Siemens SINAMICS G115D User manual

OPERATING INSTRUCTIONS
Edition
Distributed drive for conveyor applications
07/2023
www.siemens.com/drives
SINAMICS
SINAMICS G115D Wall Mounted

SINAMICS
SINAMICS G115D
SINAMICS G115D Wall Mounted
distributed drive
Operating Instructions
Edition 07/2023, Firmware V4.7 SP14
07/2023, FW V4.7 SP14
A5E52808211A AA
Preface
Changes in the manual 1
Fundamental safety
instructions 2
Overview of the SINAMICS
G115D drive 3
Mounting 4
Wiring 5
Commissioning 6
Advanced commissioning 7
Data backup and series
commissioning 8
Alarms, faults and system
messages 9
Corrective maintenance 10
Technical data 11
Additional information on
the SIMOGEAR geared
motor 12
Appendix A

Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Quali󹪝ed Personnel
The product/system described in this documentation may be operated only by personnel quali󹪝ed for the speci󹪝c
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Quali󹪝ed 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 identi󹪝ed by ® are registered trademarks of SiemensAG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Digital Industries
Postfach 48 48
90026 NÜRNBERG
GERMANY
Document order number:(nul)
Ⓟ 09/2023 Subject to change
Copyright © SiemensAG 2023.
All rights reserved

Preface
About the Manual
Who requires the operating instructions and what for?
These operating instructions primarily address 󹪝tters, 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 su󹪟cient for all standard applications and enables drives to be commissioned
as e󹪟ciently 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 con󹪝gure and
parameterize these applications, the relevant information is summarized accordingly. This
relates, e.g. to operation with 󹪝eldbus 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 speci󹪝cations 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.
You can use equivalent products from other manufacturers.
SINAMICS G115D Wall Mounted distributed drive
Operating Instructions, 07/2023, FW V4.7 SP14, A5E52808211A AA 3

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:[e-mail])
Preface
SINAMICS G115D Wall Mounted distributed drive
4Operating Instructions, 07/2023, FW V4.7 SP14, A5E52808211A AA

Table of contents
Preface ................................................................................................................................................... 3
1 Changes in the manual........................................................................................................................ 15
1.1 Changes in the manual ...................................................................................................... 15
2 Fundamental safety instructions......................................................................................................... 17
2.1 General safety instructions................................................................................................. 17
2.2 Equipment damage due to electric 󹪝elds or electrostatic discharge ..................................... 23
2.3 Warranty and liability for application examples ................................................................... 23
2.4 Cybersecurity information.................................................................................................. 23
2.5 Residual risks of power drive systems ................................................................................. 25
3 Overview of the SINAMICS G115D drive.............................................................................................. 27
3.1 System overview................................................................................................................ 27
3.2 Scope of delivery ............................................................................................................... 28
3.2.1 SINAMICS G115D Wall Mounted......................................................................................... 28
3.3 Directives and standards .................................................................................................... 33
3.4 Optional components ........................................................................................................ 34
3.4.1 External braking resistor..................................................................................................... 34
3.4.2 Connectors ........................................................................................................................ 35
3.4.3 Glanded installation kit ...................................................................................................... 36
3.4.4 Connector cover kit............................................................................................................ 36
3.4.5 SINAMICS G120 Smart Access ............................................................................................ 37
3.4.6 SAM interface kit ............................................................................................................... 37
4 Mounting ............................................................................................................................................. 39
4.1 Mounting the G115D Wall Mounted drive........................................................................... 39
4.2 Mounting the optional components ................................................................................... 42
4.2.1 Mounting the external braking resistor............................................................................... 42
4.2.2 Mounting the SINAMICS G120 Smart Access....................................................................... 44
5 Wiring .................................................................................................................................................. 49
5.1 EMC installation guidelines ................................................................................................ 49
5.1.1 Connections and interference suppression ......................................................................... 49
5.1.2 Basic EMC rules.................................................................................................................. 49
5.1.3 Equipotential bonding........................................................................................................ 50
5.2 Permissible line supplies..................................................................................................... 52
5.2.1 TN line system ................................................................................................................... 53
5.2.2 TT line system.................................................................................................................... 53
5.2.3 IT line system..................................................................................................................... 54
5.3 Requirements for the protective conductor ......................................................................... 57
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5.4 Requirements for branch circuit protection ......................................................................... 58
5.5 Operation with residual current protective device (RCD)...................................................... 58
5.6 Forming DC link capacitors................................................................................................. 59
5.7 Overview of the converter interfaces.................................................................................. 60
5.7.1 Overview........................................................................................................................... 60
5.8 Cables and connectors ....................................................................................................... 64
5.8.1 Maximum permissible cable length .................................................................................... 65
5.8.2 Cable cross-sections and cable lugs .................................................................................... 66
5.9 Connecting the line supply................................................................................................. 69
5.9.1 Interface description - X1/X3 .............................................................................................. 69
5.9.2 Connecting to the line supply using daisy chain.................................................................. 71
5.10 Connecting the motor........................................................................................................ 73
5.10.1 Interface description - X2 ................................................................................................... 74
5.10.2 Connecting the motor in a star or delta connection ............................................................ 75
5.10.2.1 Overview........................................................................................................................... 75
5.10.2.2 Con󹪝guring the star/delta connection of the wall-mounted converter ................................. 77
5.11 Connecting the 24 V power supply..................................................................................... 77
5.11.1 Interface description - X01/X02 .......................................................................................... 77
5.11.2 Connecting to the 24 V power supply using daisy chain...................................................... 79
5.12 Connecting the digital inputs and outputs .......................................................................... 81
5.12.1 Interface description - X07/X08/x05 ................................................................................... 81
5.12.2 Factory interface setting .................................................................................................... 82
5.12.3 Fail-safe digital input.......................................................................................................... 88
5.13 Connecting to PROFINET and Ethernet................................................................................ 89
5.13.1 Interface description - X150 P1/P2...................................................................................... 89
5.13.2 Communication via PROFINET IO and Ethernet ................................................................... 89
5.13.3 Protocols used ................................................................................................................... 90
5.13.4 Connecting the converter to PROFINET............................................................................... 92
5.13.5 What do you have to set for communication via PROFINET.................................................. 92
5.13.6 Installing GSDML ............................................................................................................... 93
5.13.7 Connecting the converter to Ethernet/IP ............................................................................. 94
5.13.8 What do you need for communication via Ethernet/IP?........................................................ 94
5.14 Connecting to AS-i ............................................................................................................. 95
5.14.1 General information........................................................................................................... 95
5.14.2 Interface description - X03 ................................................................................................. 96
5.14.3 Setting the address ............................................................................................................ 96
5.14.4 Using the AS-i Programmer ................................................................................................ 98
5.15 Connecting to SINAMICS G115D I/O variant...................................................................... 100
5.16 Grounding the converter housing..................................................................................... 100
5.17 Connecting the external braking resistor .......................................................................... 101
5.18 Connection examples....................................................................................................... 103
6 Commissioning .................................................................................................................................. 105
6.1 Commissioning guidelines ............................................................................................... 105
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6.2 Commissioning tools........................................................................................................ 106
6.3 Preparing for commissioning............................................................................................ 107
6.3.1 Factory settings ............................................................................................................... 107
6.3.2 Collecting motor data ...................................................................................................... 109
6.3.3 Selecting U/f control or speed control............................................................................... 111
6.3.4 Calculating maximum speed for permanent magnet synchronous motors ......................... 112
6.4 Quick commissioning....................................................................................................... 113
6.4.1 Quick commissioning with DIP switches ........................................................................... 113
6.4.2 Quick commissioning with a PC (Startdrive)...................................................................... 116
6.4.2.1 Creating a project ............................................................................................................ 117
6.4.2.2 Integrating the converter into the project ........................................................................ 117
6.4.2.3 Starting the Commissioning Wizard ................................................................................. 119
6.4.2.4 Carrying out quick commissioning ................................................................................... 119
6.4.2.5 Identifying motor data .................................................................................................... 121
6.4.3 Quick commissioning with the SINAMICS G120 Smart Access ........................................... 123
6.4.4 Self-optimization of the speed control .............................................................................. 124
6.5 Saving the settings in the converter (RAM → EEPROM) ..................................................... 124
6.6 Restoring the factory settings........................................................................................... 125
6.6.1 Restoring the factory settings/delivery condition (without safety functions) ..................... 126
6.6.2 Resetting the safety functions to the factory settings ........................................................ 127
7 Advanced commissioning.................................................................................................................. 129
7.1 Overview of converter functions ...................................................................................... 129
7.2 Sequence control when switching the motor on and o󹪜.................................................... 131
7.3 Adapt the default settings of the inputs and outputs......................................................... 133
7.3.1 Overview......................................................................................................................... 133
7.3.2 Digital Inputs ................................................................................................................... 134
7.3.3 Digital outputs................................................................................................................. 135
7.4 Controlling clockwise and counter-clockwise rotation via digital inputs ............................. 136
7.4.1 Two-wire control, method 1 ............................................................................................. 137
7.4.2 Two-wire control, method 2 ............................................................................................. 138
7.4.3 Two-wire control, method 3 ............................................................................................. 139
7.4.4 Three-wire control, method 1........................................................................................... 140
7.4.5 Three-wire control, method 2........................................................................................... 141
7.5 Drive control via PROFINET............................................................................................... 142
7.5.1 Receive data and send data.............................................................................................. 142
7.5.2 Telegrams........................................................................................................................ 143
7.5.3 Control and status word 1 ................................................................................................ 145
7.5.4 Control and status word 3 ................................................................................................ 147
7.5.5 Control and status word G115D ....................................................................................... 148
7.5.6 NAMUR message word..................................................................................................... 150
7.5.7 Parameter channel........................................................................................................... 150
7.5.8 Expanding or freely interconnecting telegrams................................................................. 154
7.5.9 Acyclically reading and writing converter parameters ....................................................... 156
7.6 Drive control via Ethernet/IP ............................................................................................. 157
7.6.1 Con󹪝guring communication via Ethernet/IP ...................................................................... 157
7.6.2 Supported objects............................................................................................................ 160
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7.6.3 Supported ODVA AC/DC assemblies .................................................................................. 171
7.6.4 Creating generic I/O module............................................................................................. 172
7.6.5 The converter as Ethernet node........................................................................................ 173
7.7 Drive control via AS-i ....................................................................................................... 173
7.7.1 Single Slave mode ........................................................................................................... 173
7.7.2 Dual Slave mode .............................................................................................................. 175
7.7.3 Assignment tables ........................................................................................................... 178
7.7.4 Cyclic and acyclic communication via CTT2....................................................................... 180
7.7.4.1 Cyclic communication...................................................................................................... 181
7.7.4.2 Acyclic communication - standard .................................................................................... 182
7.7.4.3 Acyclic communication - manufacturer-speci󹪝c ................................................................ 182
7.8 Jogging ........................................................................................................................... 184
7.9 Conveyor technology control functions (for G115D PROFINET and AS-i variants only)........ 185
7.9.1 Conveyors........................................................................................................................ 186
7.9.1.1 Conveyor, one direction and one speed (p3393 = 1) ......................................................... 186
7.9.1.2 Conveyor, one direction and two speeds (p3393 = 2)........................................................ 188
7.9.1.3 Conveyor, two directions and one speed (p3393 = 3)........................................................ 190
7.9.1.4 Conveyor, two directions and two speeds (p3393 = 4) ...................................................... 192
7.9.2 Turntables ....................................................................................................................... 194
7.9.2.1 Turntable, two positions and one speed (p3393 = 5) ........................................................ 195
7.9.2.2 Turntable, two positions and two speeds (p3393 = 6)....................................................... 198
7.9.2.3 Turntable, three positions and one speed (p3393 = 7) ...................................................... 202
7.9.2.4 Turntable, three positions and two speeds (p3393 = 8)..................................................... 205
7.9.3 Corner turntable lifts........................................................................................................ 208
7.9.3.1 Corner turntable lift, two positions and one speed (p3393 = 9)......................................... 209
7.9.3.2 Corner turntable lift, two positions and two speeds (p3393 = 10) ..................................... 212
7.9.4 Travelling trolleys............................................................................................................. 214
7.9.4.1 Travelling trolley, one speed (p3393 = 11) ........................................................................ 215
7.9.4.2 Travelling trolley, two speeds (p3393 = 12) ...................................................................... 217
7.9.5 Conveyor technology control parameters.......................................................................... 220
7.10 Switching over the drive control (command data set) ....................................................... 222
7.11 Motor holding brake ........................................................................................................ 224
7.12 Encoder Interface ............................................................................................................ 229
7.13 Free function block .......................................................................................................... 230
7.14 Selecting physical units.................................................................................................... 230
7.14.1 Motor standard................................................................................................................ 230
7.14.2 System of units................................................................................................................ 231
7.14.3 Technological unit of the technology controller ................................................................ 232
7.14.4 Setting the system of units and technology unit ............................................................... 233
7.15 Safe Torque O󹪜 (STO) safety function ............................................................................... 233
7.15.1 Function description ........................................................................................................ 234
7.15.2 Commissioning STO ......................................................................................................... 236
7.15.2.1 Commissioning tool ......................................................................................................... 236
7.15.2.2 Safety function password ................................................................................................. 236
7.15.2.3 Con󹪝guring a safety function ........................................................................................... 237
7.15.2.4 Interconnecting the "STO active" signal............................................................................. 238
7.15.2.5 Setting the 󹪝lter for fail-safe digital inputs ........................................................................ 239
7.15.2.6 Setting the forced checking procedure (test stop) ............................................................. 242
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7.15.2.7 Finalizing online commissioning....................................................................................... 243
7.15.2.8 Checking the interconnection of digital inputs.................................................................. 245
7.15.2.9 Acceptance - completion of commissioning...................................................................... 246
7.16 Safely Limited Speed (SLS) ............................................................................................... 247
7.17 Setpoints ......................................................................................................................... 255
7.17.1 Overview......................................................................................................................... 255
7.17.2 Specifying the setpoint via the 󹪝eldbus............................................................................. 256
7.17.3 Electromechanical potentiometer..................................................................................... 257
7.17.4 Motorized potentiometer as setpoint source ..................................................................... 258
7.17.5 Fixed speed setpoint as setpoint source............................................................................ 262
7.18 Setpoint processing.......................................................................................................... 265
7.18.1 Overview......................................................................................................................... 265
7.18.2 Invert setpoint ................................................................................................................. 266
7.18.3 Inhibit direction of rotation .............................................................................................. 267
7.18.4 Skip frequency bands and minimum speed....................................................................... 268
7.18.5 Speed limitation .............................................................................................................. 269
7.18.6 Ramp-function generator................................................................................................. 270
7.19 PID technology controller ................................................................................................. 275
7.20 Motor control................................................................................................................... 282
7.20.1 Setting the saturation characteristic of the permanent magnet synchronous motor (third-
party motor) .................................................................................................................... 282
7.20.2 U/f control ....................................................................................................................... 284
7.20.2.1 Characteristics of U/f control ............................................................................................ 285
7.20.2.2 Selecting the U/f characteristic ......................................................................................... 286
7.20.2.3 Optimizing motor starting................................................................................................ 287
7.20.3 Sensorless vector control with speed controller................................................................. 289
7.20.3.1 Structure of vector control without encoder (sensorless)................................................... 289
7.20.3.2 Optimizing the closed-loop speed controller..................................................................... 291
7.20.3.3 Advanced settings............................................................................................................ 293
7.20.3.4 Optimizing the operation of the permanent magnet synchronous motor........................... 295
7.20.3.5 Friction characteristic....................................................................................................... 297
7.20.3.6 Moment of inertia estimator ............................................................................................ 299
7.20.3.7 Pole position identi󹪝cation ............................................................................................... 306
7.20.4 Torque control ................................................................................................................. 308
7.21 Electrically braking the motor........................................................................................... 309
7.21.1 DC braking....................................................................................................................... 310
7.21.2 Dynamic braking.............................................................................................................. 313
7.22 Overcurrent protection..................................................................................................... 315
7.23 Converter protection using temperature monitoring ......................................................... 316
7.24 Motor temperature monitoring using a temperature sensor.............................................. 320
7.25 Motor protection by calculating the temperature .............................................................. 323
7.26 Motor and converter protection by limiting the voltage..................................................... 325
7.27 Monitoring the driven load............................................................................................... 327
7.27.1 No-load monitoring ......................................................................................................... 327
7.27.2 Rotation monitoring......................................................................................................... 328
7.27.3 Torque monitoring........................................................................................................... 329
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7.27.4 Blocking protection, leakage protection and dry-running protection.................................. 331
7.28 E󹪟ciency optimization..................................................................................................... 334
7.29 Calculating the energy saving for 󹪞uid 󹪞ow machines....................................................... 337
7.30 Switchover between di󹪜erent settings.............................................................................. 340
7.31 Activating licensed functions............................................................................................ 342
7.31.1 Licensing ......................................................................................................................... 342
7.31.2 Creating or displaying the license key ............................................................................... 343
7.31.3 Writing the license key to the card.................................................................................... 345
7.31.4 Recommended memory cards.......................................................................................... 347
8 Data backup and series commissioning ............................................................................................ 351
8.1 Transferring settings using a memory card ....................................................................... 352
8.1.1 Memory cards.................................................................................................................. 352
8.1.2 Converter → Memory card ............................................................................................... 353
8.1.3 Memory card → converter................................................................................................ 355
8.1.4 Activating message for a memory card that is not inserted ............................................... 357
8.2 Transferring settings using a PG/PC................................................................................... 358
8.2.1 Converter → PG/PC........................................................................................................... 358
8.2.2 PG/PC → converter........................................................................................................... 359
8.3 Other ways to back up settings......................................................................................... 361
8.4 Write protection............................................................................................................... 361
8.5 Know-how protection ...................................................................................................... 362
8.5.1 Extending the exception list for know-how protection ...................................................... 364
8.5.2 Activating and deactivating know-how protection ............................................................ 366
9 Alarms, faults and system messages................................................................................................. 369
9.1 Status LED overview......................................................................................................... 369
9.2 System runtime ............................................................................................................... 373
9.3 Identi󹪝cation & maintenance data (I&M) .......................................................................... 373
9.4 Alarms, alarm bu󹪜er, and alarm history ............................................................................ 374
9.5 Faults, fault bu󹪜er and fault history.................................................................................. 378
9.6 List of alarms and faults ................................................................................................... 381
10 Corrective maintenance .................................................................................................................... 387
10.1 Spare parts compatibility ................................................................................................. 387
10.2 Replacing the converter ................................................................................................... 388
10.2.1 Replacing the converter hardware .................................................................................... 388
10.2.2 Replacing a converter with active know-how protection.................................................... 390
10.2.2.1 Replacing a converter with know-how protection without copy protection ........................ 390
10.2.2.2 Replacing a converter with know-how protection with copy protection ............................. 390
10.3 Replacing the spare parts ................................................................................................. 392
10.3.1 Spare parts overview........................................................................................................ 393
10.3.2 Replacing the Electronic Module....................................................................................... 394
10.3.3 Replacing the fan unit...................................................................................................... 396
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10.4 Repair switch ................................................................................................................... 398
10.5 Local/Remote control panel .............................................................................................. 399
10.6 Firmware upgrade and downgrade................................................................................... 401
10.6.1 Preparing the memory card.............................................................................................. 403
10.6.2 Upgrading the 󹪝rmware ................................................................................................... 403
10.6.3 Downgrading the 󹪝rmware .............................................................................................. 406
10.6.4 Correcting an unsuccessful 󹪝rmware upgrade or downgrade ............................................ 408
10.7 Reduced acceptance test after component replacement and 󹪝rmware change .................. 409
11 Technical data.................................................................................................................................... 411
11.1 Technical data of the G115D wall-mounted converter....................................................... 411
11.1.1 General converter technical data...................................................................................... 411
11.1.2 Technical data of inputs and outputs ................................................................................ 413
11.1.3 Technical data dependent upon the power ....................................................................... 413
11.1.4 Technical data of braking resistors.................................................................................... 415
11.1.5 Load cycles and overload capabilities................................................................................ 417
11.1.6 Derating data................................................................................................................... 418
11.1.6.1 Torque derating as a function of the installation altitude................................................... 418
11.1.6.2 Current derating as a function of the surrounding temperature......................................... 419
11.1.6.3 Torque derating as a function of the line voltage .............................................................. 419
11.1.6.4 Current derating as a function of the pulse frequency....................................................... 420
11.1.6.5 Derating of motor cable length based on pulse frequency and surrounding temperature... 421
11.2 Low frequency operation ................................................................................................. 421
11.3 Data regarding the power loss in partial load operation .................................................... 422
11.4 Electromagnetic compatibility of the converter................................................................. 422
11.5 Protecting persons from electromagnetic 󹪝elds................................................................. 424
12 Additional information on the SIMOGEAR geared motor.................................................................. 427
12.1 General information geared motor with SINAMICS G115D Motor Mounted / Wall Mounted... 427
12.1.1 Speci󹪝c hazard types and fundamental obligations........................................................... 427
12.1.2 Rating plate ..................................................................................................................... 428
12.1.3 Surface treatment............................................................................................................ 428
12.1.3.1 General information on surface treatment........................................................................ 428
12.1.3.2 Painted version ................................................................................................................ 429
12.1.3.3 Primed version................................................................................................................. 431
12.1.4 Incoming goods............................................................................................................... 431
12.1.5 General information on transport..................................................................................... 432
12.1.6 Unpacking ....................................................................................................................... 433
12.1.7 General information concerning the installation............................................................... 433
12.1.8 Installation notes ............................................................................................................. 435
12.1.9 Thread sizes and tightening torques for fastening bolts..................................................... 436
12.1.10 Operation ........................................................................................................................ 437
12.1.11 Cleaning the geared motor............................................................................................... 437
12.1.12 Inspecting the geared motor ............................................................................................ 438
12.1.13 Disposal........................................................................................................................... 438
12.1.14 Technical data.................................................................................................................. 439
12.1.14.1 Type designation motor and converter ............................................................................. 439
12.1.14.2 Gearbox type designation ................................................................................................ 440
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12.1.14.3 General technical data ..................................................................................................... 441
12.1.14.4 Rating plate for geared motors with SINAMICS G115D Motor Mounted ............................. 442
12.1.14.5 Rating plate for geared motors with SINAMICS G115D Wall Mounted ................................ 443
12.1.14.6 Weight............................................................................................................................. 444
12.1.14.7 Sound energy level .......................................................................................................... 444
12.1.15 Spare parts ...................................................................................................................... 445
12.1.15.1 Stocking of spare parts..................................................................................................... 445
12.1.15.2 Spares on Web................................................................................................................. 446
12.2 Speci󹪝c data motor .......................................................................................................... 447
12.2.1 General motor information .............................................................................................. 447
12.2.2 Use as prescribed............................................................................................................. 447
12.2.3 General technical description ........................................................................................... 448
12.2.4 Cooling............................................................................................................................ 449
12.2.5 Terminal box and application box ..................................................................................... 449
12.2.6 Fastening for suspended transport ................................................................................... 450
12.2.7 Storage............................................................................................................................ 450
12.2.8 Installation conditions for the motor ................................................................................ 451
12.2.9 Condensation drain hole (optional) .................................................................................. 452
12.2.10 Connecting the motor in the terminal box ........................................................................ 452
12.2.10.1 General notes for motor connection (Wall Mounted)......................................................... 453
12.2.10.2 Terminal box.................................................................................................................... 454
12.2.10.3 Terminal marking............................................................................................................. 455
12.2.10.4 Direction of rotation......................................................................................................... 455
12.2.10.5 Connecting the cables in the terminal box ........................................................................ 456
12.2.10.6 External grounding .......................................................................................................... 457
12.2.10.7 Mounting and installation (Wall Mounted) ....................................................................... 457
12.2.11 Converter operation......................................................................................................... 459
12.2.12 Checking the insulation resistance (Wall Mounted)........................................................... 460
12.2.13 Commissioning the motor................................................................................................ 461
12.2.14 Faults, causes and remedies ............................................................................................. 463
12.2.15 General notes about maintenance.................................................................................... 464
12.2.16 Locking the manual release of the brake (optional)........................................................... 465
12.2.17 Lubrication ...................................................................................................................... 465
12.2.18 Checking the tightness of fastening bolts ......................................................................... 467
12.2.19 Inspection of the motor.................................................................................................... 467
12.2.20 Servicing the brake .......................................................................................................... 467
12.2.20.1 Wear of the spring-operated brake ................................................................................... 467
12.2.20.2 Maintenance intervals for the brake ................................................................................. 468
12.2.20.3 Adjusting the air gap........................................................................................................ 469
12.2.20.4 Replacing the friction lining.............................................................................................. 471
12.2.21 Circuit diagrams............................................................................................................... 472
12.2.22 Spare parts list, motor...................................................................................................... 474
12.2.22.1 Motor frame sizes 71-132............................................................................................... 474
12.2.22.2 Brake............................................................................................................................... 478
12.3 Speci󹪝c data gearbox ....................................................................................................... 479
12.3.1 General information gearbox ........................................................................................... 479
12.3.2 Use for the intended purpose ........................................................................................... 480
12.3.3 General technical description ........................................................................................... 480
12.3.4 Shaft seals ....................................................................................................................... 481
12.3.5 Cooling............................................................................................................................ 482
12.3.6 Fastening for suspended transport ................................................................................... 483
Table of contents
SINAMICS G115D Wall Mounted distributed drive
12 Operating Instructions, 07/2023, FW V4.7 SP14, A5E52808211A AA

12.3.7 Storage............................................................................................................................ 484
12.3.7.1 General information for storage ....................................................................................... 484
12.3.7.2 General notes for storage up to 36months....................................................................... 485
12.3.7.3 Gearbox 󹪝lled with operating oil and anti-corrosive agent................................................. 485
12.3.7.4 Gearbox completely 󹪝lled with oil..................................................................................... 485
12.3.8 Gearbox with foot mounting ............................................................................................ 486
12.3.9 Gearbox with 󹪞ange mounting......................................................................................... 486
12.3.10 Gearboxes in foot or 󹪞ange version .................................................................................. 487
12.3.11 Mounting an input or output element on the gearbox shaft.............................................. 488
12.3.12 Removing and installing the protection cover ................................................................... 490
12.3.13 General information on installing the shaft-mounted gearbox .......................................... 491
12.3.14 Hollow shaft with feather key........................................................................................... 492
12.3.14.1 Mounting the hollow shaft with parallel key ..................................................................... 492
12.3.14.2 Removing the hollow shaft with parallel key..................................................................... 493
12.3.15 Hollow shaft with shrink disk ........................................................................................... 495
12.3.15.1 Mounting the hollow shaft with shrink disk ...................................................................... 495
12.3.15.2 Mounting the shrink disk.................................................................................................. 496
12.3.15.3 Pulling o󹪜 the shrink disk ................................................................................................. 498
12.3.15.4 Cleaning and lubricating shrink disks................................................................................ 498
12.3.16 SIMOLOC assembly system............................................................................................... 499
12.3.16.1 General notes for the SIMOLOC assembly system.............................................................. 499
12.3.16.2 Installing SIMOLOC .......................................................................................................... 501
12.3.16.3 Removing SIMOLOC ......................................................................................................... 503
12.3.17 Hollow shaft with splines ................................................................................................. 504
12.3.18 Torque arms with slip-on gearboxes ................................................................................. 505
12.3.18.1 General information regarding torque arms...................................................................... 505
12.3.18.2 Mounting torque arms on parallel shaft gearboxes ........................................................... 505
12.3.18.3 Mounting torque arms on bevel gearboxes and helical worm gearboxes ........................... 506
12.3.19 General information about commissioning....................................................................... 507
12.3.20 Checking the oil level prior to commissioning ................................................................... 508
12.3.21 Mounting the oil expansion tank...................................................................................... 508
12.3.22 Faults, causes and remedies ............................................................................................. 510
12.3.23 General notes about maintenance work ........................................................................... 512
12.3.24 Checking and changing lubricants.................................................................................... 514
12.3.24.1 General safety instructions............................................................................................... 514
12.3.24.2 Checking the oil level ....................................................................................................... 515
12.3.24.3 Checking the oil level using the oil sight glass (optional)................................................... 516
12.3.24.4 Checking the oil level using the oil dipstick (optional) ....................................................... 516
12.3.24.5 Checking the oil quality.................................................................................................... 517
12.3.24.6 General safety notes for changing the oil.......................................................................... 518
12.3.24.7 Draining the oil................................................................................................................ 518
12.3.24.8 Flushing the gearbox when changing between incompatible oils...................................... 519
12.3.24.9 Filling in oil...................................................................................................................... 520
12.3.24.10 Topping up with oil .......................................................................................................... 520
12.3.24.11 Change the roller bearing grease...................................................................................... 521
12.3.24.12 Service life of the lubricants ............................................................................................. 521
12.3.24.13 Recommended lubricants................................................................................................. 523
12.3.25 Replace bearings.............................................................................................................. 524
12.3.26 Checking the gearbox for leaks......................................................................................... 525
12.3.27 Replacing the vent valve .................................................................................................. 525
12.3.28 Checking the oil level sensor (optional) ............................................................................ 525
12.3.29 Checking the tightness of fastening bolts ......................................................................... 526
Table of contents
SINAMICS G115D Wall Mounted distributed drive
Operating Instructions, 07/2023, FW V4.7 SP14, A5E52808211A AA 13

12.3.30 Replacing the hose of the oil expansion unit..................................................................... 526
12.3.31 Mounting positions.......................................................................................................... 527
12.3.31.1 General notes on mounting positions............................................................................... 527
12.3.31.2 Single-stage helical gearboxes.......................................................................................... 528
12.3.31.3 Two- and three-stage helical gearbox ............................................................................... 530
12.3.31.4 Parallel shaft gearbox....................................................................................................... 537
12.3.31.5 Bevel gearbox .................................................................................................................. 543
12.3.31.6 Helical worm gearbox ...................................................................................................... 552
12.3.32 Oil quantities ................................................................................................................... 561
12.3.32.1 Helical gearbox ................................................................................................................ 561
12.3.32.2 Parallel shaft gearbox....................................................................................................... 562
12.3.32.3 Bevel gearbox .................................................................................................................. 563
12.3.32.4 Helical worm gearbox ...................................................................................................... 564
12.3.33 Replacement part lists gearbox......................................................................................... 565
12.3.33.1 Helical gearbox E, sizes 39 - 89......................................................................................... 565
12.3.33.2 Helical gearbox D/Z, sizes19-89.................................................................................... 566
12.3.33.3 Parallel shaft gearbox F, sizes29-89................................................................................ 568
12.3.33.4 Bevel gearbox B, sizes19-49........................................................................................... 570
12.3.33.5 Bevel gearbox K, frame sizes39-109............................................................................... 573
12.3.33.6 Helical worm gearbox C, sizes29-89............................................................................... 575
12.3.33.7 SIMOLOC assembly system, sizes 29 - 89.......................................................................... 578
A Appendix............................................................................................................................................ 581
A.1 Interconnecting signals in the converter .......................................................................... 581
A.1.1 Fundamentals.................................................................................................................. 581
A.1.2 Application example ........................................................................................................ 583
A.2 Acceptance tests for the safety functions.......................................................................... 584
A.2.1 Recommended acceptance test........................................................................................ 584
A.2.2 Acceptance test STO (basic functions) .............................................................................. 585
A.2.3 Machine documentation .................................................................................................. 586
A.3 Manuals and technical support......................................................................................... 588
A.3.1 Overview of the manuals ................................................................................................. 588
A.3.2 Con󹪝guring support......................................................................................................... 589
A.3.3 Product support ............................................................................................................... 590
Index .................................................................................................................................................. 593
Table of contents
SINAMICS G115D Wall Mounted distributed drive
14 Operating Instructions, 07/2023, FW V4.7 SP14, A5E52808211A AA

Changes in the manual 1
1.1 Changes in the manual
Changes in the manual - 07/2023 Edition
There are no changes to this manual
SINAMICS G115D Wall Mounted distributed drive
Operating Instructions, 07/2023, FW V4.7 SP14, A5E52808211A AA 15

Changes in the manual
1.1Changes in the manual
SINAMICS G115D Wall Mounted distributed drive
16 Operating Instructions, 07/2023, FW V4.7 SP14, A5E52808211A AA

Fundamental safety instructions 2
2.1 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 quali󹪝ed for this job.
• Always observe the country-speci󹪝c safety rules.
Generally, the following steps apply when establishing safety:
1. Prepare for disconnection. Notify all those who will be a󹪜ected 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 speci󹪝ed 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 󹪝re 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 󹪝re.
• 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.
SINAMICS G115D Wall Mounted distributed drive
Operating Instructions, 07/2023, FW V4.7 SP14, A5E52808211A AA 17

WARNING
Risk of electric shock and 󹪝re 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
󹪝re.
• 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 speci󹪝ed 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
2.1General safety instructions
SINAMICS G115D Wall Mounted distributed drive
18 Operating Instructions, 07/2023, FW V4.7 SP14, A5E52808211A AA