecting the inverter with the PM250 Power Module........................................................82

4.4.9 Connecting the motor to the inverter in a star or delta connection.........................................84

4.4.10 Connecting a motor holding brake.........................................................................................85

4.4.10.1 Installing a Brake Relay - PM250 Power Module...................................................................87

4.4.10.2 Mounting and connecting the brake relay..............................................................................88

4.5 Installing Control Unit.............................................................................................................89

4.5.1 Overview of the interfaces......................................................................................................91

4.5.2 Fieldbus interface allocation...................................................................................................92

4.5.3 Terminal strips on CU240B-2 Control Units...........................................................................93

4.5.4 Factory setting of the CU240B-2 interfaces...........................................................................95

4.5.5 Default settings of the CU240B-2 interfaces..........................................................................97

4.5.6 Terminal strips on CU240E-2 Control Units.........................................................................101

4.5.7 Factory setting of the CU240E-2 interfaces.........................................................................104

4.5.8 Default settings of the CU240E-2 interfaces........................................................................106

4.5.9 Safety input of the CU240E-2..............................................................................................116

4.5.10 Wiring the terminal strip.......................................................................................................118

4.5.11 Connecting the temperature contact of the braking resistor................................................120

4.6 Connecting the inverter to the fieldbus.................................................................................121

4.6.1 PROFINET...........................................................................................................................121

4.6.1.1 Communication via PROFINET IO and Ethernet.................................................................121

4.6.1.2 Connecting the PROFINET cable to the inverter.................................................................123

4.6.1.3 What do you have to set for communication via PROFINET?.............................................123

4.6.1.4 Installing GSDML.................................................................................................................124

4.6.2 PROFIBUS...........................................................................................................................125

4.6.2.1 Connecting the PROFIBUS cable to the inverter.................................................................125

4.6.2.2 What do you have to set for communication via PROFIBUS?.............................................126

4.6.2.3 Installing the GSD................................................................................................................127

4.6.2.4 Setting the address..............................................................................................................127

5 Commissioning.........................................................................................................................................129

5.1 Commissioning guidelines...................................................................................................129

5.2 Tools to commission the inverter.........................................................................................130

5.3 Preparing for commissioning................................................................................................131

5.3.1 Collecting motor data...........................................................................................................131

5.3.2 Inverter factory setting..........................................................................................................132

5.4 Quick commissioning using the BOP-2 operator panel........................................................134

5.4.1 Inserting the BOP-2..............................................................................................................134

Table of contents

Converter with the CU240B-2 and CU240E-2 Control Units

8 Operating Instructions, 01/2017, FW V4.7 SP6, A5E34259001B AD

5.4.2 Overview of quick commissioning........................................................................................135

5.4.3 Start quick commissioning and select the application class.................................................136

5.4.4 Standard Drive Control.........................................................................................................138

5.4.5 Dynamic Drive Control.........................................................................................................140

5.4.6 Expert...................................................................................................................................142

5.4.7 Identifying the motor data and optimizing the closed-loop control.......................................147

5.5 Quick commissioning with a PC...........................................................................................149

5.5.1 Creating a project.................................................................................................................149

5.5.2 Transfer inverters connected via USB into the project.........................................................150

5.5.3 Go online and start quick commissioning.............................................................................153

5.5.4 Overview of quick commissioning........................................................................................154

5.5.5 Select the application class..................................................................................................155

5.5.6 Standard Drive Control.........................................................................................................158

5.5.7 Dynamic Drive Control.........................................................................................................159

5.5.8 Expert...................................................................................................................................160

5.5.9 Identify motor data...............................................................................................................163

5.6 Restoring the factory setting................................................................................................166

5.6.1 Resetting the safety functions to the factory setting.............................................................167

5.6.2 Restore the factory settings (without safety functions).........................................................170

6 Advanced commissioning.........................................................................................................................173

6.1 Overview of the inverter functions........................................................................................173

6.2 Sequence control when switching the motor on and off.......................................................176

6.3 Adapt the default setting of the terminal strip.......................................................................178

6.3.1 Digital inputs.........................................................................................................................179

6.3.2 Digital outputs......................................................................................................................181

6.3.3 Analog inputs.......................................................................................................................183

6.3.4 Analog outputs.....................................................................................................................187

6.4 Controlling clockwise and counter-clockwise rotation via digital inputs...............................190

6.4.1 Two-wire control, method 1..................................................................................................191

6.4.2 Two-wire control, method 2..................................................................................................192

6.4.3 Two-wire control, method 3..................................................................................................193

6.4.4 Three-wire control, method 1...............................................................................................194

6.4.5 Three-wire control, method 2...............................................................................................195

6.5 Drive control via PROFIBUS or PROFINET.........................................................................196

6.5.1 Control and status word 1....................................................................................................198

6.5.2 Control and status word 3....................................................................................................201

6.5.3 NAMUR message word........................................................................................................203

6.5.4 Data structure of the parameter channel..............................................................................204

6.5.5 Examples for using the parameter channel..........................................................................207

6.5.6 Extend telegrams and change signal interconnection..........................................................209

6.5.7 Slave-to-slave communication.............................................................................................211

6.5.8 Acyclically reading and writing inverter parameters.............................................................211

6.6 Drive control via Modbus RTU.............................................................................................212

6.7 Drive control via USS...........................................................................................................215

6.8 Drive control via Ethernet/IP................................................................................................218

6.9 Jogging.................................................................................................................................219

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Converter with the CU240B-2 and CU240E-2 Control Units

Operating Instructions, 01/2017, FW V4.7 SP6, A5E34259001B AD 9

6.10 Switching over the drive control (command data set)..........................................................220

6.11 Motor holding brake.............................................................................................................222

6.12 Free function blocks.............................................................................................................226

6.12.1 Overview..............................................................................................................................226

6.12.2 Further information...............................................................................................................226

6.13 Selecting physical units........................................................................................................227

6.13.1 Select the motor standard....................................................................................................227

6.13.2 Selecting the system of units...............................................................................................227

6.13.3 Selecting the technological unit of the technology controller...............................................229

6.13.4 Setting the motor standard, system of units and technology unit using STARTER.............229

6.14 Safe Torque Off (STO) safety function.................................................................................231

6.14.1 Function description.............................................................................................................231

6.14.2 Commissioning STO............................................................................................................233

6.14.2.1 Safety functions password...................................................................................................234

6.14.2.2 Configuring a safety function................................................................................................235

6.14.2.3 Interconnecting the "STO active" signal...............................................................................237

6.14.2.4 Setting the filter for fail-safe digital inputs............................................................................239

6.14.2.5 Setting the forced checking procedure (test stop)................................................................241

6.14.2.6 Activating the settings and checking the digital inputs.........................................................244

6.14.2.7 Acceptance - completion of commissioning.........................................................................248

6.15 Setpoints..............................................................................................................................251

6.15.1 Overview..............................................................................................................................251

6.15.2 Analog input as setpoint source...........................................................................................252

6.15.3 Specifying the setpoint via the fieldbus................................................................................253

6.15.4 Motorized potentiometer as setpoint source........................................................................254

6.15.5 Fixed speed setpoint as setpoint source..............................................................................256

6.16 Setpoint calculation..............................................................................................................259

6.16.1 Overview of setpoint processing..........................................................................................259

6.16.2 Invert setpoint.......................................................................................................................260

6.16.3 Inhibit direction of rotation....................................................................................................261

6.16.4 Skip frequency bands and minimum speed.........................................................................262

6.16.5 Speed limitation....................................................................................................................263

6.16.6 Ramp-function generator.....................................................................................................264

6.17 PID technology controller.....................................................................................................269

6.18 Motor control........................................................................................................................275

6.18.1 Reactor, filter and cable resistance at the inverter output....................................................275

6.18.2 V/f control.............................................................................................................................276

6.18.2.1 Characteristics of U/f control................................................................................................278

6.18.2.2 Optimizing motor starting.....................................................................................................281

6.18.2.3 Optimizing the motor startup for application class Standard Drive Control..........................283

6.18.3 Sensorless vector control with speed controller...................................................................285

6.18.3.1 Overview..............................................................................................................................285

6.18.3.2 Optimizing the closed-loop speed controller........................................................................286

6.18.3.3 Advanced settings................................................................................................................289

6.18.3.4 Friction characteristic...........................................................................................................291

6.18.3.5 Moment of inertia estimator..................................................................................................293

6.18.3.6 Pole position identification....................................................................................................299

6.18.4 Torque control......................................................................................................................300

Table of contents

Converter with the CU240B-2 and CU240E-2 Control Units

10 Operating Instructions, 01/2017, FW V4.7 SP6, A5E34259001B AD

6.19 Electrically braking the motor...............................................................................................302

6.19.1 DC braking...........................................................................................................................304

6.19.2 Compound braking...............................................................................................................307

6.19.3 Dynamic braking..................................................................................................................309

6.19.4 Braking with regenerative feedback to the line....................................................................311

6.20 Overcurrent protection.........................................................................................................312

6.21 Inverter protection using temperature monitoring................................................................313

6.22 Motor protection with temperature sensor............................................................................316

6.23 Motor protection by calculating the temperature..................................................................319

6.24 Motor and inverter protection by limiting the voltage............................................................322

6.25 Monitoring the driven load....................................................................................................324

6.25.1 Stall protection.....................................................................................................................325

6.25.2 No-load monitoring...............................................................................................................325

6.25.3 Stall protection.....................................................................................................................326

6.25.4 Torque monitoring................................................................................................................327

6.25.5 Blocking protection, leakage protection and dry-running protection....................................328

6.25.6 Rotation monitoring..............................................................................................................330

6.25.7 Speed deviation monitoring..................................................................................................331

6.26 Flying restart – switching on while the motor is running.......................................................333

6.27 Automatic restart..................................................................................................................335

6.28 Kinetic buffering (Vdc min control).......................................................................................339

6.29 Line contactor control...........................................................................................................341

6.30 Calculating the energy saving for fluid flow machines.........................................................343

6.31 Switchover between different settings..................................................................................345

7 Saving the settings and series commissioning.........................................................................................347

7.1 Backing up and transferring settings using a memory card.................................................348

7.1.1 Memory cards......................................................................................................................348

7.1.2 Saving setting on memory card............................................................................................349

7.1.3 Transferring the setting from the memory card....................................................................352

7.1.4 Safely remove the memory card..........................................................................................355

7.2 Saving the settings to a PC..................................................................................................357

7.3 Saving settings to an operator panel....................................................................................361

7.4 Other ways to back up settings............................................................................................363

7.5 Write protection....................................................................................................................364

7.6 Know-how protection............................................................................................................366

7.6.1 Extending the exception list for know-how protection..........................................................369

7.6.2 Activating and deactivating know-how protection................................................................370

8 Alarms, faults and system messages.......................................................................................................373

8.1 Operating states indicated on LEDs.....................................................................................374

8.2 System runtime....................................................................................................................377

Table of contents

Converter with the CU240B-2 and CU240E-2 Control Units

Operating Instructions, 01/2017, FW V4.7 SP6, A5E34259001B AD 11

8.3 Identification & maintenance data (I&M)..............................................................................378

8.4 Alarms, alarm buffer, and alarm history...............................................................................379

8.5 Faults, alarm buffer and alarm history..................................................................................382

8.6 List of alarms and faults.......................................................................................................386

9 Corrective maintenance............................................................................................................................395

9.1 Spare parts compatibility......................................................................................................395

9.2 Replacing inverter components............................................................................................396

9.2.1 Overview of replacing converter components......................................................................396

9.2.2 Replacing a Control Unit with enabled safety function.........................................................398

9.2.3 Replacing the Control Unit without the safety functions enabled.........................................402

9.2.4 Replacing the Control Unit without data backup..................................................................404

9.2.5 Replacing a Control Unit with active know-how protection..................................................404

9.2.6 Replacing a Power Module with enabled safety function.....................................................407

9.2.7 Replacing a Power Module without the safety function being enabled................................408

9.3 Firmware upgrade and downgrade......................................................................................409

9.3.1 Upgrading the firmware........................................................................................................411

9.3.2 Firmware downgrade...........................................................................................................413

9.3.3 Correcting an unsuccessful firmware upgrade or downgrade..............................................415

9.4 Reduced acceptance after component replacement and firmware change.........................416

9.5 If the converter no longer responds.....................................................................................417

10 Technical data..........................................................................................................................................419

10.1 Technical data, CU240B-2 Control Unit...............................................................................419

10.2 Technical data, CU240E-2 Control Unit...............................................................................421

10.3 Overload capability of the inverter........................................................................................424

10.4 Technical data, PM240-2 Power Module.............................................................................425

10.4.1 High overload - low overload PM240-2................................................................................425

10.4.2 General technical data, 200 V inverters...............................................................................427

10.4.3 Specific technical data, 200 V inverters...............................................................................428

10.4.4 Current derating depending on the pulse frequency, 200 V inverters..................................433

10.4.5 General technical data, 400 V inverters...............................................................................434

10.4.6 Specific technical data, 400 V inverters...............................................................................435

10.4.7 Current derating depending on the pulse frequency, 400 V inverters..................................441

10.4.8 General technical data, 690 V inverters...............................................................................442

10.4.9 Specific technical data, 690 V inverters...............................................................................443

10.4.10 Current derating depending on the pulse frequency, 690 V inverters..................................446

10.5 Technical Data, PM240P-2 Power Module..........................................................................447

10.5.1 Ambient conditions...............................................................................................................447

10.5.2 General technical data, 400 V inverters...............................................................................449

10.5.3 Specific technical data, 400 V inverters...............................................................................450

10.5.4 Current derating depending on the pulse frequency, 400 V inverters..................................452

10.5.5 General technical data, 690 V inverters...............................................................................453

10.5.6 Specific technical data, 690 V inverters...............................................................................454

10.5.7 Current derating depending on the pulse frequency, 690 V inverters..................................457

10.6 Technical data, PM230 Power Module................................................................................458

Table of contents

Converter with the CU240B-2 and CU240E-2 Control Units

12 Operating Instructions, 01/2017, FW V4.7 SP6, A5E34259001B AD

10.6.1 Ambient conditions...............................................................................................................458

10.6.2 General technical data, PM230............................................................................................460

10.6.3 Detailed technical data, PM230...........................................................................................461

10.6.4 Current reduction depending on pulse frequency................................................................466

10.7 Technical data, PM250 Power Module................................................................................467

10.7.1 High Overload - Low Overload.............................................................................................467

10.7.2 Ambient conditions...............................................................................................................467

10.7.3 General technical data, PM250............................................................................................469

10.7.4 Specific technical data, PM250............................................................................................470

10.7.5 Current reduction depending upon pulse frequency............................................................472

10.8 Data regarding the power loss in partial load operation.......................................................473

10.9 Restrictions for special ambient conditions..........................................................................474

10.9.1 PM240-2 and PM240P-2 Power Modules: Current reduction as a function of the

installation altitude and ambient temperature......................................................................474

10.9.2 PM230 and PM250 Power Modules: Current derating depending on the ambient air

temperature..........................................................................................................................475

A Appendix...................................................................................................................................................477

A.1 New and extended functions................................................................................................477

A.1.1 Firmware version 4.7 SP6....................................................................................................477

A.1.2 Firmware version 4.7 SP3....................................................................................................478

A.1.3 Firmware version 4.7............................................................................................................480

A.1.4 Firmware version 4.6 SP6....................................................................................................481

A.1.5 Firmware version 4.6............................................................................................................482

A.1.6 Firmware version 4.5............................................................................................................483

A.2 Handling the BOP 2 operator panel.....................................................................................484

A.2.1 Changing settings using BOP-2...........................................................................................485

A.2.2 Changing indexed parameters.............................................................................................486

A.2.3 Directly entering the parameter number and value..............................................................487

A.2.4 A parameter cannot be changed..........................................................................................488

A.3 The device trace in STARTER.............................................................................................489

A.4 Interconnecting signals in the inverter..................................................................................492

A.4.1 Fundamentals......................................................................................................................492

A.4.2 Example...............................................................................................................................494

A.5 Connecting a fail-safe digital input.......................................................................................496

A.6 Acceptance tests for the safety functions.............................................................................498

A.6.1 Recommended acceptance test...........................................................................................498

A.6.2 Machine documentation.......................................................................................................501

A.6.3 Documenting the settings for the basic functions, firmware V4.4 ... V4.7 SP6....................503

A.7 Manuals and technical support............................................................................................504

A.7.1 Overview of the manuals......................................................................................................504

A.7.2 Configuring support..............................................................................................................506

A.7.3 Product Support...................................................................................................................507

A.8 Mistakes and improvements................................................................................................508

Index.........................................................................................................................................................509

Table of contents

Converter with the CU240B-2 and CU240E-2 Control Units

Operating Instructions, 01/2017, FW V4.7 SP6, A5E34259001B AD 13

Table of contents

Converter with the CU240B-2 and CU240E-2 Control Units

14 Operating Instructions, 01/2017, FW V4.7 SP6, A5E34259001B AD

Fundamental safety instructions

1

1.1 General safety instructions

DANGER

Danger to life due to live parts and other energy sources

Death or serious injury can result when live parts are touched.

● Only work on electrical devices when you are qualified for this job.

● Always observe the country-specific safety rules.

Generally, six steps apply when establishing safety:

1. Prepare for shutdown and notify all those who will be affected by the procedure.

2. Disconnect the machine from the supply.

– Switch off the machine.

– Wait until the discharge time specified on the warning labels has elapsed.

– Check that it really is in a no-voltage condition, from phase conductor to phase

conductor and phase conductor to protective conductor.

– Check whether the existing auxiliary supply circuits are de-energized.

– Ensure that the motors cannot move.

3. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or

water.

4. Isolate or neutralize all hazardous energy sources by closing switches, grounding or short-

circuiting or closing valves, for example.

5. Secure the energy sources against switching on again.

6. Ensure that the correct machine is completely interlocked.

After you have completed the work, restore the operational readiness in the inverse sequence.

WARNING

Danger to life through a hazardous voltage when connecting an unsuitable power supply

Touching live components can result in death or severe injury.

● Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV-

(Protective Extra Low Voltage) output voltages for all connections and terminals of the

electronics modules.

Converter with the CU240B-2 and CU240E-2 Control Units

Operating Instructions, 01/2017, FW V4.7 SP6, A5E34259001B AD 15

WARNING

Danger to life when live parts are touched on damaged devices

Improper handling of devices can cause damage.

For damaged devices, hazardous voltages can be present at the enclosure or at exposed

components; if touched, this can result in death or severe injury.

● Ensure compliance with the limit values specified in the technical data during transport,

storage and operation.

● Do not use any damaged devices.

WARNING

Danger to life through electric shock due to unconnected cable shields

Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected

cable shields.

● As a minimum, connect cable shields and the conductors of power cables that are not

used (e.g. brake cores) at one end at the grounded housing potential.

WARNING

Danger to life due to electric shock when not grounded

For missing or incorrectly implemented protective conductor connection for devices with

protection class I, high voltages can be present at open, exposed parts, which when touched,

can result in death or severe injury.

● Ground the device in compliance with the applicable regulations.

WARNING

Danger to life due to electric shock when opening plug connections in operation

When opening plug connections in operation, arcs can result in severe injury or death.

● Only open plug connections when the equipment is in a no-voltage state, unless it has

been explicitly stated that they can be opened in operation.

WARNING

Danger to life through electric shock due to the residual charge of the power component

capacitors

Because of the capacitors, a hazardous voltage is present for up to 5 minutes after the power

supply has been switched off. Contact with live parts can result in death or serious injury.

● Wait for 5 minutes before you check that the unit really is in a no-voltage condition and

start work.

Fundamental safety instructions

1.1 General safety instructions

Converter with the CU240B-2 and CU240E-2 Control Units

16 Operating Instructions, 01/2017, FW V4.7 SP6, A5E34259001B AD

NOTICE

Material damage due to loose power connections

Insufficient tightening torques or vibrations can result in loose electrical connections. This can

result in damage due to fire, device defects or malfunctions.

● Tighten all power connections with the specified tightening torques, e.g. line supply

connection, motor connection, DC link connections.

● Check all power connections at regular intervals. This applies in particular after transport.

WARNING

Danger to life due to fire spreading if housing is inadequate

Fire and smoke development can cause severe personal injury or material damage.

● Install devices without a protective housing in a metal control cabinet (or protect the device

by another equivalent measure) in such a way that contact with fire is prevented.

● Ensure that smoke can only escape via controlled and monitored paths.

WARNING

Danger to life from electromagnetic fields

Electromagnetic fields (EMF) are generated by the operation of electrical power equipment,

such as transformers, converters, or motors.

People with pacemakers or implants are at particular risk in the immediate vicinity of this

equipment.

● If you have a heart pacemaker or implant, maintain a minimum distance of 2 m from

electrical power equipment.

WARNING

Danger to life through unexpected movement of machines when using mobile wireless

devices or mobile phones

Using mobile wireless devices or mobile phones with a transmit power > 1 W closer than

approx. 2 m to the components may cause the devices to malfunction, influence the functional

safety of machines therefore putting people at risk or causing material damage.

● Switch the wireless devices or mobile phones off in the immediate vicinity of the

components.

Fundamental safety instructions

1.1 General safety instructions

Converter with the CU240B-2 and CU240E-2 Control Units

Operating Instructions, 01/2017, FW V4.7 SP6, A5E34259001B AD 17

WARNING

Danger to life due to the motor catching fire in the event of insulation overload

There is higher stress on the motor insulation through a ground fault in an IT system. If the

insulation fails, it is possible that death or severe injury can occur as a result of smoke and

fire.

● Use a monitoring device that signals an insulation fault.

● Correct the fault as quickly as possible so the motor insulation is not overloaded.

WARNING

Danger to life due to fire if overheating occurs because of insufficient ventilation clearances

Inadequate ventilation clearances can cause overheating of components with subsequent

fire and smoke. This can cause severe injury or even death. This can also result in increased

downtime and reduced service lives for devices/systems.

● Ensure compliance with the specified minimum clearance as ventilation clearance for the

respective component.

WARNING

Danger of an accident occurring due to missing or illegible warning labels

Missing or illegible warning labels can result in accidents involving death or serious injury.

● Check that the warning labels are complete based on the documentation.

● Attach any missing warning labels to the components, in the national language if

necessary.

● Replace illegible warning labels.

NOTICE

Device damage caused by incorrect voltage/insulation tests

Incorrect voltage/insulation tests can damage the device.

● Before carrying out a voltage/insulation check of the system/machine, disconnect the

devices as all converters and motors have been subject to a high voltage test by the

manufacturer, and therefore it is not necessary to perform an additional test within the

system/machine.

Fundamental safety instructions

1.1 General safety instructions

Converter with the CU240B-2 and CU240E-2 Control Units

18 Operating Instructions, 01/2017, FW V4.7 SP6, A5E34259001B AD

WARNING

Danger to life when safety functions are inactive

Safety functions that are inactive or that have not been adjusted accordingly can cause

operational faults on machines that could lead to serious injury or death.

● Observe the information in the appropriate product documentation before commissioning.

● Carry out a safety inspection for functions relevant to safety on the entire system, including

all safety-related components.

● Ensure that the safety functions used in your drives and automation tasks are adjusted

and activated through appropriate parameterizing.

● Perform a function test.

● Only put your plant into live operation once you have guaranteed that the functions relevant

to safety are running correctly.

Note

Important safety notices for Safety Integrated functions

If you want to use Safety Integrated functions, you must observe the safety notices in the Safety

Integrated manuals.

WARNING

Danger to life or malfunctions of the machine as a result of incorrect or changed

parameterization

As a result of incorrect or changed parameterization, machines can malfunction, which in turn

can lead to injuries or death.

● Protect the parameterization (parameter assignments) against unauthorized access.

● Respond to possible malfunctions by applying suitable measures (e.g. EMERGENCY

STOP or EMERGENCY OFF).

Fundamental safety instructions

1.1 General safety instructions

Converter with the CU240B-2 and CU240E-2 Control Units

Operating Instructions, 01/2017, FW V4.7 SP6, A5E34259001B AD 19

1.2 Handling electrostatic sensitive devices (ESD)

Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules

or devices that may be damaged by either electric fields or electrostatic discharge.

NOTICE

Damage through electric fields or electrostatic discharge

Electric fields or electrostatic discharge can cause malfunctions through damaged individual

components, integrated circuits, modules or devices.

● Only pack, store, transport and send electronic components, modules or devices in their

original packaging or in other suitable materials, e.g conductive foam rubber of aluminum

foil.

● Only touch components, modules and devices when you are grounded by one of the

following methods:

– Wearing an ESD wrist strap

– Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring

● Only place electronic components, modules or devices on conductive surfaces (table with

ESD surface, conductive ESD foam, ESD packaging, ESD transport container).

Fundamental safety instructions

1.2 Handling electrostatic sensitive devices (ESD)

Converter with the CU240B-2 and CU240E-2 Control Units

20 Operating Instructions, 01/2017, FW V4.7 SP6, A5E34259001B AD

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Siemens SINAMICS G120 Operating Instructions Manual

Siemens SINAMICS G120 Operating Instructions Manual

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