Siemens SINAMICS G120 User manual

Answers for industry.
SINAMICS G120
Training Booklet
V2.0

The booklet is an easy to understand introduction to the inverter
family SINAMICS G120.
09/2010
E80001-Y910-P210-X-7600
SINAMICS G120
Training Booklet, V2.0

Materials and tools
The components listed below are presented in this booklet. To test your knowledge on the actual
product, you have the choice between the following three order alternatives:
Starter Kit
Product Order-no.
• Starter Kit SINAMICS G120 6SL3200-0AE20-0AA0
• Motor (0.55 kW) 1LA7096-4AA10
Training case
Product Order-no.
• SINAMICS G120 training case* 6ZB2480-0CJ00
• SINAMICS G120 CU240E-2 Control Unit 6SL3244-0BB12-1BA0
Single components
Product Order-no.
• SINAMICS G120 PM240-2 FSA 0.55kW 6SL3210-1PE12-3AL0
• SINAMICS G120 CU240E-2 6SL3244-0BB12-1BA0
• Motor (0.55 kW) 1LA7096-4AA10
• SINAMICS PC Connection Kit-2 6SL3255 0AA00 2CA0
• SINAMICS BOP-2 6SL3255 0AA00 4CA1
• Screening kit 2 6SL3264-1EA00-0HA0
Optional components
Product Order-no.
• IOP/BOP-2 door mounting kit 6SL3256-0AP00-0JA0
In addition you will need the following equipment:
• PC with USB interface
• Switches – commercially available*
• Potentiometer – commercially available*
• Various M4 screws and nuts (length depends on installation location) with suitable
screwdriver / wrench – commercially available*
* The training case is a complete demo station including a motor, the power module of the converter, switches, lights, and a 230V power supply
connection.

Safety instructions
Validity
These instructions apply to the following inverter:
Product Order-no.
Starter Kit SINAMICS G120 6SL3200-0AE20-0AA0
Prerequisites
You are proficient in working with the Microsoft® Windows™ operating system.
You are conversant with the principles of electronics and electrical engineering.
Warning
Dangerous currents and voltages!
The equipment contains dangerous voltages and controls potentially dangerous rotating
mechanical parts. Non-compliance with the warnings or failure to follow the instructions
contained in the documentation can result in loss of life, severe personal injury, or serious
damage to property.
Take particular notice of the general and regional installation and safety regulations regard-
ing work on dangerous voltage installations (for example, EN 50178) as well as the relevant
regulations regarding the correct use of tools and personal protective equipment (PPE).
Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation.
Commissioning and operation of a device/system may only be performed by qualified per-
sonnel. Within the context of the safety notes in this documentation, qualified persons are
defined as persons who are authorized to commission, ground, and label devices, systems,
and circuits in accordance with established safety practices and standards.
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.

Welcome to the SINAMIC G120 Training Book-
let. This booklet will help acquaint you sim-
ply, quickly, and comfortably with the frequen-
cy inverter. We’ll take you step by step through
installation, setting parameters, and initial start-
up. The tutorial is structured so that each section
builds on the one before it. As a result, we recom-
mend that you don’t skip any chapters.

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Inverter family SINAMICS G120 02‒15
1.1 Components Power Module ................................................................. 06
Control Unit .................................................................... 07
Operator Panels (BOP-2 and IOP) .................................... 08
1.2 Mounting and wiring Power Module ................................................................. 09
Control Unit .................................................................... 12
Operator Panels (BOP-2 and IOP) .................................... 14
Operator Panels (BOP-2 and IOP) 16‒37
2.1 Basic functions The BOP-2 display ........................................................... 18
2.2 Working with BOP-2 Operating pattern and menu structure .......................... 20
2.3 Quick commissioning Entering motor data ....................................................... 26
Motor data identification ................................................ 27
Setting additional parameters ........................................ 28
2.4 Application case Using fixed frequencies .................................................. 30
Testing the application ................................................... 31
2.5 Intelligent Operator Panel The device ....................................................................... 33
Working with IOP ............................................................ 34
The wizards .................................................................... 35
Accessing diagnostics .................................................... 36
STARTER software and PC 38‒63
3.1 Mounting and preparation PC preparation ................................................................ 42
Creating a STARTER project ............................................ 44
STARTER user interface ................................................... 49
Uploading inverter data .................................................. 50
3.2 Parameterization Configuration wizard ...................................................... 52
Motor data identification ................................................ 56
3.3 Safety Integrated Safety Integrated engineering with STARTER ................. 58
3.4 Application cases Setting setpoint specifications ........................................ 60
Closing a project and saving data ................................... 61
Restoring factory settings ............................................... 62
Appendix Download overview ......................................................... 65

In this section we will introduce the low- voltage
SINAMICS G120 inverter. You’ll learn about the
main components, its structure, and receive
some practice-oriented insight
about the assembly and wiring
of the frequency inverter.

Inverter family SINAMICS G120

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1.1 Components
The SINAMICS G120 frequency inverter is modular. It consists of three basic components:
The Power Module supplies
voltage to the motor.
The Control Unit controls and
monitors the Power Module.
Inverter family SINAMICS G120: Components

3+
Each Control Unit can be
freely combined with each
IP20 Power Module.
The Basic Operator Panel (BOP-2)
and the Intelligent Operator Panel
(IOP) are used to operate and
monitor the inverter.
The optional PC Connection Kit-2
can also be used to operate and
monitor the inverter.
The kit is required in order to
establish communication between
the PC and the Control Unit.
Note

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25
5 4
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3
Please check the rating
plate to make sure that the
module meets your required
specifications.
Power Module
The device is available in several sizes. Its power range is between 0.37 kW and 250 kW.
The picture shows the PM240-2.
Rating plate
Power connectors
DC link connectors
Motor connectors
PE terminals
Inverter family SINAMICS G120: Components
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Note

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Please ensure that this is the correct
device for your application.
An overview of the various control
unit versions and their differen-
tiation can be found in the official
SINAMICS G120 brochure at
Control Unit
There are various designs for the Control Unit. They differ primarily in terms of the control
terminal assignments as well as in terms of different field bus interfaces. This tutorial will
use the example of the CU240E-2 Control Unit. It was developed for stand-alone operation.
Rating plate
DIP switch, analog inputs,
and BUS
Interface for the OP
or PC Connection Kit
Two status LEDs
Terminals for digital and
analog inputs and outputs
USB interface
Interface to the Power Module
Fastening clips
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Note
http://www.siemens.com/
sinamics-g120/printmaterial

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BOP-2 IOP
Basic Operator Panel 2
The basic input and display device is used to operate and set parameters for the inverter after
being connected to the Control Unit. It is operated by pressing the buttons and features a sim-
ple commissioning thanks to the menu prompting and the two-line display (showing parameter
and parameter value simultaneously).
Intelligent Operator Panel
The advanced input and display device manages the same functions as the BOP-2 and adds sev-
eral more. Its enhanced features increase usability substantially. They include a large plain text
display, integrated application wizards, full graphical diagnostic overviews, rotary knob control,
and plain text help information. It is available in various versions and can also be used drive-
externally for series commissioning and quick on-site diagnosis.
Seven operating buttons
Display
Release catch
Door mounting screw
recess
RS232 connector
Product rating label
Graphical display
Navigation wheel
Five operating buttons
USB connection
Inverter family SINAMICS G120: Components

Normally the motor and inverter
are selected in such a way that they
match each other. This is also the
case in our example. However, the
data from the rating plate of the
motor is important for the initial
start-up of the inverter.
1.2 Mounting and wiring
Before starting assembly, check to ensure that the following conditions have been met:
• All required components, tools, and small parts have been gathered.
• All required cables and lines have been laid in accordance with specifications.
• All minimum clearances are being observed.
The Five Safety Regulations must be strictly observed
• Disconnect
• Secure against unintentional restart
• Verify that it is free of voltage
• Ground and bypass
• Cover and shield any adjacent live parts
Mounting the Power Module into the switch cabinet
Please refer to the drilling pattern accompanying the power
module for the correct drilling centers and clearance
distances above and below the power module.
Note
Example of
drilling pattern
36,5 mm (1.44")
62,3mm (2.45")
5,35 mm (0.21")
186 mm (7.32")

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3
Wiring the Power Module
• Connect the phases and the earth conductor to the pluggable terminal clamps U2, V2, W2, and PE.
Wiring the motor
• Unscrew the cover to the terminal box on the motor (the inside cover of Siemens motors
illustrates the possible wiring for the Star connection and the Delta connection).
• Remove the bridge rails from the connecting block and loosen the screws.
• Place the bridge rails on the terminal block and screw them into place (depending on the
type of connections required – Star or Delta: in this example, a Star connection is shown).
• Connect the PE connection.
• Insert the cables from the power module through the opening of the terminal box
to the motor.
• Slide the phases in accordance with the phase assignment in the connections.
• Screw the cover back onto the motor.
Wiring the power supply
• Connect the phases and the earth conductor to the pluggable terminal clamps L1, L2, L3, and PE.
The motor and Power Module are now connected together. Before continuing the commission-
ing of the motor and inverter, ensure that the motor and the inverter are isolated from the
line supply.
Connecting the Power Module to the motor
Depending on the operating environment, different cable length limits are required for the
connection between the power module and motor. Unshielded cables up to 100 meters in
length are possible in industrial electrical networks.
The electrical wiring is now complete.
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Inverter family SINAMICS G120: Mounting and wiring

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Motor lines represent interfering
transmitters. As a result, you should
use shielded cable in order to meet
the corresponding electromagnetic
compatibility requirements.
The cable lengths that can be
used depend upon the following:
‒ Operating environment
‒ Inverter being used
‒ Reactors and filters used
‒ Shielded or unshielded cable
In order to meet Class A electro-
magnetic compatibility require-
ments, you need a filter and
a shielded cable (max. length:
25 meters).
The depicted example shows a Star
connection. The rating plate pro-
vides information about the correct
circuit data: for example, 230/400V
∆/Y means that you are connecting
the motor in Y with a 400V network.
Note

12
General procedure for wiring with spring-type terminals
• Press the screwdriver on the upper release lever.
• The terminal cover opens.
• Insert the end of the wire into the terminal opening.
• Withdraw the screwdriver from the terminal.
Attaching the Control Unit
Connect the Control Unit with the fastening clips on the bottom of the Power Module and then
press the upper edge of the Control Unit against the Power Module until the locking device
snaps into place. Before wiring the control terminals, the terminal cover has to be opened.
The wire is now firmly attached.
The wiring is now complete.
Wiring the control terminals in the CU240E-2
The potentiometer:
• Attach the positive pole of the potentiometer to terminal 1.
• Attach the negative pole to 2.
• Wire the output of the potentiometer arm to 3.
• Close the circuit by connecting 4 to terminal 2.
On/Off, Reverse, and Reset buttons:
• Wire their power supply to 9.
• Attach the associated digital inputs to terminals 5, 6, and 7.
• To close the circuit, connect 9 with 20 and 22.
Indicator lights:
• Attach the power supply for the LEDs to 9.
• To close the circuit, connect 9 with 20 and 22.
• Wire the “Faults” and “Warning” LEDs to digital outputs 19 and 21.
• Connect the negative pole to terminal 28.
Display for frequency output:
• Connect the positive pole to 12.
• Connect the negative pole to 13.
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Inverter family SINAMICS G120: Mounting and wiring

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Mounting the Operator Panels (BOP-2 or IOP) on the CU
• Remove the cover of the RS232 connection by lifting it up and sliding it to the side.
• Place the bottom edge of the IOP/BOP-2 casing into the lower recess of the
Control Unit housing.
• Push the IOP/BOP-2 toward the Control Unit until the release-catch clicks into place.
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Inverter family SINAMICS G120: Mounting and wiring