Siemens SINAMICS G120C User manual

s
Product information 07/2015
Additional requirements for Branch Circuit Protection
The following information is additional information regarding the specific details of the requirements
for Branch Circuit Protection for the SINAMICS G120C converter.
Branch circuit protection according to IEC
Frame
size
Rated
power Drive
Article number
Max. rated
current of the
protection
device
Minimum
enclosure
volume
Fuse Motor starter
protector
FSA
0.55 kW
6SL3210-1KE11-8...
3NA3805 3RV2011-4AA… 16 A 0.03 m3
0.75 kW
6SL3210-1KE12-3...
1.1 kW
6SL3210-1KE13-2...
1.5 kW
6SL3210-1KE14-3...
2.2 kW
6SL3210-1KE15-8...
3 kW
6SL3210-1KE17-5...
4 kW
6SL3210-1KE18-8...
FSB
5.5 kW
6SL3210-1KE21-3...
3NA3812 3RV2021-4EA… 32 A 0.06 m3
7.5 kW
6SL3210-1KE21-7...
FSC
11 kW
6SL3210-1KE22-6...
3NA3822 3RV1041-4JA… 63 A 0.2 m3
15 kW
6SL3210-1KE23-2...
18.5 kW
6SL3210-1KE23-8...
Siemens 3NA38 series fuses and 3RV series motor starter protectors of a lower current rating than
shown may also be used. The converter must be mounted in a suitable enclosure (e.g. metal
equipment cabinet).
If a motor starter protector is used, the enclosure interior volume should not be less than that shown
in the table above.
Branch circuit protection according to UL standards
Use in North America requires protection devices that meet UL standards as detailed in the
following tables. The converter must be mounted in a UL approved enclosure not less than the
minimum enclosure volume unless the branch circuit protection is a class AJT fuse by Mersen
(Ferraz Shawmut).
Table 1: Overview of the approved protection devices according to UL standards
Protection device
UL category
Fuses of any manufacturer with faster tripping characteristic than class RK5 and rated
600V AC, e.g. class J, T, CC, G, or CF
JDDZ
SIEMENS circuit breaker
DIVQ
SIEMENS Type E combination motor controllers
NKJH
The converter is suitable for use on a circuit capable of delivering the short circuit current shown in
the tables below when protected by the branch circuit protection indicated.
SINAMICS G120C

SINAMICS G120C 2
Product information, Edition 07/2015
Table 2: Branch circuit protection with non-semiconductor fuses Class J, T, CC, G, CF (JDDZ)
Frame
size
Rated
power Drive Max. rated current of the fuse Short-circuit current rating (SCCR)
Minimum
enclosure
volume
FSA
0.55 kW
6SL3210-1KE11-8...
10 A
100 kA, 480 V AC
1830 in3
0.75 kW
6SL3210-1KE12-3...
1.1 kW
6SL3210-1KE13-2...
1.5 kW
6SL3210-1KE14-3...
2.2 kW
6SL3210-1KE15-8...
15 A
3 kW
6SL3210-1KE17-5...
4 kW
6SL3210-1KE18-8...
FSB
5.5 kW
6SL3210-1KE21-3...
35 A 3660 in3
7.5 kW
6SL3210-1KE21-7...
FSC
11 kW
6SL3210-1KE22-6...
60 A 12200 in3
15 kW
6SL3210-1KE23-2...
18.5 kW
6SL3210-1KE23-8...
Table 3: Branch circuit protection with circuit breakers (DIVQ)
Frame
size
Rated
power Drive
Max. rated
current of the
circuit breaker
Circuit breaker types
Short-circuit current
rating (SCCR)
Minimum
enclosure
volume
FSA
0.55 kW 6SL3210-1KE11-8...
15 A
3RV1742, LGG, CED6
65 kA, 480 V AC
1830 in3
3RV2711
65 kA, 480Y / 277V AC
0.75 kW 6SL3210-1KE12-3... 15 A
3RV1742, LGG, CED6
65 kA, 480 V AC
3RV2711
65 kA, 480Y / 277V AC
1.1 kW 6SL3210-1KE13-2... 15 A
3RV1742, LGG, CED6
65 kA, 480 V AC
3RV2711
65 kA, 480Y / 277V AC
1.5 kW 6SL3210-1KE14-3... 15 A
3RV1742, LGG, CED6
65 kA, 480 V AC
3RV2711
65 kA, 480Y / 277V AC
2.2 kW 6SL3210-1KE15-8... 15 A
3RV1742, LGG, CED6
65 kA, 480 V AC
3RV2711
65 kA, 480Y / 277V AC
3 kW 6SL3210-1KE17-5... 15 A
3RV1742, LGG, CED6
65 kA, 480 V AC
3RV2711
65 kA, 480Y / 277V AC
4 kW 6SL3210-1KE18-8... 15 A
3RV1742, LGG, CED6
65 kA, 480 V AC
3RV2711
65 kA, 480Y / 277V AC
FSB
5.5 kW 6SL3210-1KE21-3...
35 A
NCGA
35 kA, 480 V AC
3660 in3
3RV2721
50 kA, 480Y / 277V AC
LGG, CED6, HCGA
65 kA, 480 V AC
3RV1742
65 kA, 480Y / 277V AC*
3RV2711
65 kA, 480Y / 277V AC
7.5 kW 6SL3210-1KE21-7... 35 A
NCGA
35 kA, 480 V AC
3RV2721
50 kA, 480Y / 277V AC
LGG, CED6, HCGA
65 kA, 480 V AC
3RV1742
65 kA, 480Y / 277V AC*
3RV2711
65 kA, 480Y / 277V AC
FSC
11 kW 6SL3210-1KE22-6...
60 A
NCGA
35 kA, 480 V AC
8780 in3
LGG, CED6, HCGA
65 kA, 480 V AC
3RV1742
65 kA, 480Y / 277V AC*
15 kW 6SL3210-1KE23-2... 60 A
NCGA
35 kA, 480 V AC
LGG, CED6, HCGA
65 kA, 480 V AC
3RV1742
65 kA, 480Y / 277V AC*
18.5 kW 6SL3210-1KE23-8... 60 A
NCGA
35 kA, 480 V AC
LGG, CED6, HCGA
65 kA, 480 V AC
3RV1742
65 kA, 480Y / 277V AC*
* 65kA, 480V AC for 3RV1742 type with current rating < 35 A

3 SINAMICS G120C
Product information, Edition 07/2015
Table 4: Branch circuit protection with Type E combination motor controllers (NKJH)
Frame
size
Rated
power Drive CMC model no. *
Max. rated
current of
the CMC
Rated power
of the CMC
at 460 VAC
Short-circuit current
rating (SCCR)
Minimum
enclosure
volume
FSA
0.55 kW
6SL3210-1KE11-8...
3RV20_1-1JA…
10 A
5 HP
65 kA, 480Y / 277V AC 1830 in3
0.75 kW
6SL3210-1KE12-3...
3RV20_1-1JA…
10 A
5 HP
1.1 kW
6SL3210-1KE13-2...
3RV20_1-1JA…
10 A
5 HP
1.5 kW
6SL3210-1KE14-3...
3RV20_1-1JA…
10 A
5 HP
2.2 kW 6SL3210-1KE15-
8...
3RV20_1-4AA…
16 A
10 HP
3RV_031-4AA…
16 A
10 HP
3 kW 6SL3210-1KE17-
5...
3RV20_1-4AA…
16 A
10 HP
3RV_031-4AA…
16 A
10 HP
4 kW 6SL3210-1KE18-
8...
3RV20_1-4AA…
16 A
10 HP
3RV_031-4AA…
16 A
10 HP
FSB
5.5 kW 6SL3210-1KE21-
3...
3RV2021-4DA…
25 A
15 HP
65 kA, 480Y / 277V AC
3660 in3
3RV2021-4EA…
32 A
20 HP
50 kA, 480Y / 277V AC
3RV_031-4EA…
32 A
20 HP
65 kA, 480Y / 277V AC
7.5 kW 6SL3210-1KE21-7...
3RV2021-4DA…
25 A
15 HP
65 kA, 480Y / 277V AC
3RV2021-4EA…
32 A
20 HP
50 kA, 480Y / 277V AC
3RV_031-4EA…
32 A
20 HP
65 kA, 480Y / 277V AC
FSC
11 kW 6SL3210-1KE22-
6...
3RV_031-4HA…
50 A
40 HP
65 kA, 480Y / 277V AC 12200 in3
3RV1041-4JA…
63 A
50 HP
15 kW 6SL3210-1KE23-2...
3RV_031-4HA…
50 A
40 HP
3RV1041-4JA…
63 A
50 HP
18.5 kW 6SL3210-1KE23-
8...
3RV_031-4HA…
50 A
40 HP
3RV1041-4JA…
63 A
50 HP
* “_”can be replaced by “1” or “2”
Listed (NKJH) Siemens CMCs of the same type with a current rating lower than that specified in the
table, corresponding to G120C drive model number and with a voltage rating of at least 480V AC
may also be used.

s
Product information 07/2015
Modified behavior when commissioning the drive
With firmware V4.7 SP3, the commissioning Wizard has been revised and standardized for the
following inverters:
•SINAMICS G120 with PM240, PM240-2 or PM330 Power Module
•SINAMICS G120C
The SINAMICS application classes Standard Drive Control, Dynamic Drive Control and Expert
have been newly developed. The commissioning Wizard sets the application class depending on
the particular inverter:
•Standard Drive Control for SINAMICS G120C and SINAMICS G120 with Power Module
PM240, PM240-2 up to frame size FSD
•Dynamic Drive Control for SINAMICS G120 with PM240, PM240-2 Power Modules from
frame size FSD and with PM330 Power Modules
•Expert for SINAMICS G120 with PM230, PM250 and PM260 Power Modules
Motor data identification (MotID) is permanently set for Standard Drive Control. After the
commissioning Wizard has been exited, the inverter responds to the first ON command as follows:
1. The inverter carries out a MotID with the motor at a standstill. The duration of the MotID,
when compared to firmware V4.7, was shortened to approx. ⅓.
2. The inverter accelerates the motor to the specified setpoint. The second ON command
after the MotID is not necessary for Standard Drive Control.
For Dynamic Drive Control, a MotID is also set as default with the motor at a standstill. The default
setting can be changed:
•In addition, you can also select the MotID with rotating measurement. The inverter
optimizes the closed-loop speed control based on the results of the rotating measurement.
•You can select as to whether, after the MotID, the motor immediately accelerates to the
specified setpoint, or a second ON command is required.
To a large extent, Expert corresponds to the commissioning Wizard for firmware < V4.7 SP3.
A MotID is not set as default. You can select the following:
•No MotID, MotID with measurement with the motor at a standstill or MotID with rotating
measurement
•After the MotID, the motor immediately accelerates to the specified setpoint, or only after a
second ON command.
The following commissioning tools support the new commissioning wizard:
•STARTER from 4.4 SP1 or higher
•Startdrive from V13 SP1 and higher with Hardware Support Package V4.7 SP3
•IOP from V1.6 and higher
•BOP-2
SINAMICS G120C
SINAMICS G120
Inverter with CU230P
-2, CU240B/E-
2,
CU250S
-2 Control Units

SINAMICS G120C converter
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SINAMICS G120C converter
Operating Instructions
Edition 07/2015, firmware 4.7 SP3
Original instructions
07/2015, FW V4.7 SP3
A5E34263257B AC
Change history
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
A5E34263257B AC
Ⓟ
08/2015 Subject to change
Copyright © Siemens AG 2011 - 2015.
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.

SINAMICS G120C converter
Operating Instructions, 07/2015, FW V4.7 SP3, A5E34263257B AC 5
Change history
The most important changes with respect to the 04/2015 edition of the manual
New hardware
In Chapter
New inverter frame size AA Description (Page 25)
Installing the inverter (Page 39)
Connecting the inverter (Page 57)
Power-dependent technical data (Page 360)
Line reactor, filter, output reactors and braking
resistor as base components
Installing the inverter (Page 39)
Mounting base components (Page 44)
Accessories (Page 372)

Change history
SINAMICS G120C converter
6Operating Instructions, 07/2015, FW V4.7 SP3, A5E34263257B AC

SINAMICS G120C converter
Operating Instructions, 07/2015, FW V4.7 SP3, A5E34263257B AC 7
Table of contents
Change history........................................................................................................................................ 5
1 Fundamental safety instructions............................................................................................................ 13
1.1 General safety instructions .....................................................................................................13
1.2 Safety instructions for electromagnetic fields (EMF) ..............................................................17
1.3 Handling electrostatic sensitive devices (ESD) ......................................................................17
1.4 Industrial security ....................................................................................................................18
1.5 Residual risks of power drive systems....................................................................................19
2 Introduction........................................................................................................................................... 21
2.1 About the Manual....................................................................................................................21
2.2 Guide through the manual ......................................................................................................22
3 Description............................................................................................................................................ 25
3.1 Scope of delivery ....................................................................................................................25
3.2 Optional components for the inverter......................................................................................27
3.3 Motor series that are supported..............................................................................................28
3.4 Tools to commission the converter .........................................................................................30
4 Installing ............................................................................................................................................... 31
4.1 Procedure for installing the converter .....................................................................................31
4.2 EMC-compliant installation .....................................................................................................32
4.2.1 EMC-compliant cabinet design ...............................................................................................32
4.2.2 Installing the converter in compliance with EMC rules ...........................................................38
4.3 Installing the inverter...............................................................................................................39
4.4 Mounting base components....................................................................................................44
4.5 Mounting the line reactor ........................................................................................................47
4.6 Mounting the output reactor....................................................................................................50
4.7 Mounting the braking resistor .................................................................................................53
4.8 Connecting the inverter...........................................................................................................57
4.8.1 Permissible line supplies ........................................................................................................57
4.8.2 Connecting the inverter and inverter components to the supply ............................................60
4.8.3 Connecting the motor..............................................................................................................63
4.8.4 Operating a converter on the residual current device.............................................................64
4.8.5 Overview of the interfaces ......................................................................................................65
4.8.6 Fieldbus interface assignment ................................................................................................66
4.8.7 Terminal strips ........................................................................................................................67
4.8.8 Default setting of the interfaces ..............................................................................................71
4.8.9 Wiring the terminal strip ..........................................................................................................80

Table of contents
SINAMICS G120C converter
8Operating Instructions, 07/2015, FW V4.7 SP3, A5E34263257B AC
4.8.10 Monitoring the temperature of the braking resistor................................................................ 81
4.8.11 Connecting the inverter to the fieldbus .................................................................................. 82
4.8.11.1 Communication interfaces ..................................................................................................... 82
4.8.11.2 PROFINET ............................................................................................................................. 83
4.8.11.3 PROFIBUS............................................................................................................................. 86
5 Commissioning ..................................................................................................................................... 89
5.1 Commissioning guidelines ..................................................................................................... 89
5.2 Preparing for commissioning ................................................................................................. 90
5.2.1 Collecting motor data ............................................................................................................. 90
5.2.2 Inverter factory setting ........................................................................................................... 91
5.2.3 Defining additional requirements for the application.............................................................. 92
5.3 Commissioning using a BOP-2 operator panel...................................................................... 93
5.3.1 Starting basic commissioning ................................................................................................ 93
5.3.2 Standard Drive Control .......................................................................................................... 95
5.3.3 Dynamic Drive Control ........................................................................................................... 97
5.3.4 Basic commissioning for experts ......................................................................................... 101
5.4 Commissioning with a PC .................................................................................................... 107
5.4.1 Creating a project................................................................................................................. 108
5.4.2 Transfer inverters connected via USB into the project ........................................................ 108
5.4.3 Go online and start the configuration wizards...................................................................... 111
5.4.4 Standard Drive Control ........................................................................................................ 114
5.4.5 Dynamic Drive Control ......................................................................................................... 115
5.4.6 Configuration for experts...................................................................................................... 116
5.4.7 Identify motor data ............................................................................................................... 119
5.5 Restoring the factory setting ................................................................................................ 121
5.5.1 Resetting the safety functions to the factory setting ............................................................ 122
5.5.2 Restore the factory settings (without safety functions) ........................................................ 125
6 Advanced commissioning.....................................................................................................................127
6.1 Overview of the inverter functions........................................................................................ 127
6.2 Inverter control ..................................................................................................................... 128
6.2.1 Switching the motor on and off ............................................................................................ 128
6.2.2 Adapt the default setting of the terminal strip ...................................................................... 130
6.2.2.1 Digital inputs......................................................................................................................... 131
6.2.2.2 Fail-safe input....................................................................................................................... 133
6.2.2.3 Digital outputs ...................................................................................................................... 135
6.2.2.4 Analog input ......................................................................................................................... 136
6.2.2.5 Analog output ....................................................................................................................... 140
6.2.3 Inverter control using digital inputs ...................................................................................... 143
6.2.4 Two-wire control: method 1.................................................................................................. 144
6.2.5 Two-wire control, method 2.................................................................................................. 145
6.2.6 Two-wire control, method 3.................................................................................................. 146
6.2.7 Three-wire control, method 1 ............................................................................................... 147
6.2.8 Three-wire control, method 2 ............................................................................................... 148
6.2.9 Running the motor in jog mode (JOG function) ................................................................... 149
6.2.10 Control via PROFIBUS or PROFINET with the PROFIdrive profile..................................... 151
6.2.10.1 Control and status word 1 .................................................................................................... 153
6.2.10.2 Structure of the parameter channel ..................................................................................... 156
6.2.10.3 Examples of the parameter channel .................................................................................... 159

Table of contents
SINAMICS G120C converter
Operating Instructions, 07/2015, FW V4.7 SP3, A5E34263257B AC 9
6.2.10.4 Extend telegrams and change signal interconnection ..........................................................161
6.2.10.5 Configuring the IP interface ..................................................................................................163
6.2.10.6 Slave-to-slave communication..............................................................................................164
6.2.10.7 Acyclically reading and writing inverter parameters .............................................................164
6.2.11 Control via additional fieldbuses ...........................................................................................165
6.2.11.1 Modbus RTU.........................................................................................................................165
6.2.11.2 USS.......................................................................................................................................168
6.2.11.3 CANopen ..............................................................................................................................171
6.2.11.4 Ethernet/IP ............................................................................................................................172
6.2.12 Switching over the inverter control (command data set) ......................................................173
6.3 Setpoints ...............................................................................................................................175
6.3.1 Overview ...............................................................................................................................175
6.3.2 Analog input as setpoint source............................................................................................176
6.3.3 Specifying the setpoint via the fieldbus.................................................................................177
6.3.4 Motorized potentiometer as setpoint source.........................................................................178
6.3.5 Fixed speed as setpoint source ............................................................................................180
6.4 Setpoint calculation...............................................................................................................183
6.4.1 Overview of setpoint processing...........................................................................................183
6.4.2 Invert setpoint .......................................................................................................................184
6.4.3 Inhibit direction of rotation.....................................................................................................185
6.4.4 Skip frequency bands and minimum speed..........................................................................186
6.4.5 Speed limitation ....................................................................................................................187
6.4.6 Ramp-function generator ......................................................................................................188
6.5 Motor control .........................................................................................................................193
6.5.1 V/f control..............................................................................................................................193
6.5.1.1 Characteristics of U/f control.................................................................................................195
6.5.1.2 Optimizing motor starting......................................................................................................198
6.5.2 Vector control with speed controller......................................................................................201
6.5.2.1 Optimizing the speed controller ............................................................................................203
6.5.2.2 Friction characteristic ............................................................................................................205
6.5.2.3 Moment of inertia estimator ..................................................................................................208
6.5.2.4 Pole position identification ....................................................................................................213
6.6 Protection functions ..............................................................................................................214
6.6.1 Inverter temperature monitoring ...........................................................................................214
6.6.2 Motor temperature monitoring using a temperature sensor .................................................217
6.6.3 Overcurrent protection ..........................................................................................................220
6.6.4Limiting the maximum DC link voltage..................................................................................221
6.7 Application-specific functions................................................................................................222
6.7.1 Unit changeover....................................................................................................................223
6.7.1.1 Changing over the motor standard .......................................................................................224
6.7.1.2 Changing over the unit system .............................................................................................225
6.7.1.3 Changing over process variables for the technology controller............................................225
6.7.1.4 Switching units with STARTER.............................................................................................226
6.7.2 Calculating the energy saving...............................................................................................227
6.7.3 Electrically braking the motor................................................................................................229
6.7.3.1 DC braking ............................................................................................................................231
6.7.3.2 Compound braking................................................................................................................234
6.7.3.3 Dynamic braking ...................................................................................................................236
6.7.4 Motor holding brake ..............................................................................................................238
6.7.5 Flying restart – switching on while the motor is running .......................................................243

Table of contents
SINAMICS G120C converter
10 Operating Instructions, 07/2015, FW V4.7 SP3, A5E34263257B AC
6.7.6 Automatic restart.................................................................................................................. 245
6.7.7 Kinetic buffering (Vdc min control) ....................................................................................... 249
6.7.8 Line contactor control........................................................................................................... 251
6.7.9 PID technology controller..................................................................................................... 253
6.7.9.1 Overview .............................................................................................................................. 253
6.7.9.2 Setting the controller ............................................................................................................ 254
6.7.9.3 Optimizing the controller ...................................................................................................... 258
6.8 Safe Torque Off (STO) safety function ................................................................................ 259
6.8.1 Function description............................................................................................................. 259
6.8.2 Prerequisite for STO use ..................................................................................................... 262
6.8.3 Commissioning STO ............................................................................................................ 262
6.8.3.1 Commissioning tools............................................................................................................ 262
6.8.3.2 Protection of the settings from unauthorized changes......................................................... 263
6.8.3.3 Configuring a safety function ............................................................................................... 263
6.8.3.4 Configuring a safety function ............................................................................................... 264
6.8.3.5 Interconnecting the "STO active" signal............................................................................... 265
6.8.3.6 Setting the filter for safety-related inputs ............................................................................. 266
6.8.3.7 Setting the forced checking procedure (test stop) ............................................................... 270
6.8.3.8 Activating the settings and checking the digital inputs......................................................... 272
6.8.3.9 Acceptance - completion of commissioning......................................................................... 276
6.9 Switchover between different settings ................................................................................. 280
7 Backing up data and series commissioning ..........................................................................................283
7.1 Saving settings on a memory card....................................................................................... 284
7.1.1 Saving setting on memory card ........................................................................................... 285
7.1.2 Transferring the setting from the memory card.................................................................... 288
7.1.3 Safely remove the memory card.......................................................................................... 292
7.2 Saving settings on a PC....................................................................................................... 294
7.3 Saving settings on an operator panel .................................................................................. 298
7.4 Other ways to back up settings............................................................................................ 300
7.5 Write and know-how protection............................................................................................ 301
7.5.1 Write protection.................................................................................................................... 301
7.5.2 Know-how protection ........................................................................................................... 303
7.5.2.1 Settings for know-how protection......................................................................................... 305
7.5.2.2 Generating an exception list for know-how protection......................................................... 307
8 Corrective maintenance .......................................................................................................................309
8.1 Replacing inverter components ........................................................................................... 309
8.1.1 Overview of how to replace an inverter ............................................................................... 309
8.1.2 Replacing a converter with enabled safety function ............................................................ 310
8.1.3 Replacing a converter without enabled safety function ....................................................... 316
8.1.4 Replacing a converter without data backup......................................................................... 318
8.1.5 Replacing devices with active know-how protection............................................................ 319
8.1.6 Spare parts........................................................................................................................... 321
8.1.7 Replace the fan unit for the heat sink .................................................................................. 322
8.1.8 Replacing the roof-mounted fan........................................................................................... 324
8.2 Firmware upgrade and downgrade...................................................................................... 326
8.2.1 Upgrading the firmware........................................................................................................ 327
8.2.2 Firmware downgrade ........................................................................................................... 329

Table of contents
SINAMICS G120C converter
Operating Instructions, 07/2015, FW V4.7 SP3, A5E34263257B AC 11
8.2.3 Correcting an unsuccessful firmware upgrade or downgrade ..............................................331
8.3 Reduced acceptance after component replacement and firmware change .........................332
8.4 If the converter no longer responds ......................................................................................333
9 Alarms, faults and system messages .................................................................................................. 335
9.1 Operating states indicated on LEDs .....................................................................................336
9.2 Alarms...................................................................................................................................339
9.3 Faults ....................................................................................................................................342
9.4 List of alarms and faults........................................................................................................346
9.5 Identification & maintenance data (I&M)...............................................................................353
10 Technical data .................................................................................................................................... 355
10.1 Technical data of inputs and outputs ....................................................................................355
10.2 High Overload and Low Overload.........................................................................................357
10.3 Common technical power data .............................................................................................359
10.4 Power-dependent technical data ..........................................................................................360
10.5 Data regarding the power loss in partial load operation .......................................................364
10.6 Electromagnetic compatibility of the converters ...................................................................365
10.6.1 Assigning converters to EMC categories..............................................................................366
10.6.2 Harmonics.............................................................................................................................368
10.6.3 EMC limit values in South Korea ..........................................................................................368
10.7 Temperature and voltage derating........................................................................................369
10.8 Current derating - depending on the installation altitude......................................................370
10.9 Current reduction depending on pulse frequency.................................................................371
10.10 Accessories...........................................................................................................................372
10.10.1 Line reactor ...........................................................................................................................372
10.10.2 Line filter ...............................................................................................................................374
10.10.3 Output reactors .....................................................................................................................375
10.10.4 Sine-wave filter .....................................................................................................................377
10.10.5 Braking resistor .....................................................................................................................378
10.11 Standards..............................................................................................................................381
A Appendix............................................................................................................................................. 383
A.1 New and extended functions ................................................................................................383
A.2 Parameter .............................................................................................................................389
A.3 Using the operator panel BOP-2...........................................................................................391
A.3.1 Menu structure, symbols and keys .......................................................................................391
A.3.2 Changing settings using BOP-2............................................................................................392
A.3.3 Changing indexed parameters..............................................................................................393
A.3.4 Directly entering the parameter number and value ..............................................................394
A.3.5 A parameter cannot be changed ..........................................................................................395
A.4 The device trace in STARTER..............................................................................................396

Table of contents
SINAMICS G120C converter
12 Operating Instructions, 07/2015, FW V4.7 SP3, A5E34263257B AC
A.5 Interconnecting signals in the converter .............................................................................. 399
A.6 Connecting the safety-related input ..................................................................................... 402
A.7 Acceptance test for the safety function................................................................................ 403
A.7.1 Recommended acceptance test .......................................................................................... 403
A.7.2 Machine documentation....................................................................................................... 406
A.7.3 Log of the settings for the basic functions, firmware V4.4 ... V4.7 SP2............................... 408
A.8 Further information on your inverter..................................................................................... 409
A.8.1 Manuals for your inverter ..................................................................................................... 409
A.8.2 Configuring support.............................................................................................................. 410
A.8.3 Product Support ................................................................................................................... 410
Index ...................................................................................................................................................411

SINAMICS G120C converter
Operating Instructions, 07/2015, FW V4.7 SP3, A5E34263257B AC 13
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
SINAMICS G120C converter
14 Operating Instructions, 07/2015, FW V4.7 SP3, A5E34263257B AC
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
SINAMICS G120C converter
Operating Instructions, 07/2015, FW V4.7 SP3, A5E34263257B AC 15
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.

Fundamental safety instructions
1.1 General safety instructions
SINAMICS G120C converter
16 Operating Instructions, 07/2015, FW V4.7 SP3, A5E34263257B AC
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.
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).