Siemens SINAMICS S120 Quick start guide

SINAMICS S120 Commissioning
SINAMICS S120
sinamics
s
Commissioning Manual 07/2007

Preface
Preparations for
Commissioning
1
Commissioning
2
Diagnosis
3
Parameterizing using the
BOP20 (Basic Operator
Panel 20)
4
Appendix
A
SINAMICS
S120
Commissioning
Commissioning Manual
(IH1), 07/2007
6SL3097-2AF00-0BP7
Applies to:
Firmware version FW2.5 SP1

Safety Guidelines
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
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
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 device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.
Prescribed Usage
Note the following:
WARNING
This device may only be used for the applications described in the catalog or the technical description and only
in connection with devices or components from other manufacturers which have been approved or
recommended by Siemens. Correct, reliable operation of the product requires proper transport, storage,
positioning and assembly as well as careful operation and maintenance.
Trademarks
All names identified by ® are registered trademarks of the 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
Automation and Drives
Postfach 48 48
90327 NÜRNBERG
GERMANY
Ordernumber: 6SL3097-2AF00-0BP7
Ⓟ 08/2007
Copyright © Siemens AG 2007.
Technical data subject to change

Commissioning
Commissioning Manual, (IH1), 07/2007 Edition, 6SL3097-2AF00-0BP7 5
Preface
SINAMICS documentation
The SINAMICS documentation is organized in two parts:
● General documentation/catalogs
● Manufacturer/service documentation
A current overview of the documentation in the available languages is provided on the
Internet:
http://www.siemens.com/motioncontrol
Select the menu items "Support" --> "Technical Documentation" --> "Overview of
Publications."
The Internet version of DOConCD (DOConWEB) is available on the Internet:
http://www.automation.siemens.com/doconweb
Information on the range of training courses and FAQs (Frequently Asked Questions) are
available on the Internet:
http://www.siemens.com/motioncontrol
Select the menu item "Support".
Usage phases and their tools/documents (as an example)
Table 1 Usage phases and the available documents/tools
Usage phase Document/tool
Orientation SINAMICS S Sales Documentation
Planning/configuration •SIZER Configuration Tool
•Configuration Manuals, Motors
Deciding/ordering SINAMICS S Catalogs
Installation/assembly •SINAMICS S120 Equipment Manual for Control Units and
Additional System Components
•SINAMICS S120 Equipment Manual for Booksize Power
Units
•SINAMICS S120 Equipment Manual for Chassis Power
Units
•SINAMICS S120 Equipment Manual for AC Drives

Preface
Commissioning
6 Commissioning Manual, (IH1), 07/2007 Edition, 6SL3097-2AF00-0BP7
Usage phase Document/tool
Commissioning •STARTER Parameterization and Commissioning Tool
•SINAMICS S120 Getting Started
•SINAMICS S120 Commissioning Manual
•SINAMICS S120 CANopen Commissioning Manual
•SINAMICS S120 Function Manual
•SINAMICS S List Manual
Usage/operation •SINAMICS S120 Commissioning Manual
•SINAMICS S List Manual
Maintenance/servicing •SINAMICS S120 Commissioning Manual
•SINAMICS S List Manual
Target group
This documentation is intended for machine manufacturers, commissioning engineers, and
service personnel who use the SINAMICS S drive system.
Benefits
The Commissioning Manual describes all the information, procedures and operational
instructions required for commissioning and servicing SINAMICS S120.
The Commissioning Manual is structured as follows:
Chapter 1 Preparations for Commissioning
Chapter 2 Commissioning
Chapter 3 Diagnostics
Chapter 4 Parameterizing using the BOP20
(Basic Operator Panel 20)
Search tools
The following guides are provided to help you locate information in this manual:
1. Contents
2. List of abbreviations
3. Index
Standard scope
The scope of the functionality described in this document may differ from the scope of the
functionality of the drive system that is actually supplied.
● It may be possible for other functions not described in this documentation to be executed
in the drive system. However, no claim can be made regarding the availability of these
functions when the equipment is first supplied or in the event of servicing.
● Functions that are not available in a particular product version of the drive system may be
described in the documentation. The functionality of the supplied drive system should
only be taken from the ordering documentation.

Preface
Commissioning
Commissioning Manual, (IH1), 07/2007 Edition, 6SL3097-2AF00-0BP7 7
● Extensions or changes made by the machine manufacturer must be documented by the
machine manufacturer.
For reasons of clarity, this documentation does not contain all of the detailed information on
all of the product types. This documentation cannot take into consideration every
conceivable type of installation, operation and service/maintenance.
Technical Support
If you have any questions, please contact us on the following hotline:
European and African time zones
A&D Technical Support
Tel.: [phone] - 222
Fax: [phone] - 223
Internet: http://www.siemens.de/automation/support-request
Asian and Australian time zones
A&D Technical Support
Tel: [phone]
Fax: [phone]
E-mail: [e-mail]
American time zone
A&D Technical Support
Tel: [phone]
Fax: [phone]
E-mail: techsupport.s[email protected]
Note
National telephone numbers for technical support are provided under the following Internet
address:
http://www.siemens.com/automation/service&support
Questions on the manual
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following fax number or e-mail address:
Fax: [phone] / 98 - 63315
E-mail: [email protected]m
Fax form: Refer to the reply form at the end of this manual

Preface
Commissioning
8 Commissioning Manual, (IH1), 07/2007 Edition, 6SL3097-2AF00-0BP7
Internet address for SINAMICS
http://www.siemens.com/sinamics.
EC Declaration of Conformity
The EC Declaration of Conformity for the EMC Directive can be obtained from:
● Internet
http://www.ad.siemens.de/csinfo
Product/order number: 15257461
● Branch offices
For the responsible regional offices of the A&D MC business division of Siemens AG.
Notation
The following notation and abbreviations are used in this documentation:
Notation for parameters (examples):
● p0918 Adjustable parameter 918
● r1024 Visualization parameter 1024
● p1070[1] Adjustable parameter 1070, index 1
● p2098[1].3 Adjustable parameter 2098, index 1, bit 3
● p0099[0...3] Adjustable parameter 99, indices 0 to 3
● r0945[2](3) Visualization parameter 945, index 2 of drive object 3
● p0795.4 Adjustable parameter 795, bit 4
Notation for faults and alarms (examples):
● F12345 Fault 12345
● A67890 Alarm 67890

Preface
Commissioning
Commissioning Manual, (IH1), 07/2007 Edition, 6SL3097-2AF00-0BP7 9
ESD Notes
CAUTION
Electrostatic sensitive devices (ESD) are single components, integrated circuits or devices
that can be damaged by electrostatic fields or electrostatic discharges.
Regulations for the ESD handling:
During the handling of electronic components, pay attention to the grounding of the person,
workplace and packaging!
Electronic components may be touched by persons only when
•these persons are grounded using an ESD bracelet, or
•these persons in ESD areas with a conducting floor wear ESD shoes or ESD grounding
straps.
Electronic components should be touched only when this is unavoidable. The touching is
permitted only on the front panel or on the circuit board edge.
Electronic components must not be brought into contact with plastics or clothing made of
artificial fibers.
Electronic components may only be placed on conducting surfaces (table with ESD coating,
conducting ESD foamed material, ESD packing bag, ESD transport container).
Electronic components may not be placed near display units, monitors or televisions
(minimum distance from the screen > 10 cm).
Measurements may be made on electronic components when the measuring unit is
grounded (e.g. with a protective conductor) or prior to measuring with a potential-free
measuring unit, the measuring head is briefly discharged (e.g. by touching a bare metal
housing).

Preface
Commissioning
10 Commissioning Manual, (IH1), 07/2007 Edition, 6SL3097-2AF00-0BP7
Safety-related information
DANGER
•Commissioning must not start until you have ensured that the machine in which the
components described here are to be installed complies with Directive 98/37/EC.
•SINAMICS devices and AC motors may only be commissioned by suitably qualified
personnel.
•The personnel must take into account the information provided in the technical customer
documentation for the product, and be familiar with and observe the specified danger
and warning notices.
•When electrical equipment and motors are operated, the electrical circuits automatically
conduct a dangerous voltage.
•Dangerous mechanical movements are possible during system operations.
•All the work carried-out on the electrical machine or system must be carried-out with it in
a no-voltage condition.
•SINAMICS devices with AC motors may only be connected to the power supply via an
AC-DC residual-current-operated device with selective switching once verification has
been provided that the SINAMICS device is compatible with the residual-current-
operated device in accordance with EN 50178, Chapter 5.2.11.2.
WARNING
•The successful and safe operation of this equipment and motors is dependent on
professional transport, storage, installation and mounting as well as careful operations,
service and maintenance.
•Information and data from the catalogs and quotations also apply to special versions of
the equipment and motors.
•In addition to the danger and warning information provided in the technical customer
documentation, the applicable national, local, and plant-specific regulations and
requirements must be taken into account.
•Only protective extra-low voltages (PELV) that comply with EN60204-1 may be
connected to all connections and terminals between 0 and 48 V.
CAUTION
•The motors can have surface temperatures of over +80 °C.
•This is why temperature-sensitive components, e.g. cables or electronic components
must not be in contact with or attached to the motor.
•When connecting up cables, please ensure that they
– are not damaged
– are not subject to tensile stress
– cannot be touched by rotating components.

Preface
Commissioning
Commissioning Manual, (IH1), 07/2007 Edition, 6SL3097-2AF00-0BP7 11
CAUTION
•As part of routine tests, SINAMICS devices with AC motors undergo a voltage test in
accordance with EN 50178. Before the voltage test is performed on the electrical
equipment of industrial machines to EN 60204-1, Section 19.4, all connectors of
SINAMICS equipment must be disconnected/unplugged to prevent the equipment from
being damaged.
•Motors should be connected up according to the circuit diagram provided otherwise they
may be destroyed.
Note
When operated in dry operating areas, SINAMICS equipment with AC motors conforms to
low-voltage Directive 73/23/EEC.

Commissioning
Commissioning Manual, (IH1), 07/2007 Edition, 6SL3097-2AF00-0BP7 13
Contents
Preface ...................................................................................................................................................... 5
1 Preparations for Commissioning.............................................................................................................. 17
1.1 Requirements for commissioning.................................................................................................17
1.2 PROFIBUS components..............................................................................................................21
1.3 PROFINET components ..............................................................................................................21
1.4 Connection via serial interface.....................................................................................................22
1.5 Rules for wiring with DRIVE-CLiQ ...............................................................................................24
1.5.1 General rules................................................................................................................................25
1.5.2 Sample wiring for vector drives....................................................................................................28
1.5.3 Sample wiring of Vector drives connected in parallel ..................................................................30
1.5.4 Sample wiring: Power Modules....................................................................................................32
1.5.5 Changing the offline topology in STARTER.................................................................................33
1.5.6 Sample wiring for servo drives.....................................................................................................34
1.5.7 Sample wiring for vector U/f drives ..............................................................................................35
1.5.8 Notes on the number of controllable drives .................................................................................36
1.5.8.1 Introduction ..................................................................................................................................36
1.5.8.2 Number of controllable drives ......................................................................................................36
1.6 Powering-up/powering-down the drive system............................................................................39
2 Commissioning ........................................................................................................................................ 43
2.1 Sequence of operations during commissioning...........................................................................43
2.1.1 Safety guidelines..........................................................................................................................43
2.2 STARTER commissioning tool.....................................................................................................44
2.2.1 Important STARTER functions.....................................................................................................44
2.2.2 Activating online operation: STARTER via PROFIBUS...............................................................46
2.2.3 Activating online operation: STARTER via PROFINET IO ..........................................................48
2.3 Basic Operator Panel 20 (BOP20)...............................................................................................53
2.3.1 Important functions via BOP20 ....................................................................................................53
2.4 Creating a project in STARTER...................................................................................................54
2.4.1 Creating a project offline ..............................................................................................................54
2.4.2 Searching for a drive unit online ..................................................................................................56
2.4.3 Searching for nodes that can be accessed..................................................................................58
2.5 Initial commissioning using servo (booksize) as an example ......................................................58
2.5.1 Task .............................................................................................................................................59
2.5.2 Component wiring (example).......................................................................................................60
2.5.3 Signal flow for commissioning example.......................................................................................61
2.5.4 Commissioning with Starter (example) ........................................................................................62
2.6 Initial commissioning using vector (booksize) as an example.....................................................65
2.6.1 Task .............................................................................................................................................65
2.6.2 Component wiring (example).......................................................................................................66
2.6.3 Signal flow for commissioning example.......................................................................................68

Contents
Commissioning
14 Commissioning Manual, (IH1), 07/2007 Edition, 6SL3097-2AF00-0BP7
2.6.4 Commissioning with STARTER (example) ................................................................................. 68
2.7 Initial commissioning using vector (chassis) as an example ...................................................... 72
2.7.1 Task............................................................................................................................................. 72
2.7.2 Component wiring (example) ...................................................................................................... 74
2.7.3 Signal flow for commissioning example...................................................................................... 75
2.7.4 Commissioning with STARTER (example) ................................................................................. 75
2.8 Commissioning for the first time using as an example Vector AC DRIVE with BOP20.............. 80
2.8.1 Task............................................................................................................................................. 80
2.8.2 Component wiring (example) ...................................................................................................... 81
2.8.3 Quick commissioning using the BOP (example)......................................................................... 82
2.9 Commissioning for the first time using as an example Servo AC DRIVE with BOP20............... 85
2.9.1 Task............................................................................................................................................. 85
2.9.2 Component wiring (example) ...................................................................................................... 86
2.9.3 Quick commissioning using the BOP (example)......................................................................... 87
2.10 Commissioning linear motors (servo) ......................................................................................... 88
2.10.1 General information on commissioning linear motors................................................................. 88
2.10.2 Commissioning: Linear motor with one primary section ............................................................. 90
2.10.3 Commissioning: Linear motor with several identical primary sections ....................................... 93
2.10.4 Thermal motor protection............................................................................................................ 94
2.10.5 Measuring system ....................................................................................................................... 96
2.10.6 Checking the linear motor by taking measurements................................................................... 98
2.11 Notes on commissioning SSI encoders .................................................................................... 100
2.12 Notes on the commissioning of a 2-pole resolver as absolute encoder ................................... 103
2.13 Temperature sensor connections for SINAMICS components................................................. 104
3 Diagnosis............................................................................................................................................... 111
3.1 Diagnostics via LEDs ................................................................................................................ 111
3.1.1 LEDs when the Control Unit is booted...................................................................................... 111
3.1.2 LEDs after the Control Unit CU320 has booted........................................................................ 112
3.1.3 LEDs after the Control Unit CU310 has booted........................................................................ 114
3.1.4 Active Line Module.................................................................................................................... 115
3.1.5 Basic Line Module..................................................................................................................... 116
3.1.6 5 kW and 10 kW Smart Line Modules....................................................................................... 117
3.1.7 Smart Line Modules ≥ 16 kW.................................................................................................... 118
3.1.8 Single Motor Module / Double Motor Module / Power Module ................................................. 119
3.1.9 Braking Module Booksize.......................................................................................................... 120
3.1.10 Control Supply Module.............................................................................................................. 120
3.1.11 Sensor Module Cabinet SMC10 / SMC20 ................................................................................ 120
3.1.12 SMC30 Sensor Module Cabinet ............................................................................................... 121
3.1.13 Terminal Module TM15 ............................................................................................................. 122
3.1.14 Terminal Module TM31 ............................................................................................................. 122
3.1.15 Terminal Module TM41 ............................................................................................................. 123
3.1.16 Terminal Module TM54F as of FW2.5 SP1............................................................................... 124
3.1.17 Communication Board CAN (CBC10)....................................................................................... 125
3.1.18 Communication Board Ethernet CBE20 ................................................................................... 126
3.1.19 Voltage Sensing Module VSM10 .............................................................................................. 127
3.1.20 DRIVE-CLiQ Hub Module DMC20 ............................................................................................ 128
3.2 Diagnostics via STARTER ........................................................................................................ 128
3.2.1 Function generator .................................................................................................................... 129
3.2.2 Trace function ........................................................................................................................... 132
3.2.3 Measuring function.................................................................................................................... 133

Contents
Commissioning
Commissioning Manual, (IH1), 07/2007 Edition, 6SL3097-2AF00-0BP7 15
3.2.4 Measuring sockets .....................................................................................................................135
3.3 Fault and alarm messages.........................................................................................................139
3.3.1 General information about faults and alarms.............................................................................139
3.3.2 Buffer for faults and alarms........................................................................................................141
3.3.3 Configuring messages ...............................................................................................................144
3.3.4 Parameters and function diagrams for faults and alarms..........................................................146
3.3.5 Forwarding of faults and alarms.................................................................................................146
4 Parameterizing using the BOP20 (Basic Operator Panel 20)................................................................. 149
4.1 General information about the BOP20.......................................................................................149
4.2 Displays and using the BOP20 ..................................................................................................152
4.3 Fault and alarm displays ............................................................................................................156
4.4 Controlling the drive using the BOP20.......................................................................................157
A Appendix................................................................................................................................................ 159
A.1 Availability of hardware components .........................................................................................159
A.2 List of abbreviations ...................................................................................................................160
Index...................................................................................................................................................... 171

Commissioning
Commissioning Manual, (IH1), 07/2007 Edition, 6SL3097-2AF00-0BP7 17
Preparations for Commissioning 1
Before you start commissioning, you will need to carry out the preparations described in this
chapter:
● Requirements for commissioning
● PROFIBUS/PROFINET components
● Rules for wiring with DRIVE-CLiQ
1.1 Requirements for commissioning
The following are the basic requirements for commissioning a SINAMICS S drive system:
● STARTER commissioning tool
● PROFIBUS or PROFINET interface
● Wired drive line-up (see Equipment Manual)
The following diagram shows a basic sample configuration with booksize and chassis
components.

Preparations for Commissioning
1.1 Requirements for commissioning
Commissioning
18 Commissioning Manual, (IH1), 07/2007 Edition, 6SL3097-2AF00-0BP7
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Figure 1-1 Component configuration (example)
Checklist for commissioning booksize power units
The following checklist must be carefully observed. Read the safety information in the
Equipment Manuals before starting work.

Preparations for Commissioning
1.1 Requirements for commissioning
Commissioning
Commissioning Manual, (IH1), 07/2007 Edition, 6SL3097-2AF00-0BP7 19
Table 1-1 Checklist for commissioning (booksize)
Check O. K.
The ambient conditions must be permissible. See Equipment Manuals.
The components must be firmly attached to the fixing points provided.
The cooling air can flow unobstructed.
The ventilation clearances for the components must be observed.
The CompactFlash Card must be inserted in the Control Unit.
All necessary components of the configured drive line-up are installed and available.
The DRIVE-CLiQ topology rules must be observed.
The line-side and motor-side power cables must be dimensioned and routed in
accordance with the ambient and routing conditions. The maximum permissible cable
lengths between the converter and the motor must be observed depending on the type
of cables used.
The cables must be properly connected with the correct torque to the component
terminals. The cables for the motor and low-voltage switchgear must also be
connected with the required torques.
Has all wiring work been successfully completed?
Are all connectors correctly plugged in and screwed in place?
Have all the screws been tightened to the specified torque?
Have all the covers for the DC link been closed and latched into place?
Are the shield connections installed correctly?
Checklist for commissioning chassis power units
The following checklist must be carefully observed. Read the safety information in the
Equipment Manuals before starting work.
Table 1-2 Checklist for commissioning (chassis)
Activity O. K.
The ambient conditions must be permissible. See Equipment Manuals.
The components must be properly installed in the cabinet units.
The air flow for the modules, which undergo forced cooling, must be ensured. The
ventilation clearances must be ensured. The air flow specified in the technical
specifications must be ensured. An air short-circuit must not be allowed to form between
the chassis air inlet and outlet on account of the installation.
The ventilation clearances for the components must be observed.
The CompactFlash Card must be inserted in the Control Unit.
All necessary components of the configured drive line-up are installed and available.
The DRIVE-CLiQ topology rules must be observed.

Preparations for Commissioning
1.1 Requirements for commissioning
Commissioning
20 Commissioning Manual, (IH1), 07/2007 Edition, 6SL3097-2AF00-0BP7
Activity O. K.
The line-side and motor-side power cables must be dimensioned and routed in
accordance with the ambient and routing conditions. The maximum permissible cable
lengths between the converter and the motor must be observed depending on the type of
cables used.
The ground for the motor should be directly connected to the ground for the Motor
Module (short distance).
The cables must be properly connected with the correct torque to the component
terminals. The cables for the motor and low-voltage switchgear must also be connected
with the required torques.
The busbar/wiring for the DC connection between the infeed and the Motor Modules
must be checked with regard to the load and installation conditions. When more than one
motor is used, the total current of the DC connection must be observed.
The cables between the low-voltage switchgear and the power section must be protected
with line fuses for conductor protection (VDE 636, Part 10). Combined fuses are
recommended for conductor and semi-conductor protection (VDE 636, Part 40 / EN
60269-4). For information about the relevant fuses, see the catalog.
Ensure that measures are taken to relieve strain on the cables.
When EMC-shielded cables are used, screwed glands that connect the shield to ground
with the greatest possible surface area must be provided on the motor terminal box.
The cable shields must be connected as close to the conductor terminal connections as
possible to ensure a low-impedance connection with cabinet ground.
The cable shields must be properly applied and the cabinet properly grounded at the
appropriate points.
The connection voltage for the fans in the chassis components must be adapted
accordingly to the supply voltages by making the appropriate settings on the fan
transformers.
The connection bracket for the interference-suppression capacitor must be removed from
the infeeds for operation with an ungrounded supply.
The cabinet type plate can be used to ascertain the date of manufacture. If the period
from the date of manufacture to initial commissioning or the downtime of the power
components is less than two years, the DC link capacitors do not have to be reformed. If
the downtime period is longer than two years, they must be reformed in accordance with
the description in the "Maintenance and Servicing" chapter in the Equipment Manual.
With an external auxiliary supply, the cables must be connected in accordance with the
Equipment Manual.
Drive operation by higher-level controller/control room. The control cables must be
connected in accordance with the required interface configuration and the shield applied.
Taking into account electrical interference and the distance from power cables, the digital
and analog signals must be routed with separate cables.