Siemens SIMOTICS S-1FK7 G2 Operating instructions

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SIMOTICS
Drive technology
Replacing an encoder for
SIMOTICS S-1FK7 G2, S-1FG1
and S-1FT7
Service Instructions
01/2018
A5E34676237B AC
Introduction
General safety instructions
1
Description
2

Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E34676237B AC
Ⓟ
02/2018 Subject to change
Copyright © Siemens AG 2014 - 2018.
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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Service Manual, 01/2018, A5E34676237B AC 3
Introduction
Information regarding third-party products
Note
Recommendation relating to third-party products
This document contains recommendations relating to third
-party products. Siemens accepts
the fundamental suitability of these third
-party products.
You can use equivalent products from other manufacturers.
Siemens does not accept
any warranty for the properties of third-party products.
What is the target group for these service instructions?
These service instructions address electricians, fitters and service technicians.
What do these instructions contain?
For 1FK7 G2, 1FG1 and 1FT7 motors, a defective encoder can be replaced by an identical
part. The encoder can be replaced without special tools simply by adjusting the coupling
element opposite the motor shaft.
These service instructions describe how to order a replacement encoder as well as the
replacement procedure itself.
Note
The encoder (either with or without Sensor Module) is regarded in this document as a single
entity and referred to in the following as the "encoder".
For a precise definition of the various encoder
types, refer to section "Which encoders can
be replaced?
(Page 19)".
●Carefully read these service instructions before replacing the encoder. In this way you
guarantee safe, problem-free operation and a maximum service life.
These service instructions are valid in conjunction with the relevant documentation for the
converter and motor.
You can download these documents from the Internet.
Siemens continually strives to improve the quality of information provided in these service
instructions. If you find any mistakes or would like to offer suggestions about how this
document could be improved, please contact the Siemens Service Center.
●Always follow the safety instructions and notices in these service instructions. The
warning notice system is explained on the rear of the inside front.

Introduction
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4Service Manual, 01/2018, A5E34676237B AC
What is shown and how?
Notes
Notes are shown as follows:
Note
A Note is an important item of information about th
e product, handling of the product or the
relevant section of the document. Notes provide you with help or further suggestions/ideas.
In addition to the notes that you must observe for your own personal safety as well as to
avoid material damage, in this document you will find the following text features:
Instructions
An instruction with a specified sequence starts with the subtitle:
Procedure
The individual handling steps are numbered.
1. Execute the operating instructions in the specified sequence.
A square at the end of the final sentence indicates the end of a specific instruction.
❒
Operating instructions without a specified sequence are identified using a bullet point:
●Execute the operating instructions.
Enumerations
●Enumerations are identified by a bullet point without any additional symbols.
–Enumerations at the second level are hyphenated.
Links
Links to additional information are underlined in blue.
When passing over the link, the mouse pointer changes to a hand symbol.
Where can I find additional information?
Information on the following topics is available at:
●Ordering documentation / overview of documentation
●Additional links to download documents
●Using documentation online (find and search in manuals / information)
More information (https://support.industry.siemens.com/cs/de/en/view/108998034)
If you have any questions regarding the technical documentation (e.g. suggestions,
corrections), please send an e-mail to the following address E-mail
(mailto:[e-mail]).

Introduction
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Service Manual, 01/2018, A5E34676237B AC 5
Where can I find information about SIEMENS drive technology in the Internet?
You can find information about SIEMENS drive technology at the following websites:
Internet address for motors: http://www.siemens.com/motors
Internet address for products: http://www.siemens.com/motioncontrol
(http://www.siemens.com/motioncontrol)
Internet address for SINAMICS: http://www.siemens.com/sinamics
Where can I find information about the product documentation?
Information is provided at the following link regarding how you can individually compile
documentation based on Siemens content, and adapt it for your own specific machine
documentation:
My support (https://support.industry.siemens.com/My/de/en/documentation)
Note
If you want to use this function, you must fir
st register.
Later, you can log on with your login data.
Where can I find training courses for SIEMENS products?
The following link provides information on SITRAIN - training from Siemens for products,
systems and automation engineering solutions:
SITRAIN (http://siemens.com/sitrain)
Who answers the technical questions?
If you have any technical questions, please contact Technical Support
Country-specific telephone numbers for technical support are provided on the Internet under
Contact:
Technical Support (https://support.industry.siemens.com/sc/ww/en/sc/2090)
Websites of third parties
This publication contains hyperlinks to websites of third parties. Siemens does not take any
responsibility for the contents of these websites or adopt any of these websites or their
contents as their own, because Siemens does not control the information on these websites
and is also not responsible for the contents and information provided there. Use of these
websites is at the risk of the person doing so.

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Table of contents
Introduction............................................................................................................................................. 3
1 General safety instructions...................................................................................................................... 9
1.1 General safety instructions .......................................................................................................9
1.2 Equipment damage due to electric fields or electrostatic discharge ......................................13
1.3 Industrial security ....................................................................................................................14
1.4 Residual risks of power drive systems....................................................................................16
2 Description............................................................................................................................................ 17
2.1 Which motors have encoders that can be replaced? .............................................................17
2.2 Which encoders can be replaced? .........................................................................................19
2.3 Different encoder replacement types......................................................................................20
2.4 How do you determine the replacement encoder?.................................................................22
2.5 How do you order a replacement encoder?............................................................................29
2.6 How do you replace the defective encoder? ..........................................................................34
2.7 How do you program an encoder that has not been loaded with data? .................................38
2.7.1 For SINAMICS, this is how you program the encoder using STARTER ................................39
2.7.2 For SINAMICS, this is how you program the encoder with SINUMERIK ...............................41
2.7.3 For SINAMICS, this is how you program the encoder with STARTDRIVE ............................44
2.8 How do you backup the data of the electronic type plate? .....................................................45
2.8.1 For SINAMICS, this is how you backup the electronic type plate data ..................................46
2.8.2 For SINUMERIK, this is how you backup the electronic type plate data................................47
2.9 Where can you find the electronic type plate in the Internet?.................................................48
Index..................................................................................................................................................... 51

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General safety instructions
1
1.1
General safety instructions
WARNING
Electric shock and danger to life due to other energy sources
Touching live components can result in death or severe injury.
•Only work on electrical devices when you are qualified for this job.
•Always observe the country-specific safety rules.
Generally, the following six steps apply when establishing safety:
1. Prepare for disconnection. Notify all those who will be affected by the procedure.
2. Isolate the drive system from the power supply and take measures to prevent it being
switched back on again.
3. Wait until the discharge time specified on the warning labels has elapsed.
4. Check that there is no voltage between any of the power connections, and between any
of the power connections and the protective conductor connection.
5. Check whether the existing auxiliary supply circuits are de-energized.
6. Ensure that the motors cannot move.
7. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or
water. Switch the energy sources to a safe state.
8. Check that the correct drive system is completely locked.
After you have completed the work, restore the operational readiness in the inverse
sequence.
WARNING
Electric shock due to damaged motors or devices
Improper handling of motors or devices can damage them.
Hazardous voltages can be present at the enclosure or at exposed components on
damaged motors or devices.
•Ensure compliance with the limit values specified in the technical data during transport,
storage and operation.
•Do not use any damaged motors or devices.

General safety instructions
1.1 General safety instructions
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WARNING
Arcing when a plug connection is opened during operation
Opening a plug connection when a system is operation can result in arcing that may cause
serious 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
Property damage due to loose power connections
Insufficient tightening torques or vibration can result in loose power connections. This can
result in damage due to fire, device defects or malfunctions.
•Tighten all power connections to the prescribed torque.
•Check all power connections at regular intervals, particularly after equipment has been
transported.
WARNING
Unexpected movement of machines caused by radio devices or mobile phones
When radio devices or mobile phones with a transmission power > 1 W are used in the
immediate vicinity of components, they may cause the equipment to malfunction.
Malfunctions may impair the functional safety of machines and can therefore put people in
danger or lead to property damage.
•If you come closer than around 2 m to such components, switch off any radios or mobile
phones.
•Use the "SIEMENS Industry Online Support app" only on equipment that has already
been switched off.
WARNING
Unrecognized dangers due to missing or illegible warning labels
Dangers might not be recognized if warning labels are missing or illegible. Unrecognized
dangers may cause accidents resulting in serious injury or death.
•Check that the warning labels are complete based on the documentation.
•Attach any missing warning labels to the components, where necessary in the national
language.
•Replace illegible warning labels.

General safety instructions
1.1 General safety instructions
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WARNING
Unexpected movement of machines caused by inactive safety functions
Inactive or non-adapted safety functions can trigger unexpected machine movements that
may result in serious injury or death.
•Observe the information in the appropriate product documentation before
commissioning.
•Carry out a safety inspection for functions relevant to safety on the entire system,
including all safety-related components.
•Ensure that the safety functions used in your drives and automation tasks are adjusted
and activated through appropriate parameterizing.
•Perform a function test.
•Only put your plant into live operation once you have guaranteed that the functions
relevant to safety are running correctly.
Note
Important safety notices for Safety Integrated functions
If you want to use Safety Integrated functions, you must observe the safety notices in the
Safety Inte
grated manuals.
WARNING
Influence of active implants by electromagnetic fields
Electromagnetic fields (EMF) are generated by the operation of electrical power equipment,
such as transformers, converters, or motors. People with pacemakers or implants are at
particular risk in the immediate vicinity of this equipment.
•If you are affected, maintain a minimum distance of 300 mm away from the motor.
WARNING
Influence of active implants by permanent magnet fields
Even when switched off, electric motors with permanent magnets represent a potential risk
for persons with heart pacemakers or implants if they are close to converters/motors.
•If you are affected, maintain a minimum distance of 300 mm.
•When transporting or storing permanent-magnet motors always use the original packing
materials with the warning labels attached.
•Clearly mark the storage locations with the appropriate warning labels.
•IATA regulations must be observed when transported by air.

General safety instructions
1.1 General safety instructions
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WARNING
Injury caused by moving or ejected parts
Contact with moving motor parts or drive output elements and the ejection of loose motor
parts (e.g. feather keys) out of the motor enclosure can result in severe injury or death.
•Remove any loose parts or secure them so that they cannot be flung out.
•Do not touch any moving parts.
•Safeguard all moving parts using the appropriate safety guards.
WARNING
Fire due to inadequate cooling
Inadequate cooling can cause the motor to overheat, resulting in death or severe injury as a
result of smoke and fire. This can also result in increased failures and reduced service lives
of motors.
•Comply with the specified cooling requirements for the motor.
WARNING
Fire due to incorrect operation of the motor
When incorrectly operated and in the case of a fault, the motor can overheat resulting in fire
and smoke. This can result in severe injury or death. Further, excessively high
temperatures destroy motor components and result in increased failures as well as shorter
service lives of motors.
•Operate the motor according to the relevant specifications.
•Only operate the motors in conjunction with effective temperature monitoring.
•Immediately switch off the motor if excessively high temperatures occur.
CAUTION
Burn injuries caused by hot surfaces
In operation, the motor can reach high temperatures, which can cause burns if touched.
•Mount the motor so that it is not accessible in operation.
Measures when maintenance is required:
•Allow the motor to cool down before starting any work.
•Use the appropriate personnel protection equipment, e.g. gloves.

General safety instructions
1.2 Equipment damage due to electric fields or electrostatic discharge
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1.2
Equipment damage due to electric fields or electrostatic discharge
Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules
or devices that may be damaged by either electric fields or electrostatic discharge.
NOTICE
Equipment damage due to electric fields or electrostatic discharge
Electric fields or electrostatic discharge can cause malfunctions through damaged
individual components, integrated circuits, modules or devices.
•Only pack, store, transport and send electronic components, modules or devices in their
original packaging or in other suitable materials, e.g conductive foam rubber of
aluminum foil.
•Only touch components, modules and devices when you are grounded by one of the
following methods:
–Wearing an ESD wrist strap
–Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring
•Only place electronic components, modules or devices on conductive surfaces (table
with ESD surface, conductive ESD foam, ESD packaging, ESD transport container).

General safety instructions
1.3 Industrial security
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1.3
Industrial security
Note
Industrial security
Siemens provides products and solutions with industrial security functions tha
t support the
secure operation of plants, systems, machines and networks.
In order to protect plants, systems, machines and networks against cyber threats, it is
necessary to implement
– and continuously maintain – a holistic, state-of-the-art industrial
s
ecurity concept. Siemens’ products and solutions constitute one element of such a concept.
Customers are responsible for preventing unauthorized access to their plants, systems,
machines and networks. Such systems, machines and components should only be
co
nnected to an enterprise network or the Internet if and to the extent such a connection is
necessary and only when appropriate security measures (e.g. firewalls and/or network
segmentation) are in place.
For additional information on industrial security m
easures that may be implemented, please
visit:
Industrial security (
http://www.siemens.com/industrialsecurity)
Siemens’ products and solutions undergo continuous development to make them more
sec
ure. Siemens strongly recommends that product updates are applied as soon as they are
available and that the latest product versions are used. Use of product versions that are no
longer supported, and failure to apply the latest updates may increase custom
er’s exposure
to cyber threats.
To stay informed about product updates, subscribe to the Siemens Industrial Security RSS
Feed at:
Industrial security (
http://www.siemens.com/industrialsecurity)
Further information is provided on the Internet:
Industrial Security Configuration Manual
(https://support.industry.siemens.com/cs/ww/en/view/108862708)

General safety instructions
1.3 Industrial security
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WARNING
Unsafe operating states resulting from software manipulation
Software manipulations (e.g. viruses, trojans, malware or worms) can cause unsafe
operating states in your system that may lead to death, serious injury, and property
damage.
•Keep the software up to date.
•Incorporate the automation and drive components into a holistic, state-of-the-art
industrial security concept for the installation or machine.
•Make sure that you include all installed products into the holistic industrial security
concept.
•Protect files stored on exchangeable storage media from malicious software by with
suitable protection measures, e.g. virus scanners.
•Protect the drive against unauthorized changes by activating the "know-how protection"
drive function.

General safety instructions
1.4 Residual risks of power drive systems
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1.4
Residual risks of power drive systems
When assessing the machine- or system-related risk in accordance with the respective local
regulations (e.g., EC Machinery Directive), the machine manufacturer or system installer
must take into account the following residual risks emanating from the control and drive
components of a drive system:
1. Unintentional movements of driven machine or system components during
commissioning, operation, maintenance, and repairs caused by, for example,
–Hardware and/or software errors in the sensors, control system, actuators, and cables
and connections
–Response times of the control system and of the drive
–Operation and/or environmental conditions outside the specification
–Condensation/conductive contamination
–Parameterization, programming, cabling, and installation errors
–Use of wireless devices/mobile phones in the immediate vicinity of electronic
components
–External influences/damage
–X-ray, ionizing radiation and cosmic radiation
2. Unusually high temperatures, including open flames, as well as emissions of light, noise,
particles, gases, etc., can occur inside and outside the components under fault conditions
caused by, for example:
–Component failure
–Software errors
–Operation and/or environmental conditions outside the specification
–External influences/damage
3. Hazardous shock voltages caused by, for example:
–Component failure
–Influence during electrostatic charging
–Induction of voltages in moving motors
–Operation and/or environmental conditions outside the specification
–Condensation/conductive contamination
–External influences/damage
4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a
risk to people with a pacemaker, implants or metal replacement joints, etc., if they are too
close
5. Release of environmental pollutants or emissions as a result of improper operation of the
system and/or failure to dispose of components safely and correctly
6. Influence of network-connected communication systems, e.g. ripple-control transmitters
or data communication via the network
For more information about the residual risks of the drive system components, see the
relevant sections in the technical user documentation.

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Description
2
2.1
Which motors have encoders that can be replaced?
Which motors have encoders that can be replaced?
●1FT7
●2nd generation of 1FK7
●1FG1
You can recognize the motors as a result of the offset, round encoder mounting at the end of
the motor frame and at the rating plate.
①
Encoder that can be replaced
Figure 2-1 Example 1FK7042
Data for the mounted encoder is stamped on the rating plate.

Description
2.1 Which motors have encoders that can be replaced?
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1FT7
2nd generation of 1FK7
1FG1
①
Data about the encoder type
②
Identifying 1FK7, 2nd generation: The 8th position of the Article No. is a 2, 3 or 4
Note
1FK7 motors with a number other than 2, 3 or 4 at the 8th position of the Article No. are not
2nd generation 1FK7 motors. For these motors, you cannot repl
ace the encoder.
•
You must either replace the complete motor or have the motor and encoder repaired.