Siemens SINAMICS G150 User manual

Converter cabinet units
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SINAMICS
SINAMICS G150
Converter cabinet units
Operating Instructions
Control version V4.8
07/2016
A5E03347396A
Foreword
Safety notes
1
Device overview
2
Mechanical installation
3
Electrical installation
4
Commissioning
5
Operation
6
Setpoint channel and closed-
loop control
7
Output terminals
8
Functions, monitoring, and
protective functions
9
Diagnosis/faults and alarms
10
Maintenance and servicing
11
Technical specifications
12
Appendix
A

Siemens AG
Division Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E03347396A
Ⓟ
07/2016 Subject to change
Copyright © Siemens AG 2010 - 2016.
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by
personnel qualified
for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

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Operating Instructions, 07/2016, A5E03347396A 5
Foreword
Structure of this documentation
The customer documentation comprises general and individual documentation.
The general documentation describes the topics that apply to all cabinet units:
●
Operating Instructions
The Operating Instructions consist of the following sections:
–Device description
–Mechanical installation
–Electrical installation
–Commissioning guide
–Description of function
–Maintenance instructions
–Technical data
●
Overview diagrams
These provide a general overview of the functionality of the cabinet units.
●
List Manual
The List Manual consists of the following sections:
–Parameter list
–Function diagrams
–Fault / warning list
●
Documentation for Drive Control Chart (DCC)
–Programming and Operating Manual: DCC Editor description
–Function Manual: Description of the standard DCC blocks
The individual documentation describes precisely one customized cabinet unit and contains
the following:
●
Dimension drawing
The dimension drawing documents the dimensions of the ordered cabinet unit.
●
Layout diagram
The components installed in the ordered cabinet units are shown in the layout diagram
with the equipment and location codes.
●
Circuit diagram
The circuit diagram shows the electrical components installed in the ordered cabinet unit
with the equipment and location codes, their interconnections and the customer
interfaces.

Foreword
Converter cabinet units
6Operating Instructions, 07/2016, A5E03347396A
●
Terminal diagram
The terminal diagram shows all the customer terminals in the ordered cabinet unit, and
the associated internal wiring in the cabinet unit. This diagram documents the line-side
target wiring.
●
Spare parts list
All of the available spare parts for the ordered cabinet units are listed in the spare parts
list with the equipment and the location codes.
●
Additional operating instructions
The instructions for supplier components installed in the ordered cabinet unit are included
as original documentation.
Documentation in the Internet
The documentation on SINAMICS G150 can be found on the Internet under the following link
(https://support.industry.siemens.com/cs/ww/en/ps/13227/man).
Technical support
Time zone Europe/Africa
Phone
[phone]
Fax
[phone]
Internet
https://support.industry.siemens.com/sc/ww/en/sc/2090
Time zone America
Phone
[phone]
Fax
[phone]
Internet
[e-mail]
Time zone Asia/Pacific
Phone
[phone]
Fax
[phone]
Internet
[e-mail]
Spare parts
Spare parts are available on the Internet at:
https://support.industry.siemens.com/sc/de/en/sc/2110
The spare parts available for the ordered drive can be found in the spare parts list.
These are provided on the customer DVD.

Foreword
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Operating Instructions, 07/2016, A5E03347396A 7
Internet address
Information about SINAMICS can be found on the Internet at the following address:
http://www.siemens.com/sinamics
EMC limit values for South Korea
The mandatory EMC limits for Korea correspond to the limits of EN 61800-3 (EMC product
standard for adjustable speed electrical drive systems) for category C2 or to limit class A,
Group 1 according to EN 55011.
Compliance with the limits according to category C2 or class A, group 1 is achieved with
suitable additional measures. Furthermore, additional measures such as the use of an
additional radio interference suppression filter (EMC filter) may be required.
In addition, measures for proper plant design to meet EMC requirements are described in
detail in this manual and the "SINAMICS Low Voltage Configuration Manual".
Certifications
The following certifications can be found on the Internet under the link SINAMICS G150
certificates (https://support.industry.siemens.com/cs/de/en/ps/13227/cert):
●EC declaration of conformity with reference to the EMC directive:
●EC declaration of conformity with reference to the machinery directive (safety)
●Manufacturers declaration in reference to Safety Integrated

Foreword
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8Operating Instructions, 07/2016, A5E03347396A

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Operating Instructions, 07/2016, A5E03347396A 9
Table of contents
Foreword ................................................................................................................................................ 5
1 Safety notes.......................................................................................................................................... 19
1.1 General safety instructions .....................................................................................................19
1.2 Safety instructions for electromagnetic fields (EMF) ..............................................................23
1.3 Handling electrostatic sensitive devices (ESD) ......................................................................24
1.4 Industrial security ....................................................................................................................25
1.5 Residual risks of power drive systems....................................................................................26
2 Device overview.................................................................................................................................... 27
2.1 Chapter content ......................................................................................................................27
2.2 Application range and characteristics .....................................................................................27
2.2.1 Field of applications ................................................................................................................27
2.2.2 Characteristics, quality, service ..............................................................................................27
2.3 Design.....................................................................................................................................29
2.3.1 General ...................................................................................................................................29
2.3.2 Device overview......................................................................................................................29
2.4 Wiring principle .......................................................................................................................31
2.5 Type plate ...............................................................................................................................33
3 Mechanical installation .......................................................................................................................... 39
3.1 Chapter content ......................................................................................................................39
3.2 Transportation and storage.....................................................................................................39
3.3 Mounting .................................................................................................................................41
3.3.1 Mechanical installation: checklist............................................................................................42
3.3.2 Preparation .............................................................................................................................42
3.3.2.1 Requirements on the installation location ...............................................................................42
3.3.2.2 Requirements on the levelness of the floor ............................................................................43
3.3.2.3 Shipping and handling monitors .............................................................................................44
3.3.2.4 Unpacking ...............................................................................................................................46
3.3.2.5 Required tools.........................................................................................................................46
3.3.3 Installation...............................................................................................................................47
3.3.3.1 Lifting the cabinet off the transport pallet................................................................................47
3.3.3.2 Removing the crane transport aids.........................................................................................49
3.3.3.3 Connection to the foundation..................................................................................................50
3.3.4 Connecting separately shipped transport units ......................................................................51
3.3.5 Fitting additional canopies (option M21) or hoods (option M23, M43, M54) ..........................54

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4 Electrical installation ............................................................................................................................. 61
4.1 Chapter content...................................................................................................................... 61
4.2 Checklist for electrical installation .......................................................................................... 62
4.3 Important safety precautions.................................................................................................. 68
4.4 Introduction to EMC ............................................................................................................... 69
4.5 EMC-compliant design........................................................................................................... 71
4.6 Electrical connection .............................................................................................................. 74
4.6.1 General .................................................................................................................................. 74
4.6.2 Connecting the PE busbars ................................................................................................... 74
4.6.3 Connecting the DC link connections ...................................................................................... 77
4.6.4 Connecting the power supply and the signal cables.............................................................. 80
4.6.5 The DRIVE-CLiQ node must be connected........................................................................... 80
4.7 Power connections................................................................................................................. 82
4.7.1 Cable lugs .............................................................................................................................. 82
4.7.2 Connection cross-sections and cable lengths ....................................................................... 83
4.7.3 Connecting shielded three-phase current cables .................................................................. 84
4.7.4 Minimum cable lengths for motor connection to a motor with one-winding system .............. 85
4.7.5 Connecting the motor and power cables ............................................................................... 85
4.7.6 Adjusting the fan voltage (-T1-T10/-T20 and -T2-T10) .......................................................... 87
4.7.7 Removing the connection clip to the basic interference suppression module for
operation on an ungrounded line supply (IT system)............................................................. 89
4.7.8 Setting the circuit-breaker ...................................................................................................... 91
4.8 External supply of the auxiliary supply from a secure line..................................................... 92
4.9 Signal connections................................................................................................................. 93
4.9.1 Control Unit CU320-2 DP....................................................................................................... 93
4.9.2 Customer terminal module TM31 (-A60) (option G60) ........................................................ 109
4.10 Other connections................................................................................................................ 118
4.10.1 dv/dt filter compact plus Voltage Peak Limiter (Option L07)................................................ 119
4.10.2 dv/dt filter plus Voltage Peak Limiter (option L10) ............................................................... 121
4.10.3 Connection for external auxiliary equipment (option L19) ................................................... 123
4.10.4 Overvoltage limitation (option L21) ...................................................................................... 125
4.10.5 EMERGENCY OFF pushbutton installed in the cabinet door (option L45) ......................... 126
4.10.6 Cabinet illumination with service socket (option L50).......................................................... 127
4.10.7 Cabinet anti-condensation heating (option L55) .................................................................. 128
4.10.8 EMERGENCY OFF category 0; 230 V AC or 24 V DC (option L57) ................................... 129
4.10.9 EMERGENCY STOP category 1; 230 V AC (option L59) ................................................... 131
4.10.10 EMERGENCY STOP category 1; 24 V DC (option L60) ..................................................... 132
4.10.11 Braking unit 50 kW (option L62)........................................................................................... 133
4.10.11.1 Commissioning..................................................................................................................... 136
4.10.11.2 Diagnosis and duty cycles ................................................................................................... 137
4.10.11.3 Threshold switch .................................................................................................................. 138
4.10.12 Thermistor motor protection unit (option L83/L84)............................................................... 140
4.10.13 PT100 evaluation unit (option L86) ...................................................................................... 141
4.10.14 Insulation monitor (option L87) ............................................................................................ 142
4.10.15 CBC10 CAN Communication Board (option G20) ............................................................... 144
4.10.16 Communication Board Ethernet CBE20 (option G33) ......................................................... 147
4.10.17 TM150 temperature sensor module (option G51)................................................................ 150

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4.10.17.1 Description ............................................................................................................................150
4.10.17.2 Connecting............................................................................................................................151
4.10.17.3 Connection examples ...........................................................................................................154
4.10.18 SMC30 Sensor Module Cabinet-Mounted (option K50) .......................................................156
4.10.18.1 Description ............................................................................................................................156
4.10.18.2 Connection............................................................................................................................160
4.10.18.3 Connection examples ...........................................................................................................164
4.10.19 Voltage Sensing Module for determining the actual motor speed and the phase angle
(option K51) ..........................................................................................................................165
4.10.20 Additional SMC30 Sensor Module (option K52) ...................................................................166
4.10.21 Customer terminal block (option G60) ..................................................................................166
4.10.22 Additional customer terminal block TM31 (option G61)........................................................167
4.10.23 Terminal Board TB30 (option G62).......................................................................................167
4.10.24 Safety license for 1 axis (option K01) ...................................................................................172
4.10.25 Auxiliary power supply, 230 V AC (option K74) ....................................................................173
4.10.26 Terminal module for activation of "Safe Torque Off" and "Safe STOP 1" (option K82)........174
4.10.27 Terminal Module TM54F (option K87) ..................................................................................175
4.10.28 Safe Brake Adapter SBA 230 V AC (option K88) .................................................................177
4.10.29 Control Unit CU320-2 PN (option K95).................................................................................179
4.10.30 NAMUR terminal block (option B00).....................................................................................192
4.10.31 Separate 24 V DC power supply for NAMUR (option B02) ..................................................194
4.10.32 Outgoing section for external auxiliary equipment for NAMUR (option B03) .......................194
5 Commissioning ................................................................................................................................... 195
5.1 Chapter content ....................................................................................................................195
5.2 STARTER commissioning tool .............................................................................................196
5.2.1 Installing the STARTER commissioning tool ........................................................................198
5.2.2 Layout of the STARTER user interface ................................................................................198
5.3 Procedure for commissioning with STARTER......................................................................199
5.3.1 Creating the project...............................................................................................................199
5.3.2 Configure the drive unit.........................................................................................................207
5.3.3 Additional settings required ..................................................................................................231
5.3.4 Transferring the drive project................................................................................................232
5.3.5 Commissioning with STARTER via Ethernet........................................................................234
5.4 The AOP30 operator panel...................................................................................................240
5.5 First commissioning with the AOP30 ....................................................................................241
5.5.1 Initial ramp-up .......................................................................................................................241
5.5.2 Basic commissioning ............................................................................................................243
5.6 Status after commissioning...................................................................................................253
5.7 Commissioning an encoder with gear factor ........................................................................254
5.8 Parameter reset to factory settings.......................................................................................254
6 Operation............................................................................................................................................ 257
6.1 Chapter content ....................................................................................................................257
6.2 General information about command and setpoint sources.................................................258
6.3 Basic information about the drive system.............................................................................259
6.3.1 Parameters ...........................................................................................................................259

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6.3.2 Drive objects ........................................................................................................................ 262
6.3.2.1 Drive objects ........................................................................................................................ 262
6.3.3 Data Sets ............................................................................................................................. 264
6.3.4 BICO technology: interconnecting signals ........................................................................... 269
6.3.5 Propagation of faults ............................................................................................................ 275
6.4 Command sources............................................................................................................... 276
6.4.1 "PROFIdrive" default setting ................................................................................................ 276
6.4.2 "TM31 terminals" default setting .......................................................................................... 278
6.4.3 "NAMUR" default setting...................................................................................................... 280
6.4.4 "PROFIdrive NAMUR" default setting.................................................................................. 282
6.5 Setpoint sources .................................................................................................................. 284
6.5.1 Analog inputs ....................................................................................................................... 284
6.5.2 Motorized potentiometer ...................................................................................................... 286
6.5.3 Fixed speed setpoints .......................................................................................................... 287
6.6 Control via the operator panel.............................................................................................. 289
6.6.1 Operator panel (AOP30) overview and menu structure....................................................... 289
6.6.2 Menu: Operation screen ...................................................................................................... 291
6.6.3 Parameterization menu........................................................................................................ 292
6.6.4 Menu: Fault/alarm memory .................................................................................................. 294
6.6.5 Menu commissioning / service............................................................................................. 295
6.6.5.1 Drive commissioning ............................................................................................................ 295
6.6.5.2 Device commissioning ......................................................................................................... 295
6.6.5.3 Drive diagnostics.................................................................................................................. 296
6.6.5.4 AOP settings ........................................................................................................................ 297
6.6.5.5 AOP diagnostics................................................................................................................... 304
6.6.6 Sprachauswahl/Language selection .................................................................................... 306
6.6.7 Operation via the operator panel (LOCAL mode) ................................................................ 306
6.6.7.1 LOCAL/REMOTE key .......................................................................................................... 306
6.6.7.2 ON key / OFF key ................................................................................................................ 307
6.6.7.3 Switching between clockwise and counter-clockwise rotation............................................. 308
6.6.7.4 Jog ....................................................................................................................................... 308
6.6.7.5 Increase setpoint / decrease setpoint .................................................................................. 308
6.6.7.6 AOP setpoint ........................................................................................................................ 309
6.6.7.7 Lock AOP LOCAL mode ...................................................................................................... 310
6.6.7.8 Acknowledge error from the AOP ........................................................................................ 310
6.6.7.9 CDS setting via AOP............................................................................................................ 310
6.6.7.10 Operator input inhibit / parameterization inhibit ................................................................... 311
6.6.8 Faults and alarms................................................................................................................. 312
6.6.9 Saving the parameters permanently .................................................................................... 314
6.6.10 Parameterization errors ....................................................................................................... 314
6.7 Communication according to PROFIdrive ........................................................................... 315
6.7.1 General information ............................................................................................................. 315
6.7.2 Application classes .............................................................................................................. 317
6.7.3 Cyclic communication .......................................................................................................... 318
6.7.3.1 Telegrams and process data ............................................................................................... 319
6.7.3.2 Structure of the telegrams.................................................................................................... 321
6.7.3.3 Overview of control words and setpoints ............................................................................. 322
6.7.3.4 Overview of status words and actual values........................................................................ 323
6.7.4 Acyclic communication......................................................................................................... 323
6.7.4.1 Structure of requests and responses................................................................................... 325

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6.7.4.2 Determining the drive object numbers ..................................................................................331
6.7.4.3 Example 1: Reading parameters ..........................................................................................331
6.7.4.4 Example 2: Writing parameters (multi-parameter request)...................................................333
6.7.5 Diagnostics channels............................................................................................................337
6.7.5.1 Diagnostics via PROFINET ..................................................................................................338
6.7.5.2 Diagnostics via PROFIBUS ..................................................................................................340
6.7.6 Further information about PROFIdrive communication ........................................................344
6.8 Communication via PROFIBUS DP......................................................................................345
6.8.1 PROFIBUS connection .........................................................................................................345
6.8.2 Control via PROFIBUS .........................................................................................................349
6.8.3 Monitoring: Telegram failure .................................................................................................351
6.8.4 Further information about communication via PROFIBUS DP.............................................352
6.9 Communication via PROFINET IO .......................................................................................352
6.9.1 Activating online operation: STARTER via PROFINET IO ...................................................352
6.9.2 General information about PROFINET IO ............................................................................356
6.9.2.1 General information about PROFINET IO for SINAMICS ....................................................356
6.9.2.2 Real-time (RT) and isochronous real-time (IRT) communication .........................................357
6.9.2.3 Addresses .............................................................................................................................358
6.9.2.4 Data transmission .................................................................................................................360
6.9.2.5 Communication channels .....................................................................................................361
6.9.3 PROFIenergy ........................................................................................................................362
6.9.3.1 Description ............................................................................................................................362
6.9.3.2 Tasks of PROFIenergy .........................................................................................................363
6.9.3.3 PROFIenergy - properties of the drive system .....................................................................363
6.9.3.4 PROFIenergy commands .....................................................................................................364
6.9.3.5 PROFIenergy measured values ...........................................................................................365
6.9.3.6 PROFIenergy energy-saving mode ......................................................................................365
6.9.3.7 Transition into the energy-saving mode from the PROFIdrive operating state (S4) ............366
6.9.3.8 Inhibit PROFIenergy and idle time........................................................................................366
6.9.3.9 PROFIenergy applications....................................................................................................367
6.9.3.10 Function diagrams and parameters ......................................................................................367
6.9.4 Support of I&M data sets 1...4 ..............................................................................................367
6.9.5 Further information about communication via PROFINET IO ..............................................370
6.10 Communication via SINAMICS Link .....................................................................................370
6.10.1 Basic principles of SINAMICS Link.......................................................................................370
6.10.2 Topology ...............................................................................................................................372
6.10.3 Configuring and commissioning
............................................................................................374
6.10.4 Example ................................................................................................................................379
6.10.5 Communication failure when booting or in cyclic operation..................................................381
6.10.6 Transmission times for SINAMICS Link................................................................................382
6.10.7 Function diagrams and parameters ......................................................................................383
6.11 Communication via EtherNet/IP............................................................................................384
6.11.1 Overview ...............................................................................................................................384
6.11.2 Connect drive device to Ethernet/IP .....................................................................................384
6.11.3 Configuring communication ..................................................................................................385
6.11.4 Supported objects .................................................................................................................386
6.11.5 Integrate the drive device into the Ethernet network via DHCP ...........................................395
6.11.6 Parameters, faults and alarms..............................................................................................396
6.12 Communication via MODBUS TCP ......................................................................................397
6.12.1 Overview ...............................................................................................................................397

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6.12.2 Configuring Modbus TCP via interface X150....................................................................... 398
6.12.3 Configuring Modbus TCP via interface X1400..................................................................... 399
6.12.4 Mapping tables..................................................................................................................... 400
6.12.5 Write and read access using function codes ....................................................................... 403
6.12.6 Communication via data set 47............................................................................................ 405
6.12.6.1 Communication details......................................................................................................... 406
6.12.6.2 Examples: Read parameters ............................................................................................... 407
6.12.6.3 Examples: Write parameter ................................................................................................. 408
6.12.7 Communication procedure................................................................................................... 409
6.12.8 Parameters, faults and alarms ............................................................................................. 410
6.13 Communication services and used port numbers................................................................ 411
6.14 Parallel operation of communication interfaces ................................................................... 413
6.15 Engineering Software Drive Control Chart (DCC) ............................................................... 417
7 Setpoint channel and closed-loop control .............................................................................................419
7.1 Chapter content.................................................................................................................... 419
7.2 Setpoint channel .................................................................................................................. 420
7.2.1 Setpoint addition .................................................................................................................. 420
7.2.2 Direction reversal ................................................................................................................. 421
7.2.3 Skip frequency bands and minimum speed......................................................................... 422
7.2.4 Speed limitation.................................................................................................................... 423
7.2.5 Ramp-function generator ..................................................................................................... 424
7.3 V/f control ............................................................................................................................. 428
7.3.1 Voltage boost ....................................................................................................................... 431
7.3.2 Resonance damping ............................................................................................................ 434
7.3.3 Slip compensation................................................................................................................ 435
7.4 Vector speed/torque control with/without encoder............................................................... 437
7.4.1 Vector control without encoder ............................................................................................ 438
7.4.2 Vector control with encoder ................................................................................................. 445
7.4.3 Actual speed value filter....................................................................................................... 446
7.4.4 Speed controller ................................................................................................................... 447
7.4.4.1 Speed controller pre-control (integrated pre-control with balancing)................................... 450
7.4.4.2 Reference model.................................................................................................................. 452
7.4.4.3 Speed controller adaptation ................................................................................................. 454
7.4.4.4 Droop function...................................................................................................................... 456
7.4.4.5 Open actual speed value ..................................................................................................... 458
7.4.5 Closed-loop torque control................................................................................................... 460
7.4.6 Torque limiting...................................................................................................................... 462
7.4.7 Current setpoint filters.......................................................................................................... 464
7.4.8 Current controller adaptation ............................................................................................... 465
7.4.9 Permanent-magnet synchronous motors............................................................................. 466
8 Output terminals ..................................................................................................................................469
8.1 Chapter content.................................................................................................................... 469
8.2 Analog outputs ..................................................................................................................... 470
8.2.1 List of signals for the analog signals .................................................................................... 471
8.3 Digital outputs ...................................................................................................................... 473

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9 Functions, monitoring, and protective functions ................................................................................... 475
9.1 Chapter content ....................................................................................................................475
9.2 Drive functions ......................................................................................................................476
9.2.1 Motor data identification and automatic speed controller optimization.................................476
9.2.1.1 Motor data identification........................................................................................................477
9.2.1.2 Rotating measurement and speed controller optimization ...................................................480
9.2.1.3 Shortened rotating measurement .........................................................................................482
9.2.1.4 Parameters ...........................................................................................................................483
9.2.2 Efficiency optimization ..........................................................................................................483
9.2.3 Fast magnetization for induction motors...............................................................................485
9.2.4 Vdc control ............................................................................................................................487
9.2.5 Automatic restart function .....................................................................................................492
9.2.6 Flying restart .........................................................................................................................495
9.2.6.1 Flying restart without encoder...............................................................................................496
9.2.6.2 Flying restart with encoder....................................................................................................499
9.2.6.3 Parameters ...........................................................................................................................500
9.2.7 Motor changeover/selection..................................................................................................501
9.2.7.1 Description ............................................................................................................................501
9.2.7.2 Example of changing over between two motors...................................................................501
9.2.7.3 Function diagram ..................................................................................................................502
9.2.7.4 Parameters ...........................................................................................................................503
9.2.8 Friction characteristic curve ..................................................................................................504
9.2.9 Armature short-circuit braking, DC brake .............................................................................506
9.2.9.1 General .................................................................................................................................506
9.2.9.2 External armature short-circuit braking.................................................................................506
9.2.9.3 Internal armature short-circuit braking ..................................................................................507
9.2.9.4 DC braking ............................................................................................................................508
9.2.10 Increasing the output frequency ...........................................................................................511
9.2.10.1 Description ............................................................................................................................511
9.2.10.2 Default pulse frequencies .....................................................................................................511
9.2.10.3 Increasing the pulse frequency.............................................................................................511
9.2.10.4 Maximum output frequency achieved by increasing the pulse frequency ............................512
9.2.10.5 Parameters ...........................................................................................................................513
9.2.11 Derating behavior at increased pulse frequency ..................................................................513
9.2.12 Pulse frequency wobbling.....................................................................................................514
9.2.13 Runtime (operating hours counter) .......................................................................................516
9.2.14 Simulation operation .............................................................................................................517
9.2.15 Direction reversal ..................................................................................................................
518
9.2.16 Unit changeover....................................................................................................................520
9.2.17 Simple brake control .............................................................................................................522
9.2.18 Synchronization ....................................................................................................................525
9.2.19 Energy saving indicator for pumps, fans, and compressors.................................................526
9.2.20 Write protection.....................................................................................................................529
9.2.21 Know-how protection ............................................................................................................531
9.2.21.1 Description ............................................................................................................................531
9.2.21.2 Activating know-how protection ............................................................................................533
9.2.21.3 Deactivating know-how protection........................................................................................534
9.2.21.4 Changing the know-how protection password......................................................................535
9.2.21.5 OEM exception list ................................................................................................................535
9.2.21.6 Memory card copy protection ...............................................................................................536
9.2.21.7 Replacing devices for know-how protection with copy protection ........................................536

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16 Operating Instructions, 07/2016, A5E03347396A
9.2.21.8 Overview of important parameters....................................................................................... 537
9.2.22 Essential service mode ........................................................................................................ 538
9.2.23 Web server........................................................................................................................... 541
9.2.23.1 Description ........................................................................................................................... 541
9.2.23.2 Starting the web server ........................................................................................................ 543
9.2.23.3 Web server configuration ..................................................................................................... 546
9.2.23.4 Display areas ....................................................................................................................... 547
9.2.23.5 Overview of important parameters....................................................................................... 549
9.3 Extended functions .............................................................................................................. 549
9.3.1 Technology controller........................................................................................................... 549
9.3.2 Bypass function.................................................................................................................... 552
9.3.2.1 Bypass with synchronizer with degree of overlapping (p1260 = 1) ..................................... 553
9.3.2.2 Bypass with synchronizer without degree of overlapping (p1260 = 2) ................................ 556
9.3.2.3 Bypass without synchronizer (p1260 = 3)............................................................................ 558
9.3.2.4 Function diagram ................................................................................................................. 560
9.3.2.5 Parameters........................................................................................................................... 560
9.3.3 Extended brake control ........................................................................................................ 561
9.3.4 Extended monitoring functions............................................................................................. 566
9.3.5 Moment of inertia estimator ................................................................................................. 568
9.4 Monitoring and protective functions ..................................................................................... 574
9.4.1 Protecting power components ............................................................................................. 574
9.4.2 Thermal monitoring and overload responses ...................................................................... 575
9.4.3 Block protection.................................................................................................................... 577
9.4.4 Stall protection (only for vector control) ............................................................................... 578
9.4.5 Thermal motor protection..................................................................................................... 579
9.4.5.1 Description ........................................................................................................................... 579
9.4.5.2 Temperature sensor connection at the customer terminal block TM31 (option G60) ......... 579
9.4.5.3 Temperature sensor connection at a Sensor Module (option K50) ..................................... 580
9.4.5.4 Temperature sensor connection directly to the Control Interface Module........................... 581
9.4.5.5 Temperature sensor evaluation ........................................................................................... 582
9.4.5.6 Thermal motor models ......................................................................................................... 583
9.4.5.7 Function diagram ................................................................................................................. 586
9.4.5.8 Parameters........................................................................................................................... 586
9.4.6 Temperature measurement via TM150 (option G51) .......................................................... 587
9.4.6.1 Description ........................................................................................................................... 587
9.4.6.2 Measurement with up to 6 channels .................................................................................... 589
9.4.6.3 Measurement with up to 12 channels .................................................................................. 589
9.4.6.4 Forming groups of temperature sensors.............................................................................. 590
9.4.6.5 Evaluating temperature channels ........................................................................................ 591
9.4.6.6 Function diagram ................................................................................................................. 592
9.4.6.7 Parameter ............................................................................................................................ 592
10 Diagnosis/faults and alarms .................................................................................................................593
10.1 Chapter content.................................................................................................................... 593
10.2 Diagnosis ............................................................................................................................. 594
10.2.1 Diagnostics using LEDs ....................................................................................................... 594
10.2.2 Diagnostics via parameters.................................................................................................. 602
10.2.3 Indicating and rectifying faults.............................................................................................. 606
10.3 Overview of warnings and faults .......................................................................................... 607
10.3.1 "External alarm 1" ................................................................................................................ 608

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10.3.2 "External fault 1" ...................................................................................................................608
10.3.3 "External fault 2" ...................................................................................................................609
10.3.4 "External fault 3" ...................................................................................................................609
11 Maintenance and servicing.................................................................................................................. 611
11.1 Chapter content ....................................................................................................................611
11.2 Maintenance .........................................................................................................................613
11.2.1 Cleaning................................................................................................................................613
11.3 Maintenance .........................................................................................................................614
11.3.1 Installation device .................................................................................................................615
11.3.2 Using crane lifting lugs to transport power blocks ................................................................616
11.4 Replacing components .........................................................................................................619
11.4.1 Replacing the filter mats .......................................................................................................619
11.4.2 Replacing the Control Interface Module, frame size GB, GD ...............................................620
11.4.3 Replacing the Control Interface Module, frame size JX .......................................................622
11.4.4 Replacing the power block, frame sizes GB, GD .................................................................624
11.4.5 Replacing the power block, frame size JX............................................................................627
11.4.6 Replacing the fan, frame sizes GB, GD................................................................................629
11.4.7 Replacing the fan, frame size JX ..........................................................................................631
11.4.8 Replacing the DC fuses in the Motor Module .......................................................................633
11.4.9 Replacing cylindrical fuses ...................................................................................................635
11.4.10 Replacing the LV HRC fuses ................................................................................................636
11.4.11 Replacing the cabinet operator panel ...................................................................................638
11.4.12 Replacing the Backup Battery for the Cabinet Operator Panel ............................................638
11.5 Forming the DC link capacitors.............................................................................................640
11.6 Messages after replacing DRIVE-CLiQ components ...........................................................641
11.7 Upgrading the cabinet unit firmware .....................................................................................642
11.8 Load the new operator panel firmware from the PC.............................................................643
12 Technical specifications ...................................................................................................................... 645
12.1 Chapter content ....................................................................................................................645
12.2 General data .........................................................................................................................646
12.2.1 Derating data ........................................................................................................................647
12.2.1.1 Current derating as a function of the ambient temperature..................................................647
12.2.1.2 Installation altitudes between 2000 m and 5000 m above sea level ....................................648
12.2.1.3 Current derating as a function of the pulse frequency..........................................................650
12.2.2 Overload capability ...............................................................................................................651
12.3 Technical data.......................................................................................................................652
12.3.1 Cabinet devices version A, 660 V - 690 V 3 AC ...................................................................653
A Appendix............................................................................................................................................. 657
A.1 List of abbreviations..............................................................................................................657
A.2 Parameter macros ................................................................................................................659
Index................................................................................................................................................... 671

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18 Operating Instructions, 07/2016, A5E03347396A

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Operating Instructions, 07/2016, A5E03347396A 19
Safety notes
1
1.1
General safety instructions
DANGER
Danger to life due to live parts and other energy sources
Death or serious injury can result when live parts are touched.
•Only work on electrical equipment if you are appropriately qualified.
•Always observe the country-specific safety rules for all work.
Generally, six steps apply when establishing safety:
1. Prepare for shutdown and notify all those who will be affected by the procedure.
2. Disconnect the machine from the supply.
–Switch off the machine.
–Wait until the discharge time specified on the warning labels has elapsed.
–Check that it really is in a zero-voltage state, from phase conductor to phase
conductor and phase conductor to protective conductor.
–Check that every auxiliary circuit is de-energized.
–Ensure that the motors cannot move.
3. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems or
water.
4. Isolate or neutralize all hazardous energy sources by closing switches, grounding or
short-circuiting or closing valves, for example.
5. Take measures to prevent reconnection of the energy sources.
6. Ensure that the correct machine is completely interlocked.
After you have completed the work, restore the operational readiness by following the
above steps in the reverse order.
WARNING
Danger to life through a hazardous voltage when connecting an unsuitable power supply
Death or serious injury can result when live parts are touched in the event of a fault.
•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.

Safety notes
1.1 General safety instructions
Converter cabinet units
20 Operating Instructions, 07/2016, A5E03347396A
WARNING
Danger to life when live parts are touched on damaged devices
Improper handling of devices can cause damage.
For damaged devices, hazardous voltages can be present at the enclosure or at exposed
components; if touched, this can result in death or severe injury.
•Ensure compliance with the limit values specified in the technical data during transport,
storage and operation.
•Do not use any damaged devices.
WARNING
Danger to life through electric shock due to unconnected cable shields
Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected
cable shields.
•Connect cable shields and unused conductors of power cables (e.g. brake conductors)
at least on one side to the grounded housing potential.
WARNING
Danger to life due to electric shock when not grounded
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
Danger to life due to electric shock when opening plug connections in operation
When opening plug connections in operation, arcs can result in severe injury or death.
•Only open plug connections when the equipment is in a voltage-free state, unless it has
been explicitly stated that they can be opened in operation.
NOTICE
Material damage due to loose power connections
Insufficient tightening torques or vibrations can result in loose electrical connections. This
can result in damage due to fire, device defects or malfunctions.
•Tighten all power connections with the specified tightening torques, e.g. line supply
connection, motor connection, DC link connections.
•Check all power connections at regular intervals. This applies in particular after
transport.