Siemens SINAMICS G120 User 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
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
6Operating Instructions, 01/2017, FW V4.7 SP6, A5E34259001B AD

Table of contents
Changes in the current manual....................................................................................................................5
1Fundamental 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
8Operating 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