Siemens SINAMICS S120 Quick start guide

SINAMICS
Commissioning Manual · 01/2013
SINAMICS S120
s

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Commissioning Manual
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SINAMICS
S120
Commissioning Manual
Commissioning Manual
Applies to:
Firmware version 4.6
(IH1), 01/2013
6SL3097-4AF00-0BP3
Preface
Preparation for
commissioning
1
Commissioning
2
Diagnostics
3
Appendix
A

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6SL3097-4AF00-0BP3
Ⓟ 01/2013 Technical data subject to change
Copyright © Siemens AG 2004 - 2013.
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.

Commissioning Manual
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Preface
SINAMICS documentation
The SINAMICS documentation is organized in the following categories:
● General documentation/catalogs
● User documentation
● Manufacturer/service documentation
More information
The following link provides information on the topics:
● Ordering documentation/overview of documentation
● Additional links to download documents
● Using documentation online (find and browse through manuals/information)
http://www.siemens.com/motioncontrol/docu
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following e-mail address:
[e-mail]
My Documentation Manager
Under the following link there is information on how to create your own individual
documentation based on Siemens' content, and adapt it for your own machine
documentation:
http://www.siemens.com/mdm
Training
Under the following link there is information on SITRAIN - training from Siemens for
products, systems and automation engineering solutions:
http://www.siemens.com/sitrain
FAQs
You can find Frequently Asked Questions in the Service&Support pages under Product
Support:
http://support.automation.siemens.com
SINAMICS
You can find information on SINAMICS under:
http://www.siemens.com/sinamics

Preface
Commissioning Manual
4 Commissioning Manual, (IH1), 01/2013, 6SL3097-4AF00-0BP3
Usage phases and their documents/tools (as an example)
Table 1 Usage phases and the available documents/tools
Usage phase Document/tool
Orientation SINAMICS S Sales Documentation
Planning/configuration •SIZER engineering tool
•Configuration Manuals, Motors
Deciding/ordering SINAMICS S120 catalogs
•SIMOTION, SINAMICS S120 and Motors for Production
Machines (Catalog PM 21)
•SINAMICS and motors for single-axis drives (catalog D 31)
•SINUMERIK & SINAMICS
Equipment for Machine Tools (Catalog NC 61)
•SINUMERIK 840D sl Type 1B
Equipment for Machine Tools (Catalog NC 62)
Installation/assembly •SINAMICS S120 Equipment Manual for Control Units and
Additional System Components
•SINAMICS S120 Equipment Manual for Booksize Power Units
•SINAMICS S120 Equipment Manual for Chassis Power Units
•SINAMICS S120 Equipment Manual for AC Drives
•SINAMICS S120M Equipment Manual Distributed Drive
Technology
Commissioning •STARTER commissioning tool
•SINAMICS S120 Getting Started
•SINAMICS S120 Commissioning Manual
•SINAMICS S120 CANopen Commissioning Manual
•SINAMICS S120 Function Manual
•SINAMICS S120 Safety Integrated Function Manual
•SINAMICS S120/S150 List Manual
Usage/operation •SINAMICS S120 Commissioning Manual
•SINAMICS S120/S150 List Manual
Maintenance/servicing •SINAMICS S120 Commissioning Manual
•SINAMICS S120/S150 List Manual
References •SINAMICS S120/S150 List Manual
Target group
This documentation is intended for machine manufacturers, commissioning engineers, and
service personnel who use the SINAMICS drive system.

Preface
Commissioning Manual
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Benefits
This Manual describes all the information, procedures and operational instructions required
for commissioning and servicing SINAMICS S120.
Standard scope
The scope of the functionality described in this document can differ from the scope of the
functionality of the drive system that is actually supplied.
● It may be possible for other functions not described in this documentation to be executed
in the drive system. However, no claim can be made regarding the availability of these
functions when the equipment is first supplied or in the event of servicing.
● Functions that are not available in a particular product version of the drive system may be
described in the documentation. The functionality of the supplied drive system should
only be taken from the ordering documentation.
● Extensions or changes made by the machine manufacturer must be documented by the
machine manufacturer.
For reasons of clarity, this documentation does not contain all of the detailed information on
all of the product types. This documentation cannot take into consideration every
conceivable type of installation, operation and service/maintenance.
Technical Support
Country-specific telephone numbers for technical support are provided in the Internet under
Contact:
http://www.siemens.com/automation/service&support
EC Declaration of Conformity
The EC Declaration of Conformity for the EMC Directive can be found on the Internet at:
http://support.automation.siemens.com
There – as a search term – enter the number 15257461 or contact your local Siemens office.
The EC Declaration of Conformity for the Low Voltage Directive can be found on the Internet
at:
http://support.automation.siemens.com
There – as a search term – enter the number 22383669.
Note
When operated in dry areas, SINAMICS S units conform to Low-Voltage Directive
2006/95/EC.

Preface
Commissioning Manual
6 Commissioning Manual, (IH1), 01/2013, 6SL3097-4AF00-0BP3
Note
SINAMICS S units fulfill EMC Directive 2004/108/EC in the configuration specified in the
associated EC Declaration of Conformity for EMC and when the EMC installation guideline
provided in the Configuration Manual with Order No. 6FC5297-0AD30-0P is
implemented.
Note
The Commissioning Manual describes a desired state, which, if maintained, ensures the
required level of operational reliability and compliance with EMC limit values.
Should there be any deviation from the requirements in the Commissioning Manual,
appropriate actions (e.g. measurements) must be taken to check/prove that the required
level of operational reliability and compliance with EMC limit values are ensured.
EMC limit values in South Korea
The EMC limit values to be complied with for South Korea correspond to the limit values of
the EMC product standard for variable-speed electric drives EN 61800-3, Category C2 or
limit value class A, Group 1 according to EN 55011. By applying suitable supplementary
measures, the limit values according to Category C2 or according to limit value class A,
Group 1, are maintained. Further, additional measures may be required, for instance, using
an additional radio interference suppression filter (EMC filter).
The measures for EMC-compliant design of the system are described in detail in this manual
respectively in the Configuration Manual EMC Installation Guideline.
Please note that the final statement regarding compliance with the standard is given by the
respective label attached to the individual unit.
Spare parts
Spare parts are available on the Internet at:
http://support.automation.siemens.com/WW/view/de/16612315
Test certificates
The Safety Integrated functions of SINAMICS components are generally certified by
independent institutes. An up-to-date list of already certified components is available on
request from your local Siemens office. If you have any questions relating to certifications
that have not yet been completed, please ask your Siemens contact.

Preface
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Explanation of symbols
Symbol Meaning
Protective earth (PE)
Ground (e.g. M 24 V)
Functional ground
Equipotential bonding
Notation
The following notation and abbreviations are used in this documentation:
Notation for faults and alarms (examples):
•F12345 Fault 12345
•A67890 Alarm 67890
Notation for parameters (examples):
•p0918 Adjustable parameter 918
•r1024 Display parameter 1024
•p1070[1] Adjustable parameter 1070, index 1
•p2098[1].3 Adjustable parameter 2098, index 1 bit 3
•p0099[0...3] Adjustable parameter 99, indices 0 to 3
•r0945[2](3) Display parameter 945, index 2 of drive object 3
•p0795.4 Adjustable parameter 795, bit 4

Preface
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ESD Notes
Electrostatic sensitive devices (ESDs) are individual components, integrated circuits,
modules or devices that may be damaged by either electrostatic fields or electrostatic
discharge.
NOTICE
Damage due to electric fields or electrostatic discharge
Electric fields or electrostatic discharge can result in malfunctions as a result of damaged
individual components, integrated circuits, modules or devices.
•Package, store, transport and send the electronic components, modules or devices only
in the original product packaging or in other suitable materials, e.g. conductive foam
rubber or aluminum foil.
•Only touch components, modules and devices, if you are grounded using one of the
following measures:
– Wearing an ESD wrist strap
– Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring
•Only place down electronic components, modules or devices on conductive surfaces
(table with ESD surface, conductive ESD foam, ESD packaging, ESD transport
container).

Preface
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Safety notices
DANGER
Danger of death when live parts are touched
Touching live parts can result in death or severe injury.
•Only work on electrical equipment if you are qualified to do so.
•When carrying out any work, always comply with the country-specific safety rules.
Generally, six steps apply when establishing safety:
1. Prepare for shutdown and inform team members who will be affected by the procedure.
2. Switch off the machine so that it is in a no-voltage state.
– Switch off the machine.
– Wait until the discharge time specified on the warning labels has elapsed.
– Check that it really is in a no-voltage condition, from phase conductor to phase
conductor and phase conductor to protective conductor.
– Check that all auxiliary circuits are also in a no-voltage state.
– Ensure that the motor 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. For instance, by closing switches,
grounding or short-circuiting or closing valves.
5. Lock out all energy sources so that they cannot be switched on again.
6. Make sure that the machine is completely locked out ... and that you have the right
machine!
After you have completed the work, restore the operational readiness in the inverse
sequence.

Preface
Commissioning Manual
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DANGER
Risk of electric shock, hazardous axis movements
•Commissioning is absolutely prohibited until it has been completely ensured that the
machine, in which the components described here are to be installed, is in full
compliance with the provisions of the EC Machinery Directive.
•SINAMICS devices and AC motors may only be commissioned by suitably qualified
personnel.
•The personnel must take into account the information provided in the technical customer
documentation for the product, and be familiar with and observe the specified danger
and warning notices.
•When electrical equipment and motors are operated, the electrical circuits automatically
conduct a dangerous voltage.
•Dangerous mechanical movements are possible during system operations.
•All the work carried out on the electrical machine or system must be carried out with it in
a no-voltage condition.
•SINAMICS devices with three-phase motors must only be connected to the power
supply via a universal current-sensitive residual current operated device with selective
switching once it has been verified that the SINAMICS device is compatible with the
residual current operated device in accordance with IEC 61800-5-1.
WARNING
Improper handling of the devices
•The successful and safe operation of this equipment and motors is dependent on
professional transport, storage, installation and mounting as well as careful operations ,
service and maintenance.
•Information and data from the catalogs and quotations also apply to special versions of
the equipment and motors.
•In addition to the danger and warning information provided in the technical customer
documentation, the applicable national, local, and plant-specific regulations and
requirements must be taken into account.
•Only protective extra-low voltages (PELV) that comply with EN60204-1 may be
connected to all connections and terminals between 0 and 48 V.
•The motors can have surface temperatures of over +100 °C.
•This is why temperature-sensitive components, e.g. cables or electronic components
must not be in contact with or attached to the motor.
•When attaching the connecting cables, you must ensure that
– they are not damaged
– they are not stressed
– they cannot come into contact with any rotating parts

Preface
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WARNING
Hazardous axis movements for safety functions that have not been parameterized
The Safe Torque Off (STO) safety function (Safety Integrated basic functions or extended
functions) must be parameterized in order to use the pulse inhibit terminals at the Motor
Modules, booksize, booksize compact, chassis and Cabinet Modules and at the Power
Modules, chassis and blocksize formats.
The procedure to do this is described in both function manuals (SINAMICS S120 Function
Manual Drive Functions and SINAMICS S120 Function Manual Safety Integrated).
NOTICE
Material damage as a result of incorrect voltage tests
•As part of routine tests, SINAMICS devices with three-phase motors are subject to a
voltage test in accordance with EN 61800-5-1. Before the voltage test is performed on
the electrical equipment of industrial machines to EN 60204-1, Section 18.4, all
connectors of SINAMICS devices must be disconnected/withdrawn to prevent the
equipment from being damaged.
•Motors should be connected up according to the circuit diagram provided otherwise they
may be destroyed.
Note
Low-voltage directive
When operated in dry areas, SINAMICS devices with three-phase motors conform to Low-
Voltage Directive 2006/95/EC.

Preface
Commissioning Manual
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Commissioning Manual
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Contents
Preface ...................................................................................................................................................... 3
1 Preparation for commissioning ................................................................................................................ 17
1.1 Requirements for commissioning.................................................................................................18
1.2 Check lists to commission SINAMICS S......................................................................................20
1.3 PROFIBUS components..............................................................................................................23
1.4 PROFINET components ..............................................................................................................24
1.5 Rules for wiring with DRIVE-CLiQ ...............................................................................................25
1.5.1 DRIVE-CLiQ diagnostics..............................................................................................................25
1.5.2 Binding DRIVE-CLiQ rules...........................................................................................................26
1.5.3 Recommended DRIVE-CLiQ rules ..............................................................................................32
1.5.4 Notes on the number of controllable drives .................................................................................35
1.5.4.1 System sampling times and number of controllable drives .........................................................35
1.5.4.2 Optimizing DRIVE-CLiQ...............................................................................................................39
1.5.4.3 Default settings for the sampling times........................................................................................39
1.5.5 Changing the offline topology in the STARTER commissioning tool...........................................41
1.5.6 Modular machine concept: Offline correction of the reference topology .....................................42
1.5.7 Topology example: Drives in vector control.................................................................................45
1.5.8 Topology example: Parallel Motor Modules in vector control ......................................................47
1.5.9 Topology example: Drives in U/f control (vector control).............................................................48
1.5.10 Topology example: Drives in servo control..................................................................................49
1.5.11 Topology example: Power Modules.............................................................................................50
1.6 Powering-up/powering-down the drive system............................................................................52
2 Commissioning ........................................................................................................................................ 57
2.1 Procedure when commissioning..................................................................................................57
2.2 STARTER commissioning tool.....................................................................................................59
2.2.1 General information on STARTER...............................................................................................59
2.2.1.1 Calling STARTER ........................................................................................................................59
2.2.1.2 Description of the user interface ..................................................................................................60
2.2.2 Important functions in the STARTER commissioning tool...........................................................61
2.2.3 Activating online operation: STARTER via PROFIBUS...............................................................67
2.2.4 Activating online operation: STARTER via Ethernet....................................................................68
2.2.5 Activating online operation: STARTER via PROFINET IO ..........................................................74
2.3 Creating a project in the STARTER commissioning tool .............................................................81
2.3.1 Creating a project offline ..............................................................................................................81
2.3.2 Creating a project online..............................................................................................................85
2.4 Commissioning the servo control booksize format for the first time ............................................89
2.4.1 Task .............................................................................................................................................89
2.4.2 Component wiring (example).......................................................................................................91
2.4.3 Signal flow of the commissioning example ..................................................................................92
2.4.4 Commissioning with STARTER (example) ..................................................................................93

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14 Commissioning Manual, (IH1), 01/2013, 6SL3097-4AF00-0BP3
2.5 Commissioning U/f vector control booksize format for the first time........................................... 99
2.5.1 Task............................................................................................................................................. 99
2.5.2 Component wiring (example) .................................................................................................... 100
2.5.3 Signal flow of the commissioning example ............................................................................... 101
2.5.4 Commissioning with STARTER (example) ............................................................................... 102
2.6 Commissioning the vector control chassis format for the first time........................................... 109
2.6.1 Task........................................................................................................................................... 109
2.6.2 Component wiring (example) .................................................................................................... 111
2.6.3 Signal flow of the commissioning example ............................................................................... 112
2.6.4 Commissioning with STARTER (example) ............................................................................... 113
2.7 First commissioning vector control AC drive blocksize format.................................................. 122
2.7.1 Task........................................................................................................................................... 122
2.7.2 Component wiring (example) .................................................................................................... 123
2.7.3 Quick commissioning using the BOP (example)....................................................................... 123
2.8 First commissioning servo control AC drive blocksize format................................................... 127
2.8.1 Task........................................................................................................................................... 127
2.8.2 Component wiring (example) .................................................................................................... 128
2.8.3 Quick commissioning using the BOP (example)....................................................................... 129
2.9 Commissioning of power units connected in parallel................................................................ 132
2.10 Learn devices............................................................................................................................ 138
2.11 Selection and configuration of encoders...................................................................................140
2.12 Notes on commissioning linear motors ..................................................................................... 149
2.12.1 General information on commissioning linear motors............................................................... 149
2.12.2 Commissioning: Linear motor with one primary section ........................................................... 152
2.12.3 Commissioning: Linear motor with several identical primary sections ..................................... 156
2.12.4 Thermal motor protection.......................................................................................................... 157
2.12.5 Measuring system ..................................................................................................................... 160
2.12.6 Checking the linear motor by taking measurements................................................................. 163
2.13 Commissioning SIMOTICS 1FW6 built-in torque motors ......................................................... 166
2.13.1 Safety instructions for commissioning....................................................................................... 166
2.13.2 Checklists for commissioning.................................................................................................... 169
2.13.3 General information for setting the commutation...................................................................... 172
2.13.4 Parameterizing a motor and encoder........................................................................................ 173
2.13.5 Parameterizing and testing the temperature sensors ............................................................... 188
2.13.6 Determining the angular commutation offset ............................................................................ 193
2.13.6.1 Checking the angular commutation offset................................................................................. 194
2.13.6.2 Checking the angular commutation offset by making a measurement..................................... 195
2.13.7 Special case of a parallel connection........................................................................................ 206
2.13.8 Optimization of the closed-loop control..................................................................................... 207
2.14 Notes on commissioning SSI encoders .................................................................................... 208
2.15 Notes on the commissioning of a 2-pole resolver as absolute encoder ................................... 212
2.16 Temperature sensors for SINAMICS components ................................................................... 213

Contents
Commissioning Manual
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2.17 Basic Operator Panel 20 (BOP20).............................................................................................224
2.17.1 Operation with BOP20 (Basic Operator Panel 20) ....................................................................224
2.17.1.1 General information about the BOP20.......................................................................................224
2.17.1.2 Displays and using the BOP20 ..................................................................................................228
2.17.1.3 Fault and alarm displays............................................................................................................233
2.17.1.4 Controlling the drive using the BOP20.......................................................................................234
2.17.2 Important functions via BOP20 ..................................................................................................235
3 Diagnostics............................................................................................................................................ 237
3.1 Diagnostics via LEDs .................................................................................................................238
3.1.1 Control Units ..............................................................................................................................238
3.1.1.1 Description of the LED states of a CU320-2..............................................................................238
3.1.1.2 Description of the LED states of a CU310-2..............................................................................244
3.1.2 Power units ................................................................................................................................249
3.1.2.1 Active Line Module booksize .....................................................................................................249
3.1.2.2 Basic Line Module booksize ......................................................................................................250
3.1.2.3 Smart Line Modules booksize 5 kW and 10 kW ........................................................................251
3.1.2.4 Smart Line Modules booksize 16 kW to 55 kW .........................................................................252
3.1.2.5 Single Motor Module / Double Motor Module / Power Module ..................................................253
3.1.2.6 Braking Modules booksize format..............................................................................................254
3.1.2.7 Smart Line Module booksize compact format............................................................................255
3.1.2.8 Motor Module booksize compact format....................................................................................256
3.1.2.9 Control Interface Module in the Active Line Module chassis format..........................................257
3.1.2.10 Control Interface Module in the Basic Line Module chassis format...........................................258
3.1.2.11 Control Interface Module in the Smart Line Module chassis format..........................................259
3.1.2.12 Control Interface Module in the Motor Module chassis format ..................................................260
3.1.2.13 Control Interface Module in the Power Module chassis format .................................................261
3.1.3 Additional modules.....................................................................................................................262
3.1.3.1 Control Supply Module...............................................................................................................262
3.1.3.2 Sensor Module Cabinet SMC10 / SMC20 .................................................................................262
3.1.3.3 Sensor Module Cabinet SMC30 ................................................................................................263
3.1.3.4 Sensor Module Cabinet SMC40 ................................................................................................264
3.1.3.5 Communication Board CBC10 for CANopen.............................................................................264
3.1.3.6 Communication Board Ethernet CBE20 ....................................................................................265
3.1.3.7 Voltage Sensing Module VSM10 ...............................................................................................267
3.1.3.8 DRIVE-CLiQ Hub Module DMC20.............................................................................................267
3.1.4 Terminal Module ........................................................................................................................268
3.1.4.1 Terminal Module TM15..............................................................................................................268
3.1.4.2 Terminal Module TM31..............................................................................................................269
3.1.4.3 Terminal Module TM120............................................................................................................269
3.1.4.4 Terminal Module TM150............................................................................................................270
3.1.4.5 Terminal Module TM41..............................................................................................................270
3.1.4.6 Terminal Module TM54F............................................................................................................271
3.2 Diagnostics via STARTER .........................................................................................................273
3.2.1 Function generator.....................................................................................................................273
3.2.2 Trace function ............................................................................................................................277
3.2.2.1 Single trace ................................................................................................................................277
3.2.2.2 Multiple trace..............................................................................................................................280
3.2.2.3 Startup trace...............................................................................................................................281
3.2.2.4 Overview of important alarms and parameters..........................................................................282
3.2.3 Measuring function.....................................................................................................................283
3.2.4 Measuring sockets .....................................................................................................................285

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16 Commissioning Manual, (IH1), 01/2013, 6SL3097-4AF00-0BP3
3.3 Diagnostic buffer ....................................................................................................................... 290
3.4 Diagnostics of uncommissioned axes....................................................................................... 293
3.5 Fault and alarm messages........................................................................................................ 296
3.5.1 General information about faults and alarms............................................................................ 296
3.5.2 Buffer for faults and alarms....................................................................................................... 298
3.5.3 Configuring messages .............................................................................................................. 302
3.5.4 Overview of important function diagrams and parameters ....................................................... 305
3.5.5 Propagation of faults ................................................................................................................. 306
3.5.6 Alarm classes............................................................................................................................ 307
3.6 Troubleshooting for encoders ................................................................................................... 309
A Appendix................................................................................................................................................ 313
A.1 Availability of hardware components ........................................................................................313
A.2 Availability of SW functions....................................................................................................... 317
A.3 List of abbreviations .................................................................................................................. 320
Index...................................................................................................................................................... 331

Commissioning Manual
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Preparation for commissioning 1
Before commissioning observe the conditions described in this chapter.
● The preconditions for commissioning must be fulfilled (in the next chapter).
● The relevant checklist must have been worked through.
● The bus components required for communication must be wired up.
● DRIVE-CLiQ wiring rules must be complied with.
● The ON-OFF responses of the drive.

Preparation for commissioning
1.1 Requirements for commissioning
Commissioning Manual
18 Commissioning Manual, (IH1), 01/2013, 6SL3097-4AF00-0BP3
1.1 Requirements for commissioning
The following are necessary for commissioning a SINAMICS S drive system:
● A programming device (PG/PC)
● STARTER commissioning tool
● A communication interface, e.g. PROFIBUS, PROFINET, Ethernet
● Completely wired-up drive line-up (see the SINAMICS S120 Manual)
The following diagram shows a configuration example with booksize and chassis
components, as well as with PROFIBUS and PROFINET communication:
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Figure 1-1 Component configuration (example)