Siemens SINAMICS G115D User manual

SINAMICS
SINAMICS G115D
SINAMICS G115D distributed drive
Operating Instructions
Edition 09/2020, Firmware V4.7 SP13
09/2020, FW V4.7 SP13
A5E48681219B
Preface
Fundamental safety
instructions
1
Overview of the SINAMICS
G115D drive
2
Mounting
3
Wiring
4
Commissioning
5
Advanced commissioning
6
Data backup and series
commissioning
7
Alarms, faults and system
messages
8
Corrective maintenance
9
Technical data
10
Additional information on
the SIMOGEAR geared
motor
11
Appendix
A

Siemens AG
Digital Industries
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E48681219B
Ⓟ
09/2020 Subject to change
Copyright © Siemens AG 2020.
All rights reserved
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.

SINAMICS G115D distributed drive
Operating Instructions, 09/2020, FW V4.7 SP13, A5E48681219B 3
Preface
About the Manual
Who requires the operating instructions and what for?
These operating instructions primarily address fitters, commissioning engineers and machine
operators. The operating instructions describe the devices and device components and
enable the target groups being addressed to install, connect-up, set, and commission the
converters safely and in the correct manner.
What is described in the operating instructions?
These operating instructions provide a summary of all the information required to operate
the drive under normal, safe conditions.
The information provided in the operating instructions has been compiled in such a way that
it is sufficient for all standard applications and enables drives to be commissioned as
efficiently as possible. Where it appears useful, additional information for entry level
personnel has been added.
The operating instructions also contain information about special applications. Since it is
assumed that readers already have a sound technical knowledge of how to configure and
parameterize these applications, the relevant information is summarized accordingly. This
relates, e.g. to operation with fieldbus systems and safety-related applications.
What is the meaning of the symbols in the manual?
Reference to further information in the manual
Download from the Internet
Example of converter function symbols
❒
End of a handling instruction
About the device
Use for the intended purpose
The device has been approved for industrial and commercial use on industrial networks.
Additional measures have to be taken when connected to public grids.
The technical specifications and information about connection conditions are indicated on
the rating plate and in the operating instructions.
Use of third-party products
This document contains recommendations relating to third-party products. Siemens accepts
the fundamental suitability of these third-party products.

Preface
SINAMICS G115D distributed drive
4Operating Instructions, 09/2020, FW V4.7 SP13, A5E48681219B
You can use equivalent products from other manufacturers.
Siemens does not accept any warranty for the properties of third-party products.
Use of OpenSSL
This product contains software developed in the OpenSSL project for use within the OpenSSL
toolkit.
This product contains cryptographic software created by Eric Young.
This product contains software developed by Eric Young.
Further information is provided on the Internet:
OpenSSL (https://www.openssl.org/)
Cryptsoft (mailto:[email protected])

SINAMICS G115D distributed drive
Operating Instructions, 09/2020, FW V4.7 SP13, A5E48681219B 5
Table of contents
Preface ................................................................................................................................................... 3
1 Fundamental safety instructions......................................................................................................... 15
1.1 General safety instructions................................................................................................. 15
1.2 Equipment damage due to electric fields or electrostatic discharge..................................... 21
1.3 Warranty and liability for application examples................................................................... 21
1.4 Security information .......................................................................................................... 21
1.5 Residual risks of power drive systems ................................................................................. 23
2 Overview of the SINAMICS G115D drive.............................................................................................. 25
2.1 System overview................................................................................................................ 25
2.2 Scope of delivery ............................................................................................................... 26
2.2.1 SINAMICS G115D Motor Mounted...................................................................................... 26
2.2.2 SINAMICS G115D Wall Mounted......................................................................................... 28
2.3 Directives and standards .................................................................................................... 32
3 Mounting ............................................................................................................................................. 35
3.1 Mounting the G115D Motor Mounted drive........................................................................ 35
3.2 Mounting the G115D Wall Mounted drive .......................................................................... 38
4 Wiring .................................................................................................................................................. 41
4.1 EMC installation guidelines ................................................................................................ 41
4.1.1 Connections and interference suppression ......................................................................... 41
4.1.2 Basic EMC rules.................................................................................................................. 41
4.1.3 Equipotential bonding ....................................................................................................... 42
4.2 Permissible line supplies .................................................................................................... 44
4.2.1 TN line system ................................................................................................................... 45
4.2.2 TT line system.................................................................................................................... 45
4.2.3 IT line system..................................................................................................................... 46
4.2.4 Removing functional grounding of the converter................................................................ 47
4.3 Requirements for the protective conductor......................................................................... 48
4.4 Requirements for branch circuit protection......................................................................... 50
4.5 Operation with residual current protective device (RCD) ..................................................... 50
4.6 Forming DC link capacitors................................................................................................. 51
4.7 Overview of the converter interfaces.................................................................................. 52
4.8 Cables and connectors ....................................................................................................... 57
4.8.1 Maximum permissible cable length .................................................................................... 58
4.8.2 Cable cross-sections and cable lugs .................................................................................... 59
4.9 Connecting the line supply................................................................................................. 62

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6Operating Instructions, 09/2020, FW V4.7 SP13, A5E48681219B
4.9.1 Interface description - X1/X3.............................................................................................. 62
4.9.2 Connecting to the line supply using daisy chain.................................................................. 63
4.10 Connecting the motor........................................................................................................ 65
4.10.1 Interface description - X2................................................................................................... 65
4.10.2 Connecting the motor in a star or delta connection ............................................................ 66
4.10.2.1 Overview........................................................................................................................... 66
4.10.2.2 Configuring the star/delta connection of the wall-mounted converter................................. 67
4.11 Connecting the 24 V power supply..................................................................................... 68
4.11.1 Interface description - X01/X02.......................................................................................... 68
4.11.2 Connecting to the 24 V power supply using daisy chain...................................................... 70
4.12 Connecting the digital inputs and outputs.......................................................................... 71
4.12.1 Interface description - X07/X08/X05................................................................................... 71
4.12.2 Factory interface setting .................................................................................................... 73
4.12.3 Fail-safe digital input ......................................................................................................... 73
4.13 Connecting to PROFINET and Ethernet ............................................................................... 74
4.13.1 Interface description - X150 P1/P2...................................................................................... 74
4.13.2 Communication via PROFINET IO and Ethernet ................................................................... 74
4.13.3 Protocols used ................................................................................................................... 76
4.13.4 Connecting the converter to PROFINET............................................................................... 77
4.13.5 What do you have to set for communication via PROFINET ................................................. 78
4.13.6 Installing GSDML ............................................................................................................... 79
4.13.7 Connecting the converter to Ethernet/IP............................................................................. 79
4.13.8 What do you need for communication via Ethernet/IP? ....................................................... 80
4.14 Grounding the converter housing ...................................................................................... 80
4.15 Connection examples ........................................................................................................ 81
5 Commissioning .................................................................................................................................... 83
5.1 Commissioning guidelines ................................................................................................. 83
5.2 Commissioning tools ......................................................................................................... 84
5.3 Preparing for commissioning ............................................................................................. 84
5.3.1 Factory settings ................................................................................................................. 84
5.3.2 Collecting motor data ........................................................................................................ 86
5.3.3 Selecting U/f control or speed control................................................................................. 88
5.4 Quick commissioning......................................................................................................... 89
5.4.1 Quick commissioning with DIP switches ............................................................................. 89
5.4.2 Quick commissioning with a PC (Startdrive) ....................................................................... 91
5.4.2.1 Creating a project .............................................................................................................. 91
5.4.2.2 Integrating the converter into the project........................................................................... 92
5.4.2.3 Starting the Commissioning Wizard.................................................................................... 93
5.4.2.4 Carrying out quick commissioning ..................................................................................... 94
5.4.2.5 Identifying motor data....................................................................................................... 95
5.5 Saving the settings in the converter (RAM → EEPROM) ....................................................... 97
5.6 Restoring the factory settings............................................................................................. 98
5.6.1 Restoring the factory settings/delivery condition (without safety functions)........................ 98
5.6.2 Resetting the safety functions to the factory settings.......................................................... 99
6 Advanced commissioning.................................................................................................................. 101

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Operating Instructions, 09/2020, FW V4.7 SP13, A5E48681219B 7
6.1 Overview of converter functions ...................................................................................... 101
6.2 Sequence control when switching the motor on and off ................................................... 103
6.3 Adapt the default settings of the inputs and outputs ........................................................ 105
6.3.1 Overview......................................................................................................................... 105
6.3.2 Digital Inputs ................................................................................................................... 106
6.3.3 Digital outputs................................................................................................................. 107
6.4 Controlling clockwise and counter-clockwise rotation via digital inputs............................. 108
6.4.1 Two-wire control, method 1............................................................................................. 109
6.4.2 Two-wire control, method 2............................................................................................. 109
6.4.3 Two-wire control, method 3............................................................................................. 110
6.4.4 Three-wire control, method 1........................................................................................... 111
6.4.5 Three-wire control, method 2........................................................................................... 112
6.5 Drive control via PROFINET............................................................................................... 112
6.5.1 Receive data and send data.............................................................................................. 112
6.5.2 Telegrams........................................................................................................................ 113
6.5.3 Control and status word 1................................................................................................ 115
6.5.4 Control and status word 3................................................................................................ 117
6.5.5 Control and status word G115D ....................................................................................... 119
6.5.6 NAMUR message word..................................................................................................... 120
6.5.7 Parameter channel........................................................................................................... 120
6.5.8 Expanding or freely interconnecting telegrams................................................................. 125
6.5.9 Acyclically reading and writing converter parameters ....................................................... 127
6.6 Drive control via Ethernet/IP............................................................................................. 127
6.6.1 Configuring communication via Ethernet/IP...................................................................... 127
6.6.2 Supported objects............................................................................................................ 130
6.6.3 Supported ODVA AC/DC assemblies.................................................................................. 141
6.6.4 Creating generic I/O module............................................................................................. 142
6.6.5 The converter as Ethernet node ....................................................................................... 143
6.7 Jogging ........................................................................................................................... 144
6.8 Conveyor technology control functions ............................................................................ 144
6.8.1 Conveyors ....................................................................................................................... 145
6.8.1.1 Conveyor, one direction and one speed (p3393 = 1)......................................................... 145
6.8.1.2 Conveyor, one direction and two speeds (p3393 = 2) ....................................................... 147
6.8.1.3 Conveyor, two directions and one speed (p3393 = 3) ....................................................... 149
6.8.1.4 Conveyor, two directions and two speeds (p3393 = 4)...................................................... 150
6.8.2 Turntables ....................................................................................................................... 152
6.8.2.1 Turntable, two positions and one speed (p3393 = 5) ........................................................ 153
6.8.2.2 Turntable, two positions and two speeds (p3393 = 6)....................................................... 156
6.8.2.3 Turntable, three positions and one speed (p3393 = 7)...................................................... 159
6.8.2.4 Turntable, three positions and two speeds (p3393 = 8) .................................................... 162
6.8.3 Corner turntable lifts........................................................................................................ 165
6.8.3.1 Corner turntable lift, two positions and one speed (p3393 = 9)......................................... 165
6.8.3.2 Corner turntable lift, two positions and two speeds (p3393 = 10) ..................................... 168
6.8.4 Travelling trolleys ............................................................................................................ 170
6.8.4.1 Travelling trolley, one speed (p3393 = 11) ....................................................................... 170
6.8.4.2 Travelling trolley, two speeds (p3393 = 12)...................................................................... 173
6.8.5 Conveyor technology control parameters ......................................................................... 175
6.9 Switching over the drive control (command data set) ....................................................... 177

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8Operating Instructions, 09/2020, FW V4.7 SP13, A5E48681219B
6.10 Motor holding brake ........................................................................................................ 179
6.11 Free function block .......................................................................................................... 183
6.12 Selecting physical units.................................................................................................... 184
6.12.1 Motor standard................................................................................................................ 184
6.12.2 System of units................................................................................................................ 185
6.12.3 Technological unit of the technology controller................................................................ 186
6.12.4 Setting the system of units and technology unit ............................................................... 186
6.13 Safe Torque Off (STO) safety function .............................................................................. 187
6.13.1 Function description ........................................................................................................ 187
6.13.2 Commissioning STO......................................................................................................... 190
6.13.2.1 Commissioning tool......................................................................................................... 190
6.13.2.2 Safety function password................................................................................................. 190
6.13.2.3 Configuring a safety function........................................................................................... 191
6.13.2.4 Interconnecting the "STO active" signal ............................................................................ 192
6.13.2.5 Setting the filter for fail-safe digital inputs........................................................................ 193
6.13.2.6 Setting the forced checking procedure (test stop)............................................................. 195
6.13.2.7 Finalizing online commissioning ...................................................................................... 197
6.13.2.8 Checking the interconnection of digital inputs.................................................................. 198
6.13.2.9 Acceptance - completion of commissioning...................................................................... 199
6.14 Setpoints......................................................................................................................... 200
6.14.1 Overview......................................................................................................................... 200
6.14.2 Specifying the setpoint via the fieldbus ............................................................................ 202
6.14.3 Electromechanical potentiometer .................................................................................... 203
6.14.4 Motorized potentiometer as setpoint source .................................................................... 204
6.14.5 Fixed speed setpoint as setpoint source............................................................................ 207
6.15 Setpoint processing ......................................................................................................... 210
6.15.1 Overview......................................................................................................................... 210
6.15.2 Invert setpoint ................................................................................................................. 211
6.15.3 Inhibit direction of rotation.............................................................................................. 212
6.15.4 Skip frequency bands and minimum speed....................................................................... 213
6.15.5 Speed limitation .............................................................................................................. 214
6.15.6 Ramp-function generator................................................................................................. 215
6.16 PID technology controller................................................................................................. 220
6.17 Motor control .................................................................................................................. 228
6.17.1 U/f control ....................................................................................................................... 228
6.17.1.1 Characteristics of U/f control ............................................................................................ 229
6.17.1.2 Selecting the U/f characteristic ......................................................................................... 230
6.17.1.3 Optimizing motor starting................................................................................................ 231
6.17.2 Sensorless vector control with speed controller ................................................................ 233
6.17.2.1 Structure of vector control without encoder (sensorless) .................................................. 233
6.17.2.2 Optimizing the closed-loop speed controller..................................................................... 235
6.17.2.3 Advanced settings ........................................................................................................... 237
6.17.2.4 Friction characteristic....................................................................................................... 239
6.17.2.5 Moment of inertia estimator ............................................................................................ 241
6.17.2.6 Pole position identification............................................................................................... 248
6.17.3Torque control................................................................................................................. 249
6.18 Electrically braking the motor........................................................................................... 250
6.18.1 DC braking....................................................................................................................... 251

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SINAMICS G115D distributed drive
Operating Instructions, 09/2020, FW V4.7 SP13, A5E48681219B 9
6.18.2 Dynamic braking.............................................................................................................. 254
6.19 Overcurrent protection .................................................................................................... 255
6.20 Converter protection using temperature monitoring......................................................... 256
6.21 Motor temperature monitoring using a temperature sensor.............................................. 259
6.22 Motor protection by calculating the temperature.............................................................. 262
6.23 Motor and converter protection by limiting the voltage .................................................... 264
6.24 Monitoring the driven load............................................................................................... 265
6.24.1 No-load monitoring ......................................................................................................... 265
6.24.2 Rotation monitoring......................................................................................................... 266
6.24.3 Torque monitoring........................................................................................................... 267
6.24.4 Blocking protection, leakage protection and dry-running protection ................................. 269
6.25 Efficiency optimization..................................................................................................... 273
6.26 Calculating the energy saving for fluid flow machines ...................................................... 276
6.27 Switchover between different settings ............................................................................. 278
7 Data backup and series commissioning ............................................................................................ 281
7.1 Transferring settings using a memory card ....................................................................... 281
7.1.1 Memory cards.................................................................................................................. 281
7.1.2 Converter → Memory card ............................................................................................... 283
7.1.3 Memory card → converter................................................................................................ 285
7.1.4 Activating message for a memory card that is not inserted ............................................... 286
7.2 Transferring settings using a PG/PC .................................................................................. 287
7.2.1 Converter → PG/PC .......................................................................................................... 287
7.2.2 PG/PC → converter........................................................................................................... 288
7.3 Other ways to back up settings ........................................................................................ 289
7.4 Write protection............................................................................................................... 290
7.5 Know-how protection ...................................................................................................... 291
7.5.1 Extending the exception list for know-how protection ...................................................... 293
7.5.2 Activating and deactivating know-how protection ............................................................ 294
8 Alarms, faults and system messages................................................................................................. 297
8.1 Status LED overview......................................................................................................... 297
8.2 System runtime ............................................................................................................... 300
8.3 Identification & maintenance data (I&M).......................................................................... 301
8.4 Alarms, alarm buffer, and alarm history............................................................................ 302
8.5 Faults, fault buffer and fault history ................................................................................. 305
8.6 List of alarms and faults ................................................................................................... 308
9 Corrective maintenance .................................................................................................................... 315
9.1 Spare parts compatibility.................................................................................................. 315
9.2 Replacing the converter ................................................................................................... 316
9.2.1 Replacing a converter with active know-how protection ................................................... 318
9.2.1.1 Replacing a converter with know-how protection without copy protection........................ 318

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SINAMICS G115D distributed drive
10 Operating Instructions, 09/2020, FW V4.7 SP13, A5E48681219B
9.2.1.2 Replacing a converter with know-how protection with copy protection............................. 318
9.3 Repair switch................................................................................................................... 320
9.4 Firmware upgrade and downgrade .................................................................................. 321
9.4.1 Preparing the memory card.............................................................................................. 323
9.4.2 Upgrading the firmware................................................................................................... 323
9.4.3 Downgrading the firmware.............................................................................................. 326
9.4.4 Correcting an unsuccessful firmware upgrade or downgrade............................................ 328
9.5 Reduced acceptance test after component replacement and firmware change.................. 329
10 Technical data.................................................................................................................................... 331
10.1 Technical data of the G115D converter with SIMOGEAR geared motor.............................. 331
10.1.1 General technical data ..................................................................................................... 331
10.1.2 Technical data of inputs and outputs................................................................................ 333
10.1.3 Technical data dependent upon the power....................................................................... 334
10.1.4 Technical data of braking resistors ................................................................................... 335
10.1.5 Load cycles and overload capabilities ............................................................................... 336
10.1.6 Derating data................................................................................................................... 337
10.1.6.1 Current derating as a function of the installation altitude ................................................. 337
10.1.6.2 Current derating as a function of the line voltage ............................................................. 337
10.1.6.3 Current and torque derating as a function of the motor speed .......................................... 338
10.2 Technical data of the G115D wall-mounted converter ...................................................... 339
10.2.1 General converter technical data...................................................................................... 339
10.2.2 Technical data of inputs and outputs................................................................................ 341
10.2.3 Technical data dependent upon the power....................................................................... 341
10.2.4 Technical data of braking resistors ................................................................................... 343
10.2.5 Load cycles and overload capabilities ............................................................................... 343
10.2.6 Derating data................................................................................................................... 344
10.2.6.1 Current derating as a function of the installation altitude ................................................. 344
10.2.6.2 Current derating as a function of the surrounding temperature ........................................ 345
10.2.6.3 Current derating as a function of the line voltage ............................................................. 345
10.2.6.4 Current derating as a function of the pulse frequency....................................................... 346
10.2.6.5 Derating of motor cable length based on pulse frequency and surrounding
temperature .................................................................................................................... 347
10.3 Low frequency operation ................................................................................................. 348
10.4 Data regarding the power loss in partial load operation .................................................... 348
10.5 Electromagnetic compatibility of the converter ................................................................ 349
10.6 Protecting persons from electromagnetic fields................................................................ 351
11 Additional information on the SIMOGEAR geared motor.................................................................. 353
11.1 General information geared motor................................................................................... 353
11.1.1 Copyright ........................................................................................................................ 353
11.1.2 Obligations of the user..................................................................................................... 353
11.1.3 The five safety rules......................................................................................................... 354
11.1.4 Particular types of hazards ............................................................................................... 355
11.1.5 Rating plate ..................................................................................................................... 356
11.1.6 Surface treatment............................................................................................................ 356
11.1.6.1 General information on surface treatment........................................................................ 356
11.1.6.2 Painted version................................................................................................................ 357

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Operating Instructions, 09/2020, FW V4.7 SP13, A5E48681219B 11
11.1.6.3 Primed version................................................................................................................. 358
11.1.7 Incoming goods............................................................................................................... 359
11.1.8 General information on transport..................................................................................... 359
11.1.9 Unpacking ....................................................................................................................... 360
11.1.10 General information concerning the installation............................................................... 361
11.1.11 Thread sizes and tightening torques for fastening bolts .................................................... 362
11.1.12 Operation........................................................................................................................ 363
11.1.13 Cleaning the geared motor .............................................................................................. 363
11.1.14 Inspecting the geared motor ............................................................................................ 363
11.1.15 Disposal........................................................................................................................... 364
11.1.16 Technical data ................................................................................................................. 365
11.1.16.1 Type designation motor and converter ............................................................................. 365
11.1.16.2 Gearbox type designation ................................................................................................ 366
11.1.16.3 General technical data ..................................................................................................... 367
11.1.16.4 Rating plate for geared motors with SINAMICS G115D Motor Mounted............................. 367
11.1.16.5 Rating plate for geared motors with SINAMICS G115D Wall Mounted................................ 368
11.1.16.6 Weight ............................................................................................................................ 369
11.1.16.7 Sound energy level .......................................................................................................... 369
11.1.17 Spare parts ...................................................................................................................... 370
11.1.17.1 Stocking of spare parts..................................................................................................... 370
11.1.17.2 Spares on Web................................................................................................................. 371
11.2 Specific data motor.......................................................................................................... 372
11.2.1 General motor information .............................................................................................. 372
11.2.2 Use as prescribed............................................................................................................. 373
11.2.3 General technical description ........................................................................................... 374
11.2.4 Cooling............................................................................................................................ 375
11.2.5 Terminal box and application box..................................................................................... 375
11.2.6 Fastening for suspended transport ................................................................................... 375
11.2.7 Storage............................................................................................................................ 376
11.2.8 Installation conditions for the motor ................................................................................ 376
11.2.9 Condensation drain hole (optional) .................................................................................. 378
11.2.10 Connecting the motor in the terminal box........................................................................ 378
11.2.10.1 General notes for motor connection (Wall Mounted) ........................................................ 378
11.2.10.2 Terminal box ................................................................................................................... 379
11.2.10.3 Terminal marking ............................................................................................................ 380
11.2.10.4 Direction of rotation ........................................................................................................ 380
11.2.10.5 Connecting the cables in the terminal box........................................................................ 381
11.2.10.6 External grounding .......................................................................................................... 382
11.2.10.7 Mounting and installation (Wall Mounted) ....................................................................... 382
11.2.11 Converter operation......................................................................................................... 384
11.2.12 Checking the insulation resistance (Wall Mounted)........................................................... 385
11.2.13 Commissioning the motor................................................................................................ 386
11.2.14 Faults, causes and remedies............................................................................................. 388
11.2.15 General notes about maintenance.................................................................................... 389
11.2.16 Locking the manual release of the brake (optional) .......................................................... 390
11.2.17 Lubrication ...................................................................................................................... 391
11.2.18 Checking the tightness of fastening bolts ......................................................................... 392
11.2.19 Inspection of the motor ................................................................................................... 393
11.2.20 Servicing the brake .......................................................................................................... 393
11.2.20.1Wear of the spring-operated brake ................................................................................... 393
11.2.20.2 Maintenance intervals for the brake ................................................................................. 394
11.2.20.3 Adjusting the air gap........................................................................................................ 394

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12 Operating Instructions, 09/2020, FW V4.7 SP13, A5E48681219B
11.2.20.4 Replacing the friction lining ............................................................................................. 396
11.2.21 Circuit diagrams............................................................................................................... 397
11.2.22 Spare parts list, motor...................................................................................................... 399
11.2.22.1 Motor frame sizes 71 - 132 .............................................................................................. 399
11.2.22.2 Brake............................................................................................................................... 402
11.3 Specific data gearbox....................................................................................................... 403
11.3.1 General information gearbox ........................................................................................... 403
11.3.2 Use for the intended purpose........................................................................................... 405
11.3.3 General technical description........................................................................................... 406
11.3.4 Shaft seals....................................................................................................................... 407
11.3.5 Cooling............................................................................................................................ 407
11.3.6 Fastening for suspended transport................................................................................... 408
11.3.7 Storage ........................................................................................................................... 408
11.3.7.1 General information for storage....................................................................................... 408
11.3.7.2 General notes for storage up to 36 months ...................................................................... 409
11.3.7.3 Gearbox filled with operating oil and anti-corrosive agent ................................................ 409
11.3.7.4 Gearbox completely filled with oil .................................................................................... 409
11.3.8 Gearbox with foot mounting............................................................................................ 410
11.3.9 Gearbox with flange mounting ........................................................................................ 411
11.3.10 Gearboxes in foot or flange version.................................................................................. 412
11.3.11 Mounting an input or output element on the gearbox shaft.............................................. 412
11.3.12 Removing and installing the protection cover................................................................... 414
11.3.13 General information on installing the shaft-mounted gearbox .......................................... 415
11.3.14 Hollow shaft with feather key .......................................................................................... 416
11.3.14.1Mounting the hollow shaft with parallel key..................................................................... 416
11.3.14.2 Removing the hollow shaft with parallel key..................................................................... 417
11.3.15 Hollow shaft with shrink disk ........................................................................................... 419
11.3.15.1 Mounting the hollow shaft with shrink disk...................................................................... 419
11.3.15.2 Mounting the shrink disk ................................................................................................. 420
11.3.15.3 Pulling off the shrink disk................................................................................................. 422
11.3.15.4 Cleaning and lubricating shrink disks................................................................................ 422
11.3.16 SIMOLOC assembly system .............................................................................................. 423
11.3.16.1 General notes for the SIMOLOC assembly system ............................................................. 423
11.3.16.2 Installing SIMOLOC .......................................................................................................... 424
11.3.16.3 Removing SIMOLOC......................................................................................................... 426
11.3.17 Hollow shaft with splines ................................................................................................. 426
11.3.18 Torque arms with slip-on gearboxes................................................................................. 427
11.3.18.1 General information regarding torque arms ..................................................................... 427
11.3.18.2 Mounting torque arms on parallel shaft gearboxes........................................................... 428
11.3.18.3 Mounting torque arms on bevel gearboxes and helical worm gearboxes........................... 429
11.3.19 General information for commissioning ........................................................................... 430
11.3.20 Checking the oil level prior to commissioning................................................................... 430
11.3.21 Mounting the oil expansion tank...................................................................................... 431
11.3.22 Faults, causes and remedies............................................................................................. 432
11.3.23 General notes about maintenance work ........................................................................... 434
11.3.24 Checking and changing lubricants.................................................................................... 435
11.3.24.1 General safety instructions............................................................................................... 435
11.3.24.2 Checking the oil level....................................................................................................... 436
11.3.24.3 Checking the oil level using the oil sight glass (optional) .................................................. 437
11.3.24.4Checking the oil level using the oil dipstick (optional)....................................................... 437
11.3.24.5 Checking the oil quality.................................................................................................... 438
11.3.24.6 General safety notes for changing the oil ......................................................................... 439

Table of contents
SINAMICS G115D distributed drive
Operating Instructions, 09/2020, FW V4.7 SP13, A5E48681219B 13
11.3.24.7 Draining the oil................................................................................................................ 439
11.3.24.8 Flushing the gearbox when changing between incompatible oils...................................... 440
11.3.24.9 Filling in oil...................................................................................................................... 441
11.3.24.10 Topping up with oil.......................................................................................................... 442
11.3.24.11 Change the roller bearing grease...................................................................................... 442
11.3.24.12 Service life of the lubricants ............................................................................................. 443
11.3.24.13 Recommended lubricants................................................................................................. 444
11.3.25 Replace bearings.............................................................................................................. 446
11.3.26 Checking the gearbox for leaks ........................................................................................ 446
11.3.27 Replacing the vent valve .................................................................................................. 446
11.3.28 Checking the oil level sensor (optional)............................................................................ 446
11.3.29 Checking the tightness of fastening bolts ......................................................................... 447
11.3.30 Replacing the hose of the oil expansion unit..................................................................... 447
11.3.31 Mounting positions.......................................................................................................... 448
11.3.31.1 General notes on mounting positions............................................................................... 448
11.3.31.2 Single-stage helical gearboxes ......................................................................................... 449
11.3.31.3 Two- and three-stage helical gearbox............................................................................... 451
11.3.31.4 Parallel shaft gearbox....................................................................................................... 458
11.3.31.5 Bevel gearbox.................................................................................................................. 464
11.3.31.6 Helical worm gearbox ...................................................................................................... 473
11.3.32 Oil quantities ................................................................................................................... 482
11.3.32.1 Helical gearbox................................................................................................................ 482
11.3.32.2 Parallel shaft gearbox....................................................................................................... 483
11.3.32.3 Bevel gearbox.................................................................................................................. 484
11.3.32.4Helical worm gearbox ...................................................................................................... 485
11.3.33 Replacement part lists gearbox......................................................................................... 486
11.3.33.1 Helical gearbox E, sizes 39 - 89 ........................................................................................ 486
11.3.33.2 Helical gearbox D / Z, sizes 19 - 89 ................................................................................... 488
11.3.33.3 Parallel shaft gearbox F, sizes 29 - 89 ............................................................................... 490
11.3.33.4 Bevel gearbox B, sizes 19 - 49 .......................................................................................... 492
11.3.33.5 Bevel gearbox K, sizes 39 - 89 .......................................................................................... 494
11.3.33.6 Helical worm gearbox C, sizes 29 - 89 .............................................................................. 496
11.3.33.7 SIMOLOC assembly system, sizes 29 - 89.......................................................................... 498
A Appendix............................................................................................................................................ 501
A.1 Interconnecting signals in the converter........................................................................... 501
A.1.1 Fundamentals.................................................................................................................. 501
A.1.2 Application example ........................................................................................................ 503
A.2 Acceptance tests for the safety functions ......................................................................... 504
A.2.1 Recommended acceptance test........................................................................................ 504
A.2.2 Acceptance test STO (basic functions) .............................................................................. 505
A.2.3 Machine documentation .................................................................................................. 507
A.3 Manuals and technical support......................................................................................... 509
A.3.1 Overview of the manuals ................................................................................................. 509
A.3.2 Configuring support......................................................................................................... 510
A.3.3 Product support ............................................................................................................... 511
Index .................................................................................................................................................. 513

Table of contents
SINAMICS G115D distributed drive
14 Operating Instructions, 09/2020, FW V4.7 SP13, A5E48681219B

SINAMICS G115D distributed drive
Operating Instructions, 09/2020, FW V4.7 SP13, A5E48681219B 15
Fundamental safety instructions
1
1.1 General safety instructions
WARNING
Electric shock and danger to life due to other energy sources
Touching live components can result in death or severe injury.
•Only work on electrical devices when you are qualified for this job.
•Always observe the country-specific safety rules.
Generally, the following steps apply when establishing safety:
1. Prepare for disconnection. Notify all those who will be affected by the procedure.
2. Isolate the drive system from the power supply and take measures to prevent it being
switched back on again.
3. Wait until the discharge time specified on the warning labels has elapsed.
4. Check that there is no voltage between any of the power connections, and between any of
the power connections and the protective conductor connection.
5. Check whether the existing auxiliary supply circuits are de-energized.
6. Ensure that the motors cannot move.
7. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or
water. Switch the energy sources to a safe state.
8. Check that the correct drive system is completely locked.
After you have completed the work, restore the operational readiness in the inverse
sequence.
WARNING
Risk of electric shock and fire from supply networks with an excessively high
impedance
Excessively low short-circuit currents can lead to the protective devices not tripping or
tripping too late, and thus causing electric shock or a fire.
•In the case of a conductor-conductor or conductor-ground short-circuit, ensure that the
short-circuit current at the point where the converter is connected to the line supply at
least meets the minimum requirements for the response of the protective device used.
•You must use an additional residual-current device (RCD) if a conductor-ground short
circuit does not reach the short-circuit current required for the protective device to
respond. The required short-circuit current can be too low, especially for TT supply
systems.

Fundamental safety instructions
1.1 General safety instructions
SINAMICS G115D distributed drive
16 Operating Instructions, 09/2020, FW V4.7 SP13, A5E48681219B
WARNING
Risk of electric shock and fire from supply networks with an excessively low
impedance
Excessively high short-circuit currents can lead to the protective devices not being able to
interrupt these short-circuit currents and being destroyed, and thus causing electric shock or
a fire.
•Ensure that the prospective short-circuit current at the line terminal of the converter
does not exceed the breaking capacity (SCCR or Icc) of the protective device used.
WARNING
Electric shock if there is no ground connection
For missing or incorrectly implemented protective conductor connection for devices with
protection class I, high voltages can be present at open, exposed parts, which when
touched, can result in death or severe injury.
•
Ground the device in compliance with the applicable regulations.
WARNING
Electric shock due to connection to an unsuitable power supply
When equipment is connected to an unsuitable power supply, exposed components may
carry a hazardous voltage. Contact with hazardous voltage can result in severe injury or
death.
•Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV-
(Protective Extra Low Voltage) output voltages for all connections and terminals of the
electronics modules.
WARNING
Electric shock due to damaged motors or devices
Improper handling of motors or devices can damage them.
Hazardous voltages can be present at the enclosure or at exposed components on damaged
motors or devices.
•Ensure compliance with the limit values specified in the technical data during transport,
storage and operation.
•
Do not use any damaged motors or devices.
WARNING
Electric shock due to unconnected cable shield
Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected
cable shields.
•Attach the cable shields at least on one side to the grounded housing potential.

Fundamental safety instructions
1.1 General safety instructions
SINAMICS G115D distributed drive
Operating Instructions, 09/2020, FW V4.7 SP13, A5E48681219B 17
WARNING
Arcing when a plug connection is opened during operation
Opening a plug connection when a system is operation can result in arcing that may cause
serious injury or death.
•Only open plug connections when the equipment is in a voltage-free state, unless it has
been explicitly stated that they can be opened in operation.
WARNING
Electric shock due to residual charges in power components
Because of the capacitors, a hazardous voltage is present for up to 5 minutes after the
power supply has been switched off. Contact with live parts can result in death or serious
injury.
•Wait for 5 minutes before you check that the unit really is in a no-voltage condition and
start work.
NOTICE
Damage to equipment due to unsuitable tightening tools.
Unsuitable tightening tools or fastening methods can damage the screws of the equipment.
•Be sure to only use screwdrivers which exactly match the heads of the screws.
•Tighten the screws with the torque specified in the technical documentation.
•Use a torque wrench or a mechanical precision nut runner with a dynamic torque sensor
and speed limitation system.
WARNING
Active implant malfunctions due to electromagnetic fields
Converters generate electromagnetic fields (EMF) in operation. Electromagnetic fields may
interfere with active implants, e.g. pacemakers. People with active implants in the
immediate vicinity of an converter are at risk.
•As the operator of an EMF-emitting installation, assess the individual risks of persons
with active implants.
•
Observe the data on EMF emission provided in the product documentation.

Fundamental safety instructions
1.1 General safety instructions
SINAMICS G115D distributed drive
18 Operating Instructions, 09/2020, FW V4.7 SP13, A5E48681219B
WARNING
Unexpected movement of machines caused by radio devices or mobile phones
Using radio devices or mobile telephones in the immediate vicinity of the components can
result in equipment malfunction. Malfunctions may impair the functional safety of machines
and can therefore put people in danger or lead to property damage.
•Therefore, if you move closer than 20 cm to the components, be sure to switch off radio
devices or mobile telephones.
•Use the "SIEMENS Industry Online Support app" only on equipment that has already been
switched off.
NOTICE
Damage to motor insulation due to excessive voltages
When operated on systems with grounded line conductor or in the event of a ground fault
in the IT system, the motor insulation can be damaged by the higher voltage to ground. If
you use motors that have insulation that is not designed for operation with grounded line
conductors, you must perform the following measures:
•IT system: Use a ground fault monitor and eliminate the fault as quickly as possible.
•TN or TT systems with grounded line conductor: Use an isolating transformer on the line
side.
WARNING
Fire due to inadequate ventilation clearances
Inadequate ventilation clearances can cause overheating of components with subsequent
fire and smoke. This can cause severe injury or even death. This can also result in increased
downtime and reduced service lives for devices/systems.
•Ensure compliance with the specified minimum clearance as ventilation clearance for the
respective component.
NOTICE
Overheating due to inadmissible mounting position
The device may overheat and therefore be damaged if mounted in an inadmissible position.
•
Only operate the device in admissible mounting positions.