Siemens SINAMICS G120C User manual

Answers for industry.
SINAMICS
SINAMICS G120C
Frequency converter
Getting Started · 03/2012

SINAMICS G120C frequency
converter
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SINAMICS
SINAMICS G120C
SINAMICS G120C frequency
converter
Getting Started
Edition 03/2012, Firmware V4.5
03/2012, FW V4.5
A5E03831830B AA
Product overview
1
Safety notes
2
Installing
3
Commissioning
4
Trouble shooting
5

Legal information
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
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the relevant information is not taken into account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E03831830B AA
Ⓟ 05/2012 Technical data subject to change
Copyright © Siemens AG 2011,
2012.
All rights reserved

SINAMICS G120C frequency converter
Getting Started, 03/2012, FW V4.5, A5E03831830B AA 3
Table of contents
1 Product overview ....................................................................................................................................... 4
2 Safety notes............................................................................................................................................... 5
3 Installing .................................................................................................................................................... 9
3.1 Mechanical installation...................................................................................................................9
3.2 Electrical installation ....................................................................................................................10
3.3 Pre-defined interface configurations ............................................................................................14
3.4 Description files for fieldbus configuration ...................................................................................18
4 Commissioning ........................................................................................................................................ 19
4.1 Basic commissioning with BOP-2 ................................................................................................22
4.2 Further settings ............................................................................................................................24
4.2.1 Changing the function of terminals ..............................................................................................25
4.2.2 Releasing "Safe Torque Off"........................................................................................................26
4.2.3 Parameter list...............................................................................................................................27
5 Trouble shooting...................................................................................................................................... 43
5.1 List of alarms and faults ...............................................................................................................43
5.2 Product support............................................................................................................................49
5.3 Spare parts...................................................................................................................................49
This Getting Started Guide describes how you install and commission the SINAMICS G120C converter.

SINAMICS G120C frequency converter
4 Getting Started, 03/2012, FW V4.5, A5E03831830B AA
1 Product overview
The SINAMICS G120C is a range of converters for controlling the speed of three phase
motors. The converter is available in three frame sizes.
You find a label with the order number:
● On the front of the converter after removing the blind cover or the operator panel.
● On one side of the converter.
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SINAMICS G120C frequency converter
Getting Started, 03/2012, FW V4.5, A5E03831830B AA 5
Safety notes 2
It has to be ensured by the machine manufacturer, that the line-side overcurrent protection
equipment interrupts within 5 s (immovable equipment and modules in immovable
equipment) in the case of minimum fault current (current on complete insulation failure to
accessible conductive parts that are not live during operation and maximum current loop
resistance).
General
WARNING
This equipment controls potentially dangerous rotating mechanical parts.
Protection in case of direct contact by means of voltages < 60V (PELV = Protective Extra
Low Voltage acc. to EN 61800-5-1) is only permissible in areas with equipotential bonding
and in dry indoor rooms. If these conditions are not fulfilled, other protective measures
against electric shock are to be taken, e.g., protective insulation.
The converter must always be properly grounded. Since the residual current for this product
is greater than 3.5mA AC, a fixed ground connection is required, and the minimum size of
the protective conductor must comply with local safety regulations for equipment with a high
leakage current.
Install the converter on a metal mounting plate in a control cabinet. The mounting plate
must not must be painted and must have good electrical conductivity.
It is strictly prohibited for any mains disconnection to be performed on the motor-side of the
system, if the converter is in operation and the output current is not equal to zero.
Take particular notice of the general and regional installation and safety regulations
regarding work on dangerous voltage installations (e.g. 61800-5-1) as well as the relevant
regulations regarding the correct use of tools and personal protective equipment (PPE).
CAUTION
Static discharges on surfaces or interfaces (e.g. terminal or connector pins) can cause
malfunctions or defects. ESD protective measures should therefore be observed when
working with converters or converter components.

Safety notes
SINAMICS G120C frequency converter
6 Getting Started, 03/2012, FW V4.5, A5E03831830B AA
Transport and storage
CAUTION
Don't drop the converter or converter components during transport and storage. Protect the
equipment from water (rainfall) and excessive temperatures.
Installation and Commissioning
WARNING
Wherever faults occurring in the control equipment can lead to substantial material damage
or even grievous bodily injury (that is, potentially dangerous faults), additional external
precautions must be taken or facilities provided to ensure or enforce safe operation, even
when a fault occurs (e.g. independent limit switches, mechanical interlocks, etc.).
Operation
DANGER
Operating the converter outside the scope of the specification given in the technical
specifications may cause malfunction or damage to the converter components. In
exceptional cases there is the potential to cause overheating, danger of fire, damage to
property, personal injury or loss of life.
WARNING
Emergency stop facilities according to EN 60204, IEC 204 (VDE 0113) must remain
operative in all operating modes of the control equipment. Any disengagement of the
emergency stop facility must not lead to an uncontrolled or an undefined restart of the
equipment.
WARNING
Use of mobile radio devices (e.g. telephones, walkie-talkies) in the immediate vicinity of the
devices (< 1.8 m) can interfere with the functioning of the equipment.
WARNING
Filtered drives can only be used on power systems with grounded neutral point.

Safety notes
SINAMICS G120C frequency converter
Getting Started, 03/2012, FW V4.5, A5E03831830B AA 7
WARNING
During operation and for a short time after switching-off the converter, the surfaces of the
converter can reach a high temperature. Avoid coming into direct contact with the converter
surface.
WARNING
Risk of fire
If an unsuitable braking resistor is used, this could result in a fire and severely damage,
people, property and equipment. Use the adequate braking resistor and install it correctly.
The temperature of a braking resistor increases significantly during operation. Avoid coming
into direct contact with braking resistors.
Repair
WARNING
Repairs on equipment may only be carried out by Siemens Service, by repair centers
authorized by Siemens or by authorized personnel who are thoroughly acquainted with all
the warnings and operating procedures contained in this manual.
Any defective parts or components must be replaced using parts contained in the relevant
spare parts list.

Safety notes
SINAMICS G120C frequency converter
8 Getting Started, 03/2012, FW V4.5, A5E03831830B AA
Residual risks
The control and drive components of a power drive system (PDS) are approved for industrial
and commercial use in industrial supply networks. Their use in public supply networks
requires a different configuration and/or additional measures.
These components may only be operated in closed housings or in higher-level control
cabinets with protective covers that are closed, and when all of the protective devices are
used.
When carrying out a risk assessment of a machine in accordance with the EU Machinery
Directive, the machine manufacturer must consider the following residual risks associated
with the control and drive components of a PDS.
1. Unintentional movements of driven machine components during commissioning,
operation, maintenance, and repairs caused by, for example:
– Hardware defects and/or software errors in the sensors, controllers, actuators, and
connection technology
– Response times of the controller and drive
– Operating and/or ambient conditions not within the scope of the specification
– Condensation / conductive contamination
– Parameterization, programming, cabling, and installation errors
– Use of radio devices / cellular phones in the immediate vicinity of the controller
– External influences / damages
2. Exceptionally high temperatures as well as emissions of noise, particles, or gas caused
by, for example:
– Component malfunctions
– Software errors
– Operating and/or ambient conditions not within the scope of the specification
– External influences / damages
3. Hazardous shock voltages caused by, for example:
– Component malfunctions
– Influence of electrostatic charging
– Induction of voltages in moving motors
– Operating and/or ambient conditions not within the scope of the specification
– Condensation / conductive contamination
– External influences / damages
4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a
risk to people with a pacemaker, implants or metal replacement joints, etc. if they are too
close.
5. Release of environmental pollutants or emissions as a result of improper operation of the
system and/or failure to dispose of components safely and correctly.

SINAMICS G120C frequency converter
Getting Started, 03/2012, FW V4.5, A5E03831830B AA 9
Installing 3
3.1 Mechanical installation
Table 3- 1 Dimensions, drill patterns and minimum distances
Frame Size A
0.55 kW … 4.0 kW
Frame Size B
5.5 kW … 7.5 kW
Frame Size C
11 kW … 18.5 kW
Height 196 mm 196 mm 295 mm
Width 73 mm 100 mm 140 mm
Depth of the
converter with
PROFINET
interface
225.4 mm 225.4 mm 225.4 mm
Depth of the
converter with
USS/MB,
CANopen or
PROFIBUS
interface
203 mm 203 mm 203 mm
+ 21 mm supplementary depth with the operator
panel IOP snapped onto the converter.
+ Depth
+ 6 mm supplementary depth with the operator
panel BOP-2.
Drill pattern
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Installing
3.2 Electrical installation
SINAMICS G120C frequency converter
10 Getting Started, 03/2012, FW V4.5, A5E03831830B AA
3.2 Electrical installation
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Installing
3.2 Electrical installation
SINAMICS G120C frequency converter
Getting Started, 03/2012, FW V4.5, A5E03831830B AA 11
Components for United States / Canadian installations (UL/CSA)
In order that the system is UL/CSA-compliant, use UL/CSA-certified J-type fuses, overload
circuit-breakers or intrinsically safe motor protection devices. For each frame size A to C use
class 1 75° C copper wire only.
Install the converter with any external recommended suppressor with the following features:
● Surge-protective devices; device shall be a Listed Surge-protective device (Category
code VZCA and VZCA7).
● Rated nominal voltage 480/277 VAC, 50/60 Hz, 3-phase.
● Clamping voltage VPR = 2000 V, IN = 3 kA min, MCOV = 550 VAC, SCCR = 40 kA.
● Suitable for Type 1 or Type 2 SPD application.
● Clamping shall be provided between phases and also between phase and ground.
EMC compliant installation
Rules for EMC-compliant installation:
Install the converter on a metal mounting plate.
The mounting plate has to be unpainted and
with a good electrical conductivity.
Use shielded cables for the following
connections:
– Motor and motor temperature sensor
– Braking resistor
– Process interfaces (Field bus, digital and
analog inputs and outputs)
Use a clamp for connecting each shielded
cable. Connect the shield to the mounting plate
or to the shield plate through a good electrical
connection and through the largest possible
surface area.
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Installing
3.2 Electrical installation
SINAMICS G120C frequency converter
12 Getting Started, 03/2012, FW V4.5, A5E03831830B AA
Overview of process and user interfaces
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Installing
3.2 Electrical installation
SINAMICS G120C frequency converter
Getting Started, 03/2012, FW V4.5, A5E03831830B AA 13
Wiring the terminal strip
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Wiring variants
① Wiring using the internal power supply Digital input = HIGH if switch closed
② Wiring using an external power supply Digital input = HIGH if switch closed
③ Wiring using the internal power supply Digital input = LOW if switch closed
④ Wiring using an external power supply Digital input = LOW if switch closed
Permissible cable cross-section: 0.5 mm² (21 AWG) … 1.5 mm² (16 AWG)
Recommended cable cross section: 1 mm² (18 AWG)
EMC-compliant installation
● Use shielded cables for connecting the terminal strip to other components.
● Use a clamp for connecting the shielded cable. Connect the shield to the mounting plate
or to the shield plate through a good electrical connection and through the largest
possible surface area. The handling of shielded cables is shown in section Electrical
installation (Page 10).

Installing
3.3 Pre-defined interface configurations
SINAMICS G120C frequency converter
14 Getting Started, 03/2012, FW V4.5, A5E03831830B AA
3.3 Pre-defined interface configurations
The converter offers different pre-defined settings for its interfaces. Select the appropriate
setting (macro) when commissioning the inverter (see section: Commissioning (Page 19))
and wire the terminal strips according to the selection.
If none of the pre-defined settings suites your application completely, do the following steps:
1. Wire the terminal strips according to your application.
2. Choose the best fitting I/O configuration (macro).
3. Select your chosen I/O configuration (macro) during basic commissioning.
4. Change the function of the inappropriate terminals.
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Installing
3.3 Pre-defined interface configurations
SINAMICS G120C frequency converter
Getting Started, 03/2012, FW V4.5, A5E03831830B AA 15
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Automatic / Manual - change over from field bus to jog
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
S 
S 
352),%86'3
352),1(7
See also section: Description files for fieldbus configuration (Page 18).

Installing
3.3 Pre-defined interface configurations
SINAMICS G120C frequency converter
16 Getting Started, 03/2012, FW V4.5, A5E03831830B AA
Motorized potentiometer
212))
023XS
023GRZQ
$FNQRZOHGJH

0RWRUL]HGSRWHQWLRPHWHU023
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)DXOW
$ODUP
6SHHG
5HVHUYHGIRU672
0DFUR
99
 ',
',
 ',
 ',
 ',
 ',





'2
'2
 $,

 $2

See also section: Releasing "Safe Torque Off" (Page 26).


212))
023XS
023GRZQ
$FNQRZOHGJH

)DXOW
$ODUP
6SHHG
0RWRUL]HGSRWHQWLRPHWHU
023
0DFUR
99
 ',
',
 ',
 ',
 ',
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'2
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
Analog setpoint
212))
5HYHUVH
6HWSRLQW
$FNQRZOHGJH

6DIHW\IXQFWLRQ672
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$ODUP
6SHHG
5HVHUYHGIRU672
0DFUR
99
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'2
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See also section: Releasing "Safe Torque Off" (Page 26).
Process industry
023XS
023GRZQ
$FNQRZOHGJH
212))
([WHUQDOIDXOW

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)DXOW
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)LHOGEXV352),%86'3
RU352),1(7
0RWRUL]HGSRWHQWLRPHWHU023
)DXOW
$ODUP
6SHHG
0DFUR
7HOHJUDPP
352),1(7
352),%86'3
/2: +,*+
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', /2:
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
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
See also section: Description files for fieldbus configuration (Page 18).

Installing
3.3 Pre-defined interface configurations
SINAMICS G120C frequency converter
Getting Started, 03/2012, FW V4.5, A5E03831830B AA 17
212))
([WHUQDOIDXOW
$FNQRZOHGJH
023XS
023GRZQ
212))
([WHUQDOIDXOW
6HWSRLQW


$FNQRZOHGJH

)DXOW
$ODUP
6SHHG
$QDORJVHWSRLQW 0RWRUL]HGSRWHQWLRPHWHU023
)DXOW
$ODUP
6SHHG
0DFUR
/2: +,*+
99 99
', /2:
 ',
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 ',
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 ',
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', +,*+
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
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
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Two or three wire control
Macro 12 is factory setting with the G120C USS/MB and G120C CAN.
7ZRZLUHFRQWURO 0RGH0RGH
0DFUR 0DFUR
0RGH
0DFUR
&RQWUROFRPPDQG
&RQWUROFRPPDQG
$FNQRZOHGJH



6HWSRLQW
)DXOW
$ODUP
6SHHG
&RQWUROFRPPDQG
&RQWUROFRPPDQG 5HYHUVH
212))ULJKW
212))OHIW
212))ULJKW
212))OHIW
212))
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8,
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5HOHDVH2))
21ULJKW
21OHIW
5HOHDVH2))
21
5HYHUVH
&RQWUROFRPPDQG
&RQWUROFRPPDQG
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$FNQRZOHGJH

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6HWSRLQW
)DXOW
$ODUP
6SHHG
'2
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8,
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Communication with the higher-level control via USS
)LHOGEXV866
EDXGUDWH
1XPEHURI3='
1XPEHURI3.:


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
$FNQRZOHGJH


)DXOW
$ODUP
6SHHG
3='3.:YDULDEOH
0DFUR
99
'2
'2
',
 ',
 ',
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 ',
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

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
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
S 
S 
S 
866
EDXG

Installing
3.4 Description files for fieldbus configuration
SINAMICS G120C frequency converter
18 Getting Started, 03/2012, FW V4.5, A5E03831830B AA
Communication with the higher-level control via CANopen
)LHOGEXV&$1RSHQ
EDXGUDWH 



$FNQRZOHGJH


)DXOW
$ODUP
6SHHG
0DFUR
99
'2
'2
',
 ',
 ',
 ',
 ',
 ',





 $,

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
S 
&$1RSHQ
N%DXG
See also section: Description files for fieldbus configuration (Page 18).
3.4 Description files for fieldbus configuration
Description file Note Download Alternative
GSD for
PROFIBUS
The General Station
Description (GSD) file
describes the characteristics
of the converter in a
PROFIBUS network.
Internet:
(http://support.automation.si
emens.com/WW/view/en/22
339653/133100)
The GSD is saved in the converter. The
converter writes its GSD to the memory
card if you insert the memory card in the
converter and set p0804 to 12. Using the
memory card, you can then transfer the
GSD to your PG/your PC.
GSDML for
PROFINET
The General Station
Description (GSDML) file
describes the characteristics
of the converter in a
PROFINET network.
Internet:
(http://support.automation.si
emens.com/WW/view/en/26
641490)
The GSDML is saved in the converter.
The converter writes its GSDML to the
memory card if you insert the memory
card in the converter and set p0804 to
12. Using the memory card, you can then
transfer the GSDML to your PG/your PC.
EDS for
CANopen
The EDS file for CAN is
required to operate the
converter as a node on a CAN
bus and announce the device
to the configuration tool.
Internet:
(http://support.automation.si
emens.com/WW/view/en/48
351511)
---