Siemens SINAMICS G120 User manual

s
Product information 08/2013
Order numbers for memory cards and licenses
Supplement to Operating Instructions 06/2013, FW V4.6, Section 3.2 Control Units
The Control Unit provides software functions that have to be enabled through licenses.
You can purchase the software as a license without memory card if you are already using
one of the memory cards listed below for operating your inverter. If you do not already use
a memory card, purchase the license on a memory card. The inverter also uses an
inserted license card as a memory card for saving settings.
Please find below a list of the memory cards and licenses available.
Memory cards
Empty memory card 6SL3054-4AG00-2AA0
Memory card with firmware 6SL3054-7XX00-2BA0
XX designates the firmware version: 4.6 ≙EG, 4.7 ≙EH, 4.8 ≙EI …
Licenses
License for
Order number for the license
Without memory card
With memory card
Basic Positioner with Vector control
6SL3074-7AA04-0AA0
6SL3054-4AG00-2AA0-Z E01
Extended safety functions with
•Safely Limited Speed (SLS)
•Safe Direction (SDI)
•Safe Speed Monitoring (SSM)
6SL3074-0AA10-0AA0 6SL3054-4AG00-2AA0-Z F01
•Basic Positioner with Vector control
•Extended safety functions
6SL3054-4AG00-2AA0-Z E01 F01
SINAMICS G120
In
verter with the
CU250S
-2 Control Unit
(
Vector)

Converter with the CU250S-2 Control Unit
(vector)
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SINAMICS
SINAMICS G120
Converter with the CU250S-2
Control Unit (vector)
Operating Instructions
Edition 06/2013, Firmware V4.6
Original instructions
06/2013, FW V4.6
A
5E31759476B AB
Changes in this manual
Safety notes
1
Introduction
2
Description
3
Installing
4
Commissioning
5
Adapt terminal strip
6
Configuring the fieldbus
7
Setting functions
8
Backing up data and series
commissioning
9
Corrective maintenance
10
Alarms, faults and system
messages
11
Technical data
12
Appendix
A

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E31759476B AB
Ⓟ
07/2013 Technical data subject to change
Copyright © Siemens AG 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.

Converter with the CU250S-2 Control Unit (vector)
Operating Instructions, 06/2013, FW V4.6, A5E31759476B AB 5
Changes in this manual
Important changes with respect to the Manual, Edition 01/2013
An overview of all new and modified functions in Firmware V4.6 can be found in section New
and extended functions (Page 411).
Revised descriptions
In Chapter
Updated Order No. of the memory card.
Overview of Control Units (Page 24)
Overview of the permissible motors has been supplemented. Motor series that are supported
(Page 37)
SMC and SME Sensor Modules supplemented.
Installing encoders (Page 66)
Licensing procedure supplemented. Activating licensed functions
(Page 413)

Changes in this manual
Converter with the CU250S-2 Control Unit (vector)
6Operating Instructions, 06/2013, FW V4.6, A5E31759476B AB

Converter with the CU250S-2 Control Unit (vector)
Operating Instructions, 06/2013, FW V4.6, A5E31759476B AB 7
Table of contents
Changes in this manual........................................................................................................................... 5
1 Safety notes.......................................................................................................................................... 15
1.1 General safety instructions ..........................................................................................................15
1.2 Safety instructions for electromagnetic fields (EMF) ...................................................................18
1.3 Handling electrostatic sensitive devices (ESD) ...........................................................................19
1.4 Residual risks of power drive systems.........................................................................................19
2 Introduction........................................................................................................................................... 21
2.1 About this manual ........................................................................................................................21
2.2 Guide through this manual...........................................................................................................22
3 Description............................................................................................................................................ 23
3.1 Identifying the converter...............................................................................................................23
3.2 Overview of Control Units ............................................................................................................24
3.3 Power Module ..............................................................................................................................26
3.4 Components for the Power Modules............................................................................................29
3.4.1 Line filter.......................................................................................................................................29
3.4.2 Line reactor ..................................................................................................................................30
3.4.3 Output reactor ..............................................................................................................................32
3.4.4 Sine-wave filter.............................................................................................................................34
3.4.5 Braking resistor ............................................................................................................................36
3.4.6 Brake Relay..................................................................................................................................37
3.4.7 Safe Brake Relay .........................................................................................................................37
3.5 Motor series that are supported ...................................................................................................37
3.6 Permissible encoders...................................................................................................................38
3.7 Sensor Module.............................................................................................................................38
3.8 Tools to commission the converter ..............................................................................................39
4 Installing ............................................................................................................................................... 40
4.1 Overview of the inverter installation.............................................................................................40
4.2 Installing reactors, filters and braking resistors............................................................................41
4.3 Installing the Power Module.........................................................................................................43
4.3.1 Installing Power Modules .............................................................................................................43
4.3.2 Dimensions, hole drilling templates, minimum clearances, tightening torques ...........................45
4.3.3 Connecting the line supply, motor, and inverter components......................................................50
4.3.3.1 Connection overview for Power Module ......................................................................................50
4.3.3.2 Power distribution systems ..........................................................................................................52
4.4 Installing Control Unit...................................................................................................................55

Table of contents
Converter with the CU250S-2 Control Unit (vector)
8Operating Instructions, 06/2013, FW V4.6, A5E31759476B AB
4.4.1 Snapping the Control Unit onto the Power Module..................................................................... 55
4.4.2 Overview of the interfaces........................................................................................................... 56
4.4.3 Terminal blocks ........................................................................................................................... 58
4.4.4 Selecting the pre-assignment for the terminal strip .................................................................... 60
4.4.5 Wiring the terminal strip .............................................................................................................. 64
4.5 Installing encoders ...................................................................................................................... 66
4.6 Connecting inverters in compliance with EMC............................................................................ 67
4.6.1 EMC-compliant connection of the converter ............................................................................... 67
4.6.2 Avoid electromagnetic interference (EMI)................................................................................... 67
5 Commissioning ..................................................................................................................................... 73
5.1 Commissioning guidelines .......................................................................................................... 73
5.2 Preparing for commissioning....................................................................................................... 74
5.2.1 Wiring examples for the factory settings ..................................................................................... 75
5.2.2 Does the motor match the converter?......................................................................................... 77
5.2.3 Factory setting of the inverter control.......................................................................................... 78
5.2.4 Inverter function modules............................................................................................................ 79
5.2.5 V/f control or vector control (speed/torque)?............................................................................... 81
5.2.6 Encoders for speed and position control..................................................................................... 82
5.2.7 Defining additional requirements for the application................................................................... 82
5.3 Restoring the factory setting ....................................................................................................... 83
5.4 Basic commissioning with STARTER ......................................................................................... 85
5.4.1 Generating a STARTER project.................................................................................................. 85
5.4.2 Transfer inverters connected via USB into the project ............................................................... 86
5.4.3 Configuring a drive ...................................................................................................................... 87
5.4.4 Adapting the encoder data .......................................................................................................... 90
5.4.5 Loading the configured data into the drive.................................................................................. 91
5.4.6 Identifying motor data.................................................................................................................. 92
6 Adapt terminal strip ............................................................................................................................... 95
6.1 Digital inputs................................................................................................................................ 96
6.2 Fail-safe input.............................................................................................................................. 99
6.3 Digital outputs ........................................................................................................................... 101
6.4 Analog inputs ............................................................................................................................ 103
6.5 Analog outputs .......................................................................................................................... 107
7 Configuring the fieldbus .......................................................................................................................111
7.1 Fieldbus versions of the Control Unit ........................................................................................ 111
7.2 Communication via PROFINET ................................................................................................ 112
7.2.1 What do you need for communication via PROFINET? ........................................................... 112
7.2.2 Connect the converter to PROFINET ....................................................................................... 113
7.2.3 Configuring communication to the control................................................................................. 114
7.2.4 Select telegram – procedure ..................................................................................................... 115
7.2.5 Activating diagnostics via the control ........................................................................................ 115
7.3 Communication via PROFIBUS ................................................................................................ 116
7.3.1 What do you need for communication via PROFIBUS? ........................................................... 116
7.3.2 Connect the frequency inverter to PROFIBUS ......................................................................... 116

Table of contents
Converter with the CU250S-2 Control Unit (vector)
Operating Instructions, 06/2013, FW V4.6, A5E31759476B AB 9
7.3.3 Configuring communication to the control .................................................................................117
7.3.4 Setting the address ....................................................................................................................118
7.3.5 Select telegram – procedure ......................................................................................................118
7.4 PROFIdrive profile for PROFIBUS and PROFINET ..................................................................120
7.4.1 Cyclic communication ................................................................................................................120
7.4.1.1 Control and status word 1 ..........................................................................................................124
7.4.1.2 Control and status word 3 ..........................................................................................................127
7.4.1.3 Extend telegrams and change signal interconnection ...............................................................128
7.4.1.4 Data structure of the parameter channel ...................................................................................130
7.4.1.5 Slave-to-slave communication ...................................................................................................135
7.4.2 Acyclic communication...............................................................................................................136
7.5 PROFIenergy profile for PROFINET..........................................................................................141
7.6 Communication via EtherNet/IP.................................................................................................144
7.6.1 Connect converter to Ethernet/IP...............................................................................................144
7.6.2 What do you need for communication via Ethernet/IP?.............................................................145
7.6.3 Communication settings for Ethernet/IP ....................................................................................145
7.6.4 Additional settings if you are working with the AC/DC profile....................................................146
7.6.5 Supported objects ......................................................................................................................147
7.6.6 Create generic I/O module.........................................................................................................156
7.7 Communication via RS485 ........................................................................................................157
7.7.1 Integrating inverters into a bus system via the RS485 interface ...............................................157
7.7.2 Communication via USS ............................................................................................................158
7.7.2.1 Basic settings for communication ..............................................................................................158
7.7.2.2 Telegram structure .....................................................................................................................159
7.7.2.3 User data range of the USS telegram........................................................................................160
7.7.2.4 USS parameter channel.............................................................................................................161
7.7.2.5 USS process data channel (PZD)..............................................................................................166
7.7.2.6 Time-out and other errors ..........................................................................................................167
7.7.3 Communication over Modbus RTU............................................................................................169
7.7.3.1 Basic settings for communication ..............................................................................................170
7.7.3.2 Modbus RTU telegram...............................................................................................................171
7.7.3.3 Baud rates and mapping tables .................................................................................................172
7.7.3.4 Write and read access via FC 03 and FC 06.............................................................................175
7.7.3.5 Communication procedure.........................................................................................................177
7.8 Communication over CANopen .................................................................................................179
7.8.1 CANopen functions of the converter ..........................................................................................179
7.8.1.1 Network management (NMT service) ........................................................................................180
7.8.1.2 SDO services .............................................................................................................................183
7.8.1.3 Access to SINAMICS parameters via SDO ...............................................................................184
7.8.1.4 Access PZD objects via SDO ....................................................................................................185
7.8.1.5 PDO and PDO services .............................................................................................................188
7.8.1.6 Predefined connection set .........................................................................................................191
7.8.1.7 Free PDO mapping ....................................................................................................................192
7.8.1.8 Interconnect objects from the receive and transmit buffers.......................................................195
7.8.1.9 CANopen operating modes........................................................................................................197
7.8.1.10 RAM to ROM via the CANopen object 1010..............................................................................197
7.8.2 Object directories .......................................................................................................................198
7.8.2.1 General objects from the CiA 301 communication profile..........................................................198
7.8.2.2 Free objects ...............................................................................................................................207
7.8.2.3 Objects from the CiA 402 drive profile .......................................................................................208

Table of contents
Converter with the CU250S-2 Control Unit (vector)
10 Operating Instructions, 06/2013, FW V4.6, A5E31759476B AB
7.8.3 Integrating the converter into CANopen.................................................................................... 210
7.8.3.1 Connecting inverter to CAN bus ............................................................................................... 211
7.8.3.2 Setting the node ID and baud rate ............................................................................................ 211
7.8.3.3 Setting the baud rate................................................................................................................. 212
7.8.3.4 Setting the monitoring of the communication............................................................................ 212
7.8.4 Free PDO mapping for example of the actual current value and torque limit........................... 213
8 Setting functions ..................................................................................................................................215
8.1 Overview of the converter functions.......................................................................................... 215
8.2 Inverter control .......................................................................................................................... 217
8.2.1 Switching the motor on and off ................................................................................................. 217
8.2.2 Inverter control using digital inputs ........................................................................................... 219
8.2.3 Two-wire control: method 1....................................................................................................... 220
8.2.4 Two-wire control, method 2....................................................................................................... 221
8.2.5 Two-wire control, method 3....................................................................................................... 222
8.2.6 Three-wire control, method 1 .................................................................................................... 223
8.2.7 Three-wire control, method 2 .................................................................................................... 224
8.2.8 Running the motor in jog mode (JOG function) ........................................................................ 225
8.2.9 Switching over the inverter control (command data set)........................................................... 226
8.3 Setpoints ................................................................................................................................... 229
8.3.1 Overview ................................................................................................................................... 229
8.3.2 Analog input as setpoint source................................................................................................ 230
8.3.3 Specifying the motor speed via the fieldbus ............................................................................. 230
8.3.4 Motorized potentiometer as setpoint source ............................................................................. 231
8.3.5 Fixed speed as setpoint source ................................................................................................ 233
8.4 Setpoint calculation ................................................................................................................... 235
8.4.1 Overview of setpoint processing ............................................................................................... 235
8.4.2 Invert setpoint............................................................................................................................ 235
8.4.3 Inhibit direction of rotation ......................................................................................................... 236
8.4.4 Minimum speed......................................................................................................................... 236
8.4.5 Maximum speed........................................................................................................................ 237
8.4.6 Ramp-function generator .......................................................................................................... 237
8.5 Motor control ............................................................................................................................. 242
8.5.1 V/f control .................................................................................................................................. 242
8.5.1.1 Characteristics of U/f control..................................................................................................... 243
8.5.1.2 Selecting the U/f characteristic ................................................................................................. 244
8.5.1.3 Optimizing with a high break loose torque and brief overload .................................................. 246
8.5.2 Closed-loop speed control ........................................................................................................ 248
8.5.2.1 Checking the encoder signal..................................................................................................... 249
8.5.2.2 Select motor control .................................................................................................................. 249
8.5.2.3 Optimizing the speed controller................................................................................................. 251
8.5.2.4 Advanced settings..................................................................................................................... 253
8.5.3 Torque control ........................................................................................................................... 254
8.6 Protection functions................................................................................................................... 255
8.6.1 Inverter temperature monitoring................................................................................................ 255
8.6.2 Motor temperature monitoring using a temperature sensor...................................................... 256
8.6.3 Overcurrent protection .............................................................................................................. 258
8.6.4 Limiting the maximum DC link voltage...................................................................................... 258
8.7 Application-specific functions .................................................................................................... 260

Table of contents
Converter with the CU250S-2 Control Unit (vector)
Operating Instructions, 06/2013, FW V4.6, A5E31759476B AB 11
8.7.1 Unit changeover.........................................................................................................................260
8.7.1.1 Changing over the motor standard ............................................................................................262
8.7.1.2 Changing over the unit system ..................................................................................................262
8.7.1.3 Changing over process variables for the technology controller.................................................263
8.7.1.4 Switching units with STARTER..................................................................................................264
8.7.2 Energy-saving display................................................................................................................265
8.7.3 Braking functions of the inverter ................................................................................................267
8.7.3.1 Electrical braking methods.........................................................................................................267
8.7.3.2 DC braking .................................................................................................................................269
8.7.3.3 Compound braking.....................................................................................................................272
8.7.3.4 Dynamic braking ........................................................................................................................274
8.7.3.5 Braking with regenerative feedback to the line ..........................................................................277
8.7.3.6 Motor holding brake ...................................................................................................................278
8.7.4 Automatic restart and flying restart ............................................................................................284
8.7.4.1 Flying restart – switching on while the motor is running ............................................................284
8.7.4.2 Automatic switch-on...................................................................................................................285
8.7.5 PID technology controller...........................................................................................................290
8.7.5.1 Overview ....................................................................................................................................290
8.7.5.2 Setting the controller ..................................................................................................................290
8.7.5.3 Optimizing the controller ............................................................................................................292
8.7.6 Monitor the load torque (system protection) ..............................................................................294
8.7.7 Load failure monitoring ..............................................................................................................296
8.7.8 Speed deviation monitoring .......................................................................................................297
8.7.9 Free function blocks...................................................................................................................299
8.8 Safe Torque Off (STO) safety function ......................................................................................302
8.8.1 Function description...................................................................................................................302
8.8.2 Prerequisite for STO use ...........................................................................................................303
8.8.3 Commissioning STO ..................................................................................................................303
8.8.3.1 Commissioning tool....................................................................................................................303
8.8.3.2 Protection of the settings from unauthorized changes...............................................................303
8.8.3.3 Resetting the safety function parameters to the factory setting.................................................304
8.8.3.4 Changing settings ......................................................................................................................305
8.8.3.5 Interconnecting the "STO active" signal.....................................................................................306
8.8.3.6 Setting the filter for fail-safe inputs.............................................................................................307
8.8.3.7 Setting forced dormant error detection ......................................................................................310
8.8.3.8 Activate settings.........................................................................................................................312
8.8.3.9 Checking the assignment of the digital inputs ...........................................................................312
8.8.3.10 Acceptance - completion of commissioning...............................................................................314
8.9 Switchover between different settings .......................................................................................320
9 Backing up data and series commissioning ......................................................................................... 323
9.1 Saving settings on a memory card.............................................................................................325
9.1.1 Saving setting on memory card .................................................................................................326
9.1.2 Transferring the setting from the memory card..........................................................................328
9.1.3 Safely remove the memory card................................................................................................330
9.2 Saving settings on a PC.............................................................................................................332
9.3 Saving settings on an operator panel ........................................................................................334
9.4 Other ways to back up settings..................................................................................................334
9.5 Write and know-how protection..................................................................................................335

Table of contents
Converter with the CU250S-2 Control Unit (vector)
12 Operating Instructions, 06/2013, FW V4.6, A5E31759476B AB
9.5.1 Write protection ......................................................................................................................... 335
9.5.2 Know-how protection................................................................................................................. 337
9.5.2.1 Settings for the know-how protection........................................................................................ 338
9.5.2.2 Creating an exception list for the know-how protection ............................................................ 340
10 Corrective maintenance .......................................................................................................................343
10.1 Overview of replacing converter components........................................................................... 343
10.2 Replacing a Control Unit with enabled safety function ............................................................. 345
10.3 Replacing the Control Unit without the safety functions enabled.............................................. 348
10.4 Replacing the Control Unit without data backup....................................................................... 350
10.5 Replacing a Control Unit with active know-how protection ....................................................... 351
10.6 Replacing a Power Module with enabled safety function ......................................................... 353
10.7 Replacing a Power Module without the safety function being enabled .................................... 354
10.8 Replacing an encoder ............................................................................................................... 355
10.8.1 Replacing the encoder - same encoder type ............................................................................ 355
10.8.2 Replacing the encoder - different encoder type ........................................................................ 356
10.9 Upgrading the firmware............................................................................................................. 358
10.10 Firmware downgrade ................................................................................................................ 360
10.11 Correcting an unsuccessful firmware upgrade or downgrade .................................................. 362
10.12 If the converter no longer responds .......................................................................................... 363
11 Alarms, faults and system messages ...................................................................................................365
11.1 Operating states indicated on LEDs ......................................................................................... 366
11.2 System runtime ......................................................................................................................... 368
11.3 Alarms ....................................................................................................................................... 369
11.4 Faults......................................................................................................................................... 372
11.5 List of alarms and faults ............................................................................................................ 376
12 Technical data .....................................................................................................................................385
12.1 Technical data, CU250S-2 Control Unit.................................................................................... 385
12.2 Technical data, Power Modules................................................................................................ 390
12.2.1 Technical data, PM240 ............................................................................................................. 392
12.2.1.1 General data, PM240 ................................................................................................................ 392
12.2.1.2 Power-dependent data, PM240 ................................................................................................ 393
12.2.2 Technical data, PM240-2 .......................................................................................................... 398
12.2.2.1 General data, PM240-2............................................................................................................. 398
12.2.2.2 Power-dependent data PM240-2 .............................................................................................. 399
12.2.3 Technical data, PM250 ............................................................................................................. 403
12.2.3.1 Power-dependent data, PM250 ................................................................................................ 404
12.2.4 Technical data, PM260 ............................................................................................................. 406
12.2.4.1 Power-dependent data, PM260 ................................................................................................ 407
12.2.5 Technical data, PM340 ............................................................................................................. 408
12.2.5.1 General data, PM340, 1 AC 200 … 240 V................................................................................ 408
12.2.5.2 Power-dependent data, PM340 ................................................................................................ 409

Table of contents
Converter with the CU250S-2 Control Unit (vector)
Operating Instructions, 06/2013, FW V4.6, A5E31759476B AB 13
A Appendix............................................................................................................................................. 411
A.1 New and extended functions......................................................................................................411
A.1.1 Firmware version 4.6 .................................................................................................................411
A.1.2 Firmware version 4.6.6 ..............................................................................................................412
A.2 Activating licensed functions......................................................................................................413
A.2.1 Licensing ....................................................................................................................................413
A.2.2 Creating or displaying the license key .......................................................................................414
A.2.3 Writing the license key to the card.............................................................................................417
A.3 Star-delta motor connection and application examples.............................................................419
A.4 Parameter ..................................................................................................................................420
A.5 Handling the BOP 2 operator panel ...........................................................................................422
A.5.1 Changing settings using BOP-2.................................................................................................423
A.5.2 Changing indexed parameters...................................................................................................424
A.5.3 Directly entering the parameter number and value....................................................................424
A.5.4 A parameter cannot be changed................................................................................................425
A.6 Handling STARTER ...................................................................................................................426
A.6.1 Change settings .........................................................................................................................426
A.6.2 Optimize the drive using the trace function................................................................................427
A.7 Interconnecting signals in the inverter .......................................................................................430
A.7.1 Fundamentals ............................................................................................................................430
A.7.2 Example .....................................................................................................................................432
A.8 Application Examples.................................................................................................................434
A.8.1 Setting an absolute encoder ......................................................................................................434
A.8.2 Configuring PROFIBUS communication in STEP 7...................................................................438
A.8.2.1 Creating a STEP 7 project and network ....................................................................................438
A.8.2.2 Inserting the inverter into the project .........................................................................................439
A.8.3 Configuring PROFINET communication in STEP 7...................................................................441
A.8.3.1 Configuring the controller and converter in HW Config .............................................................441
A.8.3.2 Activate diagnostic messages via STEP 7 ................................................................................443
A.8.4 Go online with STARTER via PROFINET .................................................................................445
A.8.4.1 Adapting the PROFINET interface.............................................................................................445
A.8.4.2 Create a reference for STARTERS............................................................................................446
A.8.4.3 Call the STARTER and go online ..............................................................................................447
A.8.5 STEP 7 program examples........................................................................................................447
A.8.5.1 STEP 7 program example for cyclic communication .................................................................448
A.8.5.2 STEP 7 program example for acyclic communication ...............................................................450
A.8.6 Configuring slave-to-slave communication in STEP 7...............................................................454
A.8.7 Connecting fail-safe digital inputs ..............................................................................................456
A.8.8 Connecting fail-safe digital inputs ..............................................................................................456
A.9 Documentation for accepting the safety functions .....................................................................458
A.9.1 Machine documentation.............................................................................................................458
A.9.2 Log the settings for the basic functions, firmware V4.4 ... V4.6.................................................460
A.10 Additional information on the inverter ........................................................................................461
A.10.1 Manuals for your converter ........................................................................................................461
A.10.2 Configuring support....................................................................................................................462
A.10.3 Product Support .........................................................................................................................463
A.11 Mistakes and improvements ......................................................................................................464
Index................................................................................................................................................... 465

Converter with the CU250S-2 Control Unit (vector)
Operating Instructions, 06/2013, FW V4.6, A5E31759476B AB 15
Safety notes
1
Use for the intended purpose
The inverter described in this manual is a device for controlling an induction motor. The
inverter is designed for installation in electrical installations or machines.
It has been approved for industrial and commercial use on industrial networks. Additional
measures have to be taken when connected to public grids.
The technical specifications and information about connection conditions are indicated on
the rating plate and in the operating instructions.
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 hazardous energy sources, e.g. compressed air, hydraulic systems,
water.
4. Isolate or neutralize all hazardous energy sources, e.g. by closing switches, grounding
or short-circuiting or closing valves.
5. Secure the energy sources against switching on again.
6. Make sure that the machine is completely locked ... and that you have the right
machine.
After you have completed the work, restore the operational readiness in the inverse
sequence.

Safety notes
1.1 General safety instructions
Converter with the CU250S-2 Control Unit (vector)
16 Operating Instructions, 06/2013, FW V4.6, A5E31759476B AB
WARNING
Danger to life through a hazardous voltage when connecting an unsuitable power supply
Death or serious injury can result when live parts are touched in the event of a fault.
•Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV-
(Protective Extra Low Voltage) output voltages for all connections and terminals of the
electronics modules.
WARNING
Danger to life when live parts are touched on damaged devices
Improper handling of devices can cause damage.
Hazardous voltages can be present at the housing or exposed components on damaged
devices.
•Ensure compliance with the limit values specified in the technical data during transport,
storage and operation.
•Do not use any damaged devices.
•Protect the components against conductive pollution, e.g., by installing them in a control
cabinet with IP54 degree of protection according to IEC 60529 or NEMA 12. Provided
conductive pollution can be prevented at the installation site, the degree of protection for
the cabinet can be decreased accordingly.
WARNING
Danger to life through electric shock due to unconnected cable shields
Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected
cable shields.
•Connect cable shields and unused conductors of power cables (e.g., brake conductors)
at least on one side to the grounded housing potential.
WARNING
Danger to life due to electric shock when not grounded
For missing or incorrectly implemented protective conductor connection for devices with
protection class I, high voltages can be present at open, exposed parts, which when
touched, can result in death or severe injury.
•Ground the device in compliance with the applicable regulations.
WARNING
Danger to life due to electric shock when opening plug connections in operation
When opening plug connections in operation, arcs can result in severe injury or death.
•Only open plug connections when the equipment is in a no-voltage state, unless it has
been explicitly stated that they can be opened in operation.

Safety notes
1.1 General safety instructions
Converter with the CU250S-2 Control Unit (vector)
Operating Instructions, 06/2013, FW V4.6, A5E31759476B AB 17
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 inside and
outside the device is prevented.
•Additionally, select the installation site so that an uncontrolled spreading of smoke can
be avoided in the case of a fire.
•Ensure that smoke can escape via designated paths.
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 transmitter power > 1 W closer than
approx. 2 m to the components may cause the devices to malfunction and 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 a greater load on the motor insulation through a ground fault in an IT system. A
possible result is the failure of the insulation with a risk for personnel through smoke
development 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 with a risk for personnel through
smoke development and fire. 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. They can be found in the dimension drawings or in the
"Product-specific safety instructions" at the start of the respective section.

Safety notes
1.2 Safety instructions for electromagnetic fields (EMF)
Converter with the CU250S-2 Control Unit (vector)
18 Operating Instructions, 06/2013, FW V4.6, A5E31759476B AB
WARNING
Danger of an accident occuring due to missing or illegible warning labels
Missing or illegible warning labels can result in death or serious injury.
•Check 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.
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.
•Run 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 functions
If you want to use safety functions, you must observe the safety notices in the safety
manuals.
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, inverters or motors.
People with pacemakers or implants are at a special risk in the immediate vicinity of these
devices/systems.
•Keep a distance of at least 2 m.

Safety notes
1.3 Handling electrostatic sensitive devices (ESD)
Converter with the CU250S-2 Control Unit (vector)
Operating Instructions, 06/2013, FW V4.6, A5E31759476B AB 19
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).
1.4
Residual risks of power drive systems
The control and drive components of a drive system are approved for industrial and
commercial use in industrial line supplies. Their use in public line supplies requires a
different configuration and/or additional measures.
These components may only be operated in closed housings or in higher-level control
cabinets with protective covers that are closed, and when all of the protective devices are
used.
These components may only be handled by qualified and trained technical personnel who
are knowledgeable and observe all of the safety instructions on the components and in the
associated technical user documentation.
When assessing the machine's risk in accordance with the respective local regulations (e.g.,
EC Machinery Directive), the machine manufacturer 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 components during commissioning,
operation, maintenance, and repairs caused by, for example:
–Hardware defects and/or software errors in the sensors, controllers, actuators, and
connection technology
–Response times of the controller and drive
–Operating and/or ambient conditions outside of the specification
–Condensation / conductive contamination

Safety notes
1.4 Residual risks of power drive systems
Converter with the CU250S-2 Control Unit (vector)
20 Operating Instructions, 06/2013, FW V4.6, A5E31759476B AB
–Parameterization, programming, cabling, and installation errors
–Use of radio devices / cellular phones in the immediate vicinity of the controller
–External influences / damage
2. In the event of a fault, exceptionally high temperatures, including an open fire, as well as
emissions of light, noise, particles, gases, etc. can occur inside and outside the inverter,
e.g.:
–Component malfunctions
–Software errors
–Operating and/or ambient conditions outside of the specification
–External influences / damage
Inverters of the Open Type / IP20 degree of protection must be installed in a metal control
cabinet (or protected by another equivalent measure) such that the contact with fire inside
and outside the inverter is not possible.
3. Hazardous shock voltages caused by, for example:
–Component malfunctions
–Influence of electrostatic charging
–Induction of voltages in moving motors
–Operating and/or ambient conditions outside of 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.
Note
The components must be protected against conductive contamination (e.g. by installing them
in a control cabinet with degree of protection IP54 according to IEC 60529 or NEMA 12).
Assuming that conductive contamination at the installation si
te can definitely be excluded, a
lower degree of cabinet protection may be permitted.
For more information about residual risks of the components in a drive system, see the
relevant sections in the technical user documentation.