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SINAMICS G120

Siemens SINAMICS G120 Operating Instructions Manual

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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
Copyright © Siemens AG 2010 - 2017.
All rights reserved
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
Table of contents
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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