Siemens SINAMICS G120 User manual

Converter with CU250S-2 Control Unit
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SINAMICS
SINAMICS G120
Converter with CU250S-2 Control
Unit
Operating Instructions
Edition 01/2016, Firmware V4.7 SP6
Original instructions
01/2016, FW V4.7 SP6
A5E31759476B AE
Changes in this manual
Fundamental safety
instructions
1
Introduction
2
Description
3
Installing
4
Commissioning
5
Advanced commissioning
6
Backing up data and series
commissioning
7
Corrective maintenance
8
Alarms, faults and system
messages
9
Technical data
10
Appendix
A

Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E31759476B AE
Ⓟ
01/2016 Subject to change
Copyright © Siemens AG 2013 - 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 requi
red 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.

Converter with CU250S-2 Control Unit
Operating Instructions, 01/2016, FW V4.7 SP6, A5E31759476B AE 5
Changes in this manual
The most important changes with respect to the 04/2015 edition of the manual
New hardware
●New Power Module – PM240-2, FSF
Power Modules (Page 31)
Installing Power Modules (Page 59)
Technical data, PM240-2 (Page 433)
New functions in firmware V4.7 SP6
●Evaluation of a PT1000 motor temperature sensor
Motor temperature monitoring of the motor using a temperature sensor (Page 253)
●Revision of the thermal motor models: p0612 bit 08, 09 and 12
Protecting the motor by calculating the motor temperature (Page 257)
●Support for 1PC1 induction motors
Motor series that are supported (Page 46)
●Changing the quick commissioning in the "Standard Drive Control" application class:
The motor data identification is no longer permanently set to p1900 = 12; instead, users
select the appropriate motor data identification.
Factory setting: p1900 = 2.
Standard Drive Control (Page 127)
You can find an overview of all new and modified functions in firmware V4.7 SP6:
New and extended functions (Page 471).
Corrections
●Article numbers for encoder cables: Correct: 6FX… (rather than 6XF…)
Installing encoders (Page 106)
●The "Moment of inertia estimator" function has been released for all permitted motors.
Moment of inertia estimator (Page 242)
●It is not permissible that the output of the friction characteristic r3841 is interconnected
with p1511 or with p1513.
Friction characteristic (Page 239)

Changes in this manual
Converter with CU250S-2 Control Unit
6Operating Instructions, 01/2016, FW V4.7 SP6, A5E31759476B AE

Converter with CU250S-2 Control Unit
Operating Instructions, 01/2016, FW V4.7 SP6, A5E31759476B AE 7
Table of contents
Changes in this manual........................................................................................................................... 5
1 Fundamental safety instructions............................................................................................................ 15
1.1 General safety instructions .....................................................................................................15
1.2 Safety instructions for electromagnetic fields (EMF) ..............................................................19
1.3 Handling electrostatic sensitive devices (ESD) ......................................................................19
1.4 Industrial security ....................................................................................................................20
1.5 Residual risks of power drive systems....................................................................................21
2 Introduction........................................................................................................................................... 23
2.1 About the Manual....................................................................................................................23
2.2 Guide through the manual ......................................................................................................24
3 Description............................................................................................................................................ 27
3.1 Identifying the converter..........................................................................................................27
3.2 Overview of Control Units .......................................................................................................29
3.3 Power Modules .......................................................................................................................31
3.4 Components for the Power Modules ......................................................................................34
3.4.1 Accessories for installation and shielding ...............................................................................34
3.4.2 Line filter .................................................................................................................................35
3.4.3 Line reactor .............................................................................................................................37
3.4.4 Output reactor .........................................................................................................................39
3.4.5 Sine-wave filter .......................................................................................................................41
3.4.6 Braking resistor .......................................................................................................................43
3.4.7 Brake Relay ............................................................................................................................45
3.4.8 Safe Brake Relay ....................................................................................................................45
3.5 Motor series that are supported..............................................................................................46
3.6 Permissible encoders..............................................................................................................48
3.7 Sensor Module........................................................................................................................48
3.8 Tools to commission the inverter ............................................................................................49
4 Installing ............................................................................................................................................... 51
4.1 Overview of the inverter installation........................................................................................51
4.2 Installing the inverter in compliance with EMC rules ..............................................................52
4.2.1 EMC-compliant connection of the converter...........................................................................52
4.2.2 Avoiding electromagnetic influence (EMI) ..............................................................................52
4.2.3 Laying EMC-compliant cables ................................................................................................55
4.3 Installing reactors, filters and braking resistors ......................................................................57
4.4 Installing Power Modules........................................................................................................59

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8Operating Instructions, 01/2016, FW V4.7 SP6, A5E31759476B AE
4.4.1 Basic installation rules ........................................................................................................... 59
4.4.2 Dimensioned drawings, drilling dimensions for the PM240-2 Power Module, IP20 .............. 61
4.4.3 Dimensioned drawings, drilling dimensions for the PM240-2 Power Module, PT
inverter ................................................................................................................................... 63
4.4.4 Dimensioned drawings, drilling dimensions for the PM240 Power Module, FSA … FSF ..... 65
4.4.5 Dimensioned drawings, drilling dimensions for the PM240 Power Module, FSGX ............... 67
4.4.6 Dimensioned drawings, drilling dimensions for the PM250 Power Module........................... 68
4.4.7 Dimensioned drawings, drilling dimensions for the PM260 Power Module........................... 70
4.4.8 Dimensioned drawings, drilling dimensions for the PM340 Power Module........................... 70
4.5 Connecting the line supply, motor, and inverter components................................................ 71
4.5.1 Permissible line supplies........................................................................................................ 71
4.5.2 Dimensioning the protective conductor.................................................................................. 75
4.5.3 Connecting the inverter.......................................................................................................... 76
4.5.4 Connecting a motor holding brake ......................................................................................... 80
4.5.4.1 Mounting and connecting the brake relay.............................................................................. 80
4.5.4.2 Mounting and connecting the brake relay.............................................................................. 81
4.5.4.3 Technical data of the brake relay?......................................................................................... 81
4.5.4.4 Install and connect Brake Relay - PM240, PM250, PM260 Power Modules......................... 82
4.5.4.5 Install and connect the Brake Relay - PM240-2 Power Module ............................................ 83
4.6 Installing Control Unit............................................................................................................. 84
4.6.1 Overview of the interfaces ..................................................................................................... 85
4.6.2 Assignment of the fieldbus and encoder interfaces ............................................................... 86
4.6.3 Terminal strips behind the upper front door........................................................................... 87
4.6.4 Terminal strips behind the lower front door ........................................................................... 88
4.6.5 Factory setting of the interfaces............................................................................................. 89
4.6.6 Default setting of the interfaces ............................................................................................. 91
4.6.7 Safety input .......................................................................................................................... 102
4.6.8 Wiring the terminal strip ....................................................................................................... 103
4.6.9 Monitoring the temperature of the braking resistor .............................................................. 105
4.7 Installing encoders ............................................................................................................... 106
4.8 Connecting the inverter to the fieldbus ................................................................................ 108
4.8.1 Fieldbus versions of the Control Unit ................................................................................... 108
4.8.2 PROFINET ........................................................................................................................... 109
4.8.2.1 What do you need for communication via PROFINET? ...................................................... 110
4.8.2.2 Integrating inverters into PROFINET ................................................................................... 110
4.8.2.3 Configuring communication to the control ........................................................................... 111
4.8.2.4 Installing GSDML ................................................................................................................. 111
4.8.3 PROFIBUS........................................................................................................................... 112
4.8.3.1 What do you need for communication via PROFIBUS? ...................................................... 112
4.8.3.2 Integrating inverters into PROFIBUS................................................................................... 112
4.8.3.3 Configuring the communication using SIMATIC S7 control................................................. 113
4.8.3.4 Installing the GSD ................................................................................................................ 113
4.8.3.5 Setting the address .............................................................................................................. 114
5 Commissioning ....................................................................................................................................115
5.1 Commissioning guidelines ................................................................................................... 115
5.2 Preparing for commissioning ............................................................................................... 116
5.2.1 Collecting motor data ........................................................................................................... 116
5.2.2 Inverter factory setting ......................................................................................................... 117
5.2.3 Inverter function modules..................................................................................................... 119

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Operating Instructions, 01/2016, FW V4.7 SP6, A5E31759476B AE 9
5.3 Quick commissioning with a PC. ..........................................................................................121
5.3.1 Creating a project..................................................................................................................121
5.3.2 Transfer inverters connected via USB into the project .........................................................121
5.3.3 Configuring a drive................................................................................................................124
5.3.3.1 Starting the configuration......................................................................................................124
5.3.3.2 Standard Drive Control .........................................................................................................127
5.3.3.3 Dynamic Drive Control..........................................................................................................128
5.3.3.4 Configure the encoder and complete the configuration........................................................132
5.3.4 Adapting the encoder data....................................................................................................133
5.3.5 Loading the configured data into the drive ...........................................................................135
5.3.6 Identifying motor data ...........................................................................................................136
5.4 Restoring the factory setting .................................................................................................139
5.4.1 Resetting the safety functions to the factory setting .............................................................140
5.4.2 Restore the factory settings (without safety functions) .........................................................143
6 Advanced commissioning.................................................................................................................... 147
6.1 Overview of the converter functions .....................................................................................147
6.2 Inverter control ......................................................................................................................149
6.2.1 Switching the motor on and off .............................................................................................149
6.2.2 Adapt the default setting of the terminal strip .......................................................................151
6.2.2.1 Digital inputs .........................................................................................................................152
6.2.2.2 Safety-related input...............................................................................................................154
6.2.2.3 Digital outputs .......................................................................................................................155
6.2.2.4 Analog inputs ........................................................................................................................157
6.2.2.5 Analog outputs ......................................................................................................................161
6.2.3 Inverter control using digital inputs .......................................................................................164
6.2.4 Two-wire control: method 1 ..................................................................................................165
6.2.5 Two-wire control, method 2 ..................................................................................................166
6.2.6 Two-wire control, method 3 ..................................................................................................167
6.2.7 Three-wire control, method 1................................................................................................168
6.2.8 Three-wire control, method 2................................................................................................169
6.2.9 Running the motor in jog mode (JOG function) ....................................................................170
6.2.10 Control via PROFIBUS or PROFINET with the PROFIdrive profile .....................................171
6.2.10.1 Control and status word 1.....................................................................................................175
6.2.10.2 Control and status word 2.....................................................................................................178
6.2.10.3 Control and status word 3.....................................................................................................179
6.2.10.4 NAMUR message word ........................................................................................................181
6.2.10.5 Control and status word, encoder.........................................................................................182
6.2.10.6 Position actual value of the encoder.....................................................................................184
6.2.10.7 Data structure of the parameter channel ..............................................................................186
6.2.10.8 Examples of the parameter channel .....................................................................................189
6.2.10.9 Extend telegrams and change signal interconnection ..........................................................191
6.2.10.10 Configuring the IP interface ..................................................................................................192
6.2.10.11 Slave-to-slave communication..............................................................................................194
6.2.10.12 Acyclically reading and writing inverter parameters .............................................................194
6.2.11 Control via additional fieldbuses ...........................................................................................195
6.2.11.1 Modbus RTU.........................................................................................................................195
6.2.11.2 USS.......................................................................................................................................198
6.2.11.3 CANopen ..............................................................................................................................201
6.2.11.4 Ethernet/IP ............................................................................................................................202
6.2.12 Switching over the inverter control (command data set) ......................................................203

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10 Operating Instructions, 01/2016, FW V4.7 SP6, A5E31759476B AE
6.3 Setpoints .............................................................................................................................. 205
6.3.1 Overview .............................................................................................................................. 205
6.3.2 Analog input as setpoint source........................................................................................... 206
6.3.3 Specifying the setpoint via the fieldbus................................................................................ 207
6.3.4 Motorized potentiometer as setpoint source........................................................................ 208
6.3.5 Fixed speed as setpoint source ........................................................................................... 210
6.3.6 Pulse input as source of setpoint value ............................................................................... 213
6.4 Setpoint calculation.............................................................................................................. 215
6.4.1 Overview of setpoint processing .......................................................................................... 215
6.4.2 Invert setpoint....................................................................................................................... 216
6.4.3 Inhibit direction of rotation.................................................................................................... 217
6.4.4 Skip frequency bands and minimum speed......................................................................... 218
6.4.5 Speed limitation.................................................................................................................... 219
6.4.6 Ramp-function generator ..................................................................................................... 220
6.5 Motor control ........................................................................................................................ 225
6.5.1 V/f control ............................................................................................................................. 225
6.5.1.1 Characteristics of U/f control................................................................................................ 227
6.5.1.2 Optimizing motor starting ..................................................................................................... 230
6.5.2 Vector control with speed controller..................................................................................... 233
6.5.2.1 Checking the encoder signal................................................................................................ 235
6.5.2.2 Optimizing the speed controller ........................................................................................... 235
6.5.2.3 Advanced settings................................................................................................................ 238
6.5.2.4 Friction characteristic ........................................................................................................... 239
6.5.2.5 Moment of inertia estimator ................................................................................................. 242
6.5.2.6 Pole position identification ................................................................................................... 247
6.5.3 Torque control ...................................................................................................................... 248
6.6 Protection functions ............................................................................................................. 250
6.6.1 Inverter temperature monitoring........................................................................................... 250
6.6.2 Motor temperature monitoring of the motor using a temperature sensor ............................ 253
6.6.3 Protecting the motor by calculating the motor temperature................................................. 257
6.6.4 Overcurrent protection ......................................................................................................... 261
6.6.5 Limiting the maximum DC link voltage................................................................................. 262
6.7 Application-specific functions............................................................................................... 264
6.7.1 Unit changeover ................................................................................................................... 265
6.7.1.1 Changing over the motor standard ...................................................................................... 266
6.7.1.2 Changing over the unit system ............................................................................................ 267
6.7.1.3 Changing over process variables for the technology controller........................................... 267
6.7.1.4 Switching units with STARTER............................................................................................ 268
6.7.2 Calculating the energy saving for fluid flow machines......................................................... 269
6.7.3 Electrically braking the motor............................................................................................... 271
6.7.3.1 DC braking ........................................................................................................................... 273
6.7.3.2 Compound braking............................................................................................................... 276
6.7.3.3 Dynamic braking .................................................................................................................. 278
6.7.3.4 Braking with regenerative feedback to the line .................................................................... 280
6.7.4 Motor holding brake ............................................................................................................. 281
6.7.5 Flying restart – switching on while the motor is running ...................................................... 286
6.7.6 Automatic restart.................................................................................................................. 288
6.7.7 Kinetic buffering (Vdc min control) ....................................................................................... 292
6.7.8 Line contactor control........................................................................................................... 294
6.7.9 PID technology controller..................................................................................................... 296

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Converter with CU250S-2 Control Unit
Operating Instructions, 01/2016, FW V4.7 SP6, A5E31759476B AE 11
6.7.9.1 Overview ...............................................................................................................................296
6.7.9.2 Setting the controller .............................................................................................................297
6.7.9.3 Optimizing the controller .......................................................................................................300
6.7.10 System protection .................................................................................................................301
6.7.10.1 No-load monitoring, blocking protection, stall protection ......................................................302
6.7.10.2 Load monitoring ....................................................................................................................304
6.7.11 Extended messages .............................................................................................................309
6.7.12 Free function blocks..............................................................................................................311
6.7.12.1 Overview ...............................................................................................................................311
6.7.12.2 Runtime groups and run sequence.......................................................................................311
6.7.12.3 List of the free function blocks ..............................................................................................312
6.7.12.4 Scaling ..................................................................................................................................323
6.7.12.5 Activating free function block ................................................................................................324
6.7.12.6 Further information................................................................................................................324
6.8 Safe Torque Off (STO) safety function .................................................................................325
6.8.1 Function description..............................................................................................................325
6.8.2 Prerequisite for STO use ......................................................................................................327
6.8.3 Commissioning STO .............................................................................................................328
6.8.3.1 Commissioning tools.............................................................................................................328
6.8.3.2 Safety functions password....................................................................................................328
6.8.3.3 Configuring a safety function ................................................................................................329
6.8.3.4 Configuring a safety function ................................................................................................330
6.8.3.5 Interconnecting the "STO active" signal ...............................................................................332
6.8.3.6 Setting the filter for safety-related inputs ..............................................................................334
6.8.3.7 Setting the forced checking procedure (test stop) ................................................................337
6.8.3.8 Activating the settings and checking the digital inputs .........................................................339
6.8.3.9 Acceptance - completion of commissioning..........................................................................343
6.9 Switchover between different settings ..................................................................................347
7 Backing up data and series commissioning ......................................................................................... 349
7.1 Saving settings on a memory card .......................................................................................350
7.1.1 Saving setting on memory card ............................................................................................351
7.1.2 Transferring the setting from the memory card ....................................................................355
7.1.3 Safely remove the memory card...........................................................................................359
7.2 Saving settings on a PC........................................................................................................361
7.3 Saving settings on an operator panel ...................................................................................365
7.4 Other ways to back up settings.............................................................................................367
7.5 Write and know-how protection ............................................................................................368
7.5.1 Write protection.....................................................................................................................368
7.5.2 Know-how protection ............................................................................................................370
7.5.2.1 Settings for know-how protection..........................................................................................372
7.5.2.2 Generating an exception list for know-how protection..........................................................374
8 Corrective maintenance ...................................................................................................................... 375
8.1 Replacing inverter components ............................................................................................375
8.1.1 Overview of replacing converter components ......................................................................375
8.1.2 Replacing a Control Unit with enabled safety function .........................................................377
8.1.3 Replacing the Control Unit without the safety functions enabled .........................................382
8.1.4 Replacing the Control Unit without data backup...................................................................385

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12 Operating Instructions, 01/2016, FW V4.7 SP6, A5E31759476B AE
8.1.5 Replacing a Control Unit with active know-how protection.................................................. 386
8.1.6 Replacing a Power Module with enabled safety function .................................................... 388
8.1.7 Replacing a Power Module without the safety function being enabled ............................... 389
8.2 Replacing an encoder .......................................................................................................... 390
8.2.1 Replacing the encoder - same encoder type ....................................................................... 390
8.2.2 Replacing the encoder - different encoder type................................................................... 391
8.3 Firmware upgrade and downgrade...................................................................................... 393
8.3.1 Upgrading firmware.............................................................................................................. 394
8.3.2 Firmware downgrade ........................................................................................................... 396
8.3.3 Correcting an unsuccessful firmware upgrade or downgrade ............................................. 398
8.4 Reduced acceptance after a component has been replaced and a firmware change ........ 399
8.5 If the converter no longer responds ..................................................................................... 400
9 Alarms, faults and system messages ...................................................................................................403
9.1 Operating states indicated on LEDs .................................................................................... 404
9.2 System runtime .................................................................................................................... 407
9.3 Alarms .................................................................................................................................. 408
9.4 Faults ................................................................................................................................... 411
9.5 List of alarms and faults ....................................................................................................... 416
9.6 Identification & maintenance data (I&M).............................................................................. 425
10 Technical data .....................................................................................................................................427
10.1 Technical data, CU250S-2 Control Unit............................................................................... 427
10.2 Technical data, Power Modules........................................................................................... 432
10.2.1 Technical data, PM240-2 ..................................................................................................... 433
10.2.1.1 General data, PM240-2 - 200 V........................................................................................... 433
10.2.1.2 Power-dependent data, PM240-2 - 200 V ........................................................................... 435
10.2.1.3 General data, PM240-2 - 400 V........................................................................................... 440
10.2.1.4 Power-dependent data, PM240-2 - 400 V ........................................................................... 442
10.2.1.5 General data, PM240-2 - 600 V........................................................................................... 449
10.2.1.6 Power-dependent data, PM240-2 - 600 V ........................................................................... 450
10.2.2 Technical data, PM240 ........................................................................................................ 453
10.2.2.1 General data, PM240........................................................................................................... 454
10.2.2.2 Power-dependent data, PM240 ........................................................................................... 456
10.2.3 Technical data, PM340 ........................................................................................................ 462
10.2.3.1 General data, PM340........................................................................................................... 462
10.2.3.2 Power-dependent data, PM340 ........................................................................................... 463
10.2.4 Technical data, PM250 ........................................................................................................ 464
10.2.4.1 General data, PM250........................................................................................................... 464
10.2.4.2 Power-dependent data, PM250 ........................................................................................... 466
10.2.5 Technical data, PM260 ........................................................................................................ 468
10.2.6 Data regarding the power loss in partial load operation ...................................................... 468
10.3 Restrictions for special ambient conditions.......................................................................... 469
A Appendix .............................................................................................................................................471
A.1 New and extended functions................................................................................................ 471

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Converter with CU250S-2 Control Unit
Operating Instructions, 01/2016, FW V4.7 SP6, A5E31759476B AE 13
A.2 Activating licensed functions.................................................................................................478
A.2.1 Licensing...............................................................................................................................478
A.2.2 Creating or displaying the license key ..................................................................................479
A.2.3 Writing the license key to the card........................................................................................482
A.3 Parameter .............................................................................................................................484
A.4 Handling the BOP 2 operator panel......................................................................................487
A.4.1 Changing settings using BOP-2............................................................................................488
A.4.2 Changing indexed parameters..............................................................................................489
A.4.3 Directly entering the parameter number and value ..............................................................489
A.4.4 A parameter cannot be changed ..........................................................................................490
A.5 The device trace in STARTER..............................................................................................491
A.6 Interconnecting signals in the inverter ..................................................................................494
A.6.1 Fundamentals .......................................................................................................................494
A.6.2 Example ................................................................................................................................496
A.7 Application Examples............................................................................................................498
A.7.1 Setting an absolute encoder .................................................................................................498
A.7.2 Connecting the safety-related input......................................................................................502
A.8 Acceptance tests for the safety functions .............................................................................504
A.8.1 Recommended acceptance test ...........................................................................................504
A.8.2 Machine documentation........................................................................................................507
A.8.3 Documenting the settings for the basic functions, firmware V4.4 ... V4.7 SP6 ....................509
A.9 Manuals and technical support .............................................................................................510
A.9.1 Overview of the manuals ......................................................................................................510
A.9.2 Configuring support...............................................................................................................513
A.9.3 Product Support ....................................................................................................................514
A.10 Mistakes and improvements .................................................................................................514
Index................................................................................................................................................... 515

Table of contents
Converter with CU250S-2 Control Unit
14 Operating Instructions, 01/2016, FW V4.7 SP6, A5E31759476B AE

Converter with CU250S-2 Control Unit
Operating Instructions, 01/2016, FW V4.7 SP6, A5E31759476B AE 15
Fundamental safety instructions
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 devices when you are qualified for this job.
•Always observe the country-specific safety rules.
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 no-voltage condition, from phase conductor to phase
conductor and phase conductor to protective conductor.
–Check whether the existing auxiliary supply circuits are 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. Secure the energy sources against switching on again.
6. Ensure that the correct machine is completely interlocked.
After you have completed the work, restore the operational readiness in the inverse
sequence.
WARNING
Danger to life through a hazardous voltage when connecting an unsuitable power supply
Touching live components can result in death or severe injury.
•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.

Fundamental safety instructions
1.1 General safety instructions
Converter with CU250S-2 Control Unit
16 Operating Instructions, 01/2016, FW V4.7 SP6, A5E31759476B AE
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.
•As a minimum, connect cable shields and the conductors of power cables that are not
used (e.g. brake cores) at one end at 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 no-voltage state, unless it has
been explicitly stated that they can be opened in operation.
WARNING
Danger to life due to fire spreading if housing is inadequate
Fire and smoke development can cause severe personal injury or material damage.
•Install devices without a protective housing in a metal control cabinet (or protect the
device by another equivalent measure) in such a way that contact with fire is prevented.
•Ensure that smoke can only escape via controlled and monitored paths.

Fundamental safety instructions
1.1 General safety instructions
Converter with CU250S-2 Control Unit
Operating Instructions, 01/2016, FW V4.7 SP6, A5E31759476B AE 17
WARNING
Danger to life through unexpected movement of machines when using mobile wireless
devices or mobile phones
Using mobile wireless devices or mobile phones with a transmit power > 1 W closer than
approx. 2 m to the components may cause the devices to malfunction, influence the
functional safety of machines therefore putting people at risk or causing material damage.
•Switch the wireless devices or mobile phones off in the immediate vicinity of the
components.
WARNING
Danger to life due to the motor catching fire in the event of insulation overload
There is higher stress on the motor insulation through a ground fault in an IT system. If the
insulation fails, it is possible that death or severe injury can occur as a result of smoke and
fire.
•Use a monitoring device that signals an insulation fault.
•Correct the fault as quickly as possible so the motor insulation is not overloaded.
WARNING
Danger to life due to fire if overheating occurs because of insufficient ventilation clearances
Inadequate ventilation clearances can cause overheating of components with subsequent
fire and smoke. This can cause severe injury or even death. This can also result in
increased downtime and reduced service lives for devices/systems.
•Ensure compliance with the specified minimum clearance as ventilation clearance for
the respective component.
WARNING
Danger of an accident occurring due to missing or illegible warning labels
Missing or illegible warning labels can result in accidents involving death or serious injury.
•Check that the warning labels are complete based on the documentation.
•Attach any missing warning labels to the components, in the national language if
necessary.
•Replace illegible warning labels.
NOTICE
Device damage caused by incorrect voltage/insulation tests
Incorrect voltage/insulation tests can damage the device.
•Before carrying out a voltage/insulation check of the system/machine, disconnect the
devices as all converters and motors have been subject to a high voltage test by the
manufacturer, and therefore it is not necessary to perform an additional test within the
system/machine.

Fundamental safety instructions
1.1 General safety instructions
Converter with CU250S-2 Control Unit
18 Operating Instructions, 01/2016, FW V4.7 SP6, A5E31759476B AE
WARNING
Danger to life when safety functions are inactive
Safety functions that are inactive or that have not been adjusted accordingly can cause
operational faults on machines that could lead to 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 Integrated manuals.
WARNING
Danger to life or malfunctions of the machine as a result of incorrect or changed
parameterization
As a result of incorrect or changed parameterization, machines can malfunction, which in
turn can lead to injuries or death.
•Protect the parameterization (parameter assignments) against unauthorized access.
•Respond to possible malfunctions by applying suitable measures (e.g. EMERGENCY
STOP or EMERGENCY OFF).

Fundamental safety instructions
1.2 Safety instructions for electromagnetic fields (EMF)
Converter with CU250S-2 Control Unit
Operating Instructions, 01/2016, FW V4.7 SP6, A5E31759476B AE 19
1.2
Safety instructions for electromagnetic fields (EMF)
WARNING
Danger to life from 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 a special risk in the immediate vicinity of these
devices/systems.
•Ensure that the persons involved are the necessary distance away (minimum 2 m).
1.3
Handling electrostatic sensitive devices (ESD)
Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules
or devices that may be damaged by either electric fields or electrostatic discharge.
NOTICE
Damage through 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).

Fundamental safety instructions
1.4 Industrial security
Converter with CU250S-2 Control Unit
20 Operating Instructions, 01/2016, FW V4.7 SP6, A5E31759476B AE
1.4
Industrial security
Note
Industrial security
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, solutions, machines, equipment and/or networks. They are
important components in a holistic industrial
security concept. With this in mind, Siemens’
products and solutions undergo continuous development. Siemens recommends strongly
that you regularly check for product updates.
For the secure operation of Siemens products and solutions, it is necessary to t
ake suitable
preventive action (e.g. cell protection concept) and integrate each component into a holistic,
state
-of-the-art industrial security concept. Third-party products that may be in use should
also be considered. For more information about industri
al security, visit this address
(
http://www.siemens.com/industrialsecurity).
To stay informed about product updates as they occur, sign up for a product
-specific
newsletter. For more information,
visit this address (http://support.automation.siemens.com
).
WARNING
Danger as a result of unsafe operating states resulting from software manipulation
Software manipulation (e.g. by viruses, Trojan horses, malware, worms) can cause unsafe
operating states to develop in your installation which can result in death, severe injuries
and/or material damage.
•Keep the software up to date.
You will find relevant information and newsletters at this address
(http://support.automation.siemens.com).
•Incorporate the automation and drive components into a holistic, state-of-the-art
industrial security concept for the installation or machine.
You will find further information at this address
(http://www.siemens.com/industrialsecurity).
•Make sure that you include all installed products into the holistic industrial security
concept.