Siemens SINAMICS G120 User manual

Operating instructions
Low voltage inverters
Built-in units with CU250S-2 Control Units and
encoder evaluation
SINAMICS G120
04/2018Edition
SINAMICS
www.siemens.com/drives

SINAMICS
SINAMICS G120
Converter with the CU250S-2
Control Units
Operating Instructions
Edition 04/2018, Firmware V4.7 SP10
04/2018, FW V4.7 SP10
A5E31759476B AG
Changes in the current edition
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
A5E31759476B AG
Ⓟ 04/2018 Subject to change
Copyright © Siemens AG 2013 - 2018.
All rights reserved

Changes in the current edition
Essential changes with respect to Edition 09/2017
New hardware
● PM240-2 Power Module, FSG
Power Module with IP20 degree of protection (Page 35)
Dimensioned drawings, drilling dimensions for the PM240-2 Power Module, IP20
(Page 62)
Specific technical data, 400 V inverters (Page 457)
Specific technical data, 690 V inverters (Page 467)
New functions
Firmware version 4.7 SP10 (Page 481)
Corrections
● Article number of the PM240-2 PT Power Module, 132 kW, corrected.
Technical data, PM240-2 Power Modules (Page 445)
● Dimensions of the PM240-2 Power Module corrected.
Dimensioned drawings, drilling dimensions for the PM240-2 Power Module, IP20
(Page 62)
● Setting the feedback signal for the line contactor control corrected.
Line contactor control (Page 355)
● SSI encoder and Endat 2.1 encoder are permissible for speed control.
Installing encoders (Page 121)
● PROFIdrive control word 2, bit 8 corrected
PROFIdrive status word 2, bit 7 corrected
Telegrams (Page 184)
Revised descriptions
● Only commissioning using the Startdrive PC-based tool is described. Commissioning with
STARTER has been removed.
Exceptions: Write and know-how protection.
You can find information on commissioning with STARTER on the Internet:
Operating Instructions, 09/2017 Edition (https://support.industry.siemens.com/cs/ww/
en/view/109751322)
Converter with the CU250S-2 Control Units
Operating Instructions, 04/2018, FW V4.7 SP10, A5E31759476B AG 3

Changes in the current edition
Converter with the CU250S-2 Control Units
4Operating Instructions, 04/2018, FW V4.7 SP10, A5E31759476B AG

Table of contents
Changes in the current edition......................................................................................................................3
1Fundamental safety instructions.................................................................................................................13
1.1 General safety instructions.....................................................................................................13
1.2 Equipment damage due to electric fields or electrostatic discharge......................................19
1.3 Warranty and liability for application examples......................................................................20
1.4 Industrial security...................................................................................................................21
1.5 Residual risks of power drive systems...................................................................................23
2 Introduction.................................................................................................................................................25
2.1 About the Manual...................................................................................................................25
2.2 Guide through the manual......................................................................................................26
3 Description..................................................................................................................................................29
3.1 Identifying the converter.........................................................................................................30
3.2 Directives and standards........................................................................................................31
3.3 Overview of Control Units......................................................................................................33
3.4 Power Modules......................................................................................................................34
3.4.1 Power Module with IP20 degree of protection.......................................................................35
3.4.2 Power Module with Push-Through technology.......................................................................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 du/dt filter plus VPL................................................................................................................45
3.5.6 Sine-wave filter.......................................................................................................................47
3.5.7 Braking resistor......................................................................................................................48
3.5.8 Brake Relay............................................................................................................................50
3.5.9 Safe Brake Relay...................................................................................................................50
3.6 Motors and multi-motor drives that can be operated..............................................................51
3.7 Encoder and Sensor Module..................................................................................................52
4 Installing.....................................................................................................................................................53
4.1 EMC-compliant installation of a machine or system..............................................................53
4.1.1 Control cabinet.......................................................................................................................54
4.1.2 Cables....................................................................................................................................55
4.1.3 Electromechanical components.............................................................................................58
4.2 Installing reactors, filters and braking resistors......................................................................59
4.3 Installing Power Modules.......................................................................................................60
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4.3.1 Basic installation rules for built-in units..................................................................................60
4.3.2 Dimensioned drawings, drilling dimensions for the PM240-2 Power Module, IP20...............62
4.3.3 Dimension drawings, drilling dimensions for PM240-2 Power Modules in push-through
technology..............................................................................................................................65
4.3.4 Dimensioned drawings, drilling dimensions for the PM250 Power Module............................69
4.4 Connecting the line supply and motor....................................................................................72
4.4.1 Permissible line supplies........................................................................................................72
4.4.1.1 TN line system.......................................................................................................................73
4.4.1.2 TT line system........................................................................................................................75
4.4.1.3 IT system................................................................................................................................76
4.4.2 Protective conductor..............................................................................................................77
4.4.3 Connecting an inverter with the PM240-2 Power Module......................................................79
4.4.4 Connecting the inverter with the PM250 Power Module........................................................84
4.4.5 Connecting the motor to the inverter in a star or delta connection.........................................86
4.4.6 Connecting a motor holding brake.........................................................................................87
4.4.6.1 Installing a Brake Relay - PM250 Power Module...................................................................89
4.4.6.2 Installing a Brake Relay - PM240-2 Power Module................................................................90
4.5 Connecting the interfaces for the inverter control..................................................................91
4.5.1 Overview of the interfaces on the front and upper side..........................................................92
4.5.2 Terminal strips behind the upper front door...........................................................................93
4.5.3 Terminal strips behind the lower front door............................................................................94
4.5.4 Fieldbus and encoder interfaces on the lower side................................................................95
4.5.5 Factory interface settings.......................................................................................................96
4.5.6 Default setting of the interfaces..............................................................................................98
4.5.7 Fail-safe digital input............................................................................................................109
4.5.8 Wire up the terminal strip and connect the shield................................................................110
4.5.9 Connecting the temperature contact of the braking resistor................................................113
4.5.10 Fieldbus interfaces...............................................................................................................113
4.5.11 Connecting the inverter to PROFINET.................................................................................114
4.5.11.1 Communication via PROFINET IO and Ethernet.................................................................114
4.5.11.2 Connecting the PROFINET cable to the inverter.................................................................115
4.5.11.3 What do you have to set for communication via PROFINET?.............................................116
4.5.11.4 Installing GSDML.................................................................................................................117
4.5.12 Connecting the inverter to PROFIBUS.................................................................................117
4.5.12.1 Connecting the PROFIBUS cable to the inverter.................................................................118
4.5.12.2 What do you have to set for communication via PROFIBUS?.............................................118
4.5.12.3 Installing the GSD................................................................................................................119
4.5.12.4 Setting the address..............................................................................................................119
4.6 Installing encoders...............................................................................................................121
5 Commissioning.........................................................................................................................................125
5.1 Commissioning guidelines...................................................................................................125
5.2 Tools to commission the inverter.........................................................................................126
5.3 Preparing for commissioning................................................................................................127
5.3.1 Collecting motor data...........................................................................................................127
5.3.2 Forming DC link capacitors..................................................................................................128
5.3.3 Inverter factory setting..........................................................................................................130
5.3.4 Inverter function modules.....................................................................................................132
5.4 Quick commissioning with a PC...........................................................................................134
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5.4.1 Creating a project.................................................................................................................134
5.4.2 Transfer inverters connected via USB into the project.........................................................135
5.4.3 Starting wizards for the quick commissioning......................................................................136
5.4.4 Standard Drive Control.........................................................................................................139
5.4.5 Dynamic Drive Control.........................................................................................................141
5.4.6 Expert...................................................................................................................................143
5.4.7 Configuring encoders...........................................................................................................147
5.4.8 Adapting the encoder data...................................................................................................148
5.4.9 Loading the settings into the inverter...................................................................................149
5.4.10 Identify motor data...............................................................................................................150
5.5 Restoring the factory setting................................................................................................152
5.5.1 Resetting the safety functions to the factory setting.............................................................153
5.5.2 Restore the factory settings (without safety functions).........................................................155
6 Advanced commissioning.........................................................................................................................157
6.1 Overview of the converter functions.....................................................................................157
6.2 Sequence control when switching the motor on and off.......................................................161
6.3 Adapt the default setting of the terminal strip.......................................................................164
6.3.1 Digital inputs.........................................................................................................................165
6.3.2 Digital outputs......................................................................................................................168
6.3.3 Analog inputs.......................................................................................................................170
6.3.4 Analog outputs.....................................................................................................................174
6.4 Controlling clockwise and counter-clockwise rotation via digital inputs...............................177
6.4.1 Two-wire control, method 1..................................................................................................178
6.4.2 Two-wire control, method 2..................................................................................................179
6.4.3 Two-wire control, method 3..................................................................................................180
6.4.4 Three-wire control, method 1...............................................................................................181
6.4.5 Three-wire control, method 2...............................................................................................182
6.5 Drive control via PROFIBUS or PROFINET.........................................................................183
6.5.1 Receive data and send data................................................................................................183
6.5.2 Telegrams............................................................................................................................184
6.5.3 Control and status word 1....................................................................................................187
6.5.4 Control and status word 2....................................................................................................190
6.5.5 Control and status word 3....................................................................................................191
6.5.6 NAMUR message word........................................................................................................193
6.5.7 Control and status word, encoder........................................................................................194
6.5.8 Position actual value of the encoder....................................................................................196
6.5.9 Parameter channel...............................................................................................................198
6.5.10 Examples for using the parameter channel..........................................................................201
6.5.11 Extending the telegram........................................................................................................203
6.5.12 Slave-to-slave communication.............................................................................................205
6.5.13 Acyclically reading and writing inverter parameters.............................................................205
6.6 Drive control via Modbus RTU.............................................................................................206
6.7 Drive control via USS...........................................................................................................209
6.8 Drive control via Ethernet/IP................................................................................................212
6.9 Drive control via CANopen...................................................................................................213
6.10 Jogging.................................................................................................................................214
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6.11 Limit position control............................................................................................................216
6.12 Switching over the drive control (command data set)..........................................................218
6.13 Motor holding brake.............................................................................................................220
6.14 Free function blocks.............................................................................................................224
6.14.1 Overview..............................................................................................................................224
6.14.2 Runtime groups and run sequence......................................................................................224
6.14.3 List of the free function blocks..............................................................................................225
6.14.4 Scaling.................................................................................................................................236
6.14.5 Activating free function block...............................................................................................237
6.14.6 Further information...............................................................................................................237
6.15 Selecting physical units........................................................................................................238
6.15.1 Motor standard.....................................................................................................................238
6.15.2 System of units.....................................................................................................................238
6.15.3 Technological unit of the technology controller....................................................................240
6.15.4 Setting the system of units and technology unit...................................................................240
6.16 Extended messages.............................................................................................................242
6.17 Safe Torque Off (STO) safety function.................................................................................244
6.17.1 Function description.............................................................................................................244
6.17.2 Commissioning STO............................................................................................................246
6.17.2.1 Safety functions password...................................................................................................246
6.17.2.2 Configuring a safety function................................................................................................248
6.17.2.3 Interconnecting the "STO active" signal...............................................................................249
6.17.2.4 Setting the filter for fail-safe digital inputs............................................................................250
6.17.2.5 Setting the forced checking procedure (test stop)................................................................252
6.17.2.6 Finalizing online commissioning...........................................................................................254
6.17.2.7 Checking the assignment of the digital inputs......................................................................255
6.17.2.8 Acceptance - completion of commissioning.........................................................................256
6.18 Setpoints..............................................................................................................................258
6.18.1 Overview..............................................................................................................................258
6.18.2 Analog input as setpoint source...........................................................................................260
6.18.3 Specifying the setpoint via the fieldbus................................................................................262
6.18.4 Motorized potentiometer as setpoint source........................................................................264
6.18.5 Fixed speed setpoint as setpoint source..............................................................................267
6.18.6 Pulse input as source of setpoint value................................................................................271
6.19 Setpoint calculation..............................................................................................................273
6.19.1 Overview..............................................................................................................................273
6.19.2 Invert setpoint.......................................................................................................................274
6.19.3 Inhibit direction of rotation....................................................................................................275
6.19.4 Skip frequency bands and minimum speed.........................................................................276
6.19.5 Speed limitation....................................................................................................................277
6.19.6 Ramp-function generator.....................................................................................................278
6.20 PID technology controller.....................................................................................................283
6.21 Motor control........................................................................................................................288
6.21.1 Reactor, filter and cable resistance at the inverter output....................................................288
6.21.2 V/f control.............................................................................................................................289
6.21.2.1 Characteristics of U/f control................................................................................................291
6.21.2.2 Optimizing motor starting.....................................................................................................294
Table of contents
Converter with the CU250S-2 Control Units
8Operating Instructions, 04/2018, FW V4.7 SP10, A5E31759476B AG