Siemens SINAMICS G120P User manual

www.siemens.com
SINAMICS G120P

2
System configuration required for commissioning
STARTER software
• Processor with min. 1 GHz (dual core recommended)
• 1024 MB RAM (2048 MB recommended)
• 3GB free HDD space
• Graphics card (min. 256 MB memory recommended)
• Screen resolution: 1024 x 768 pixels
• Internet Explorer V6.0 or higher
• Operating systems:
Microsoft® Windows™ XP (Service Pack 2 or later)
Microsoft® Windows™ 7

3
The interactive training booklet is a comfortable and easy to understand introduction to the SINAMICS G120P converter.
04/2012
SINAMICS G120P
Training Booklet

Materials and Tools
The components listed below are presented in this booklet. To test your knowledge on the actual
product, you have the choice between ordering the following alternatives:
Training case
Product
• SINAMICS G120P case*
Order No.
A5E03828108
Single components
Product
• SINAMICS G120 PM230 FSA 0.55kW
• SINAMICS G120 CU230P-2 HVAC/ BT
• Motor (0.12 kW)
• SINAMICS PC Connection Kit-2
• Basic Operator Panel BOP-2
• Intelligent Operator Panel IOP-2
• Screening Kit 2
Order No.
6SL3210-1NE11-7UL0
6SL3243 6BB30 1HA2
1LA7060-4AB10
6SL3255-0AA00-2CA0
6SL3255-0AA00-4CA1
6SL3255-0AA00-4JA0
6SL3264-1EA00-0FA0
Optional components
Product
• IOP-2/BOP-2 door mounting kit
Order No.
6SL3256-0AP00-0JA0
You will also need the following equipment:
• PC / PG with USB interface
• Switches – commercially available*
• Potentiometer – commercially available*
• Various M4 screws and nuts (length depends on installation location) with suitable screwdriver/
wrench – commercially available*
* The training case is a complete demo station including a motor, the power module of the converter, switches, lights and a
230 V power supp ly connection.

Safety instructions
Validity
These instructions apply to the following converter:
Product
SINAMICS G120P
Prerequisites
You are proficient in working with the Microsoft® Windows™ operating system.
You have a good understanding of the principles of electronics and electrical engineering.
Warning
Dangerous currents and voltages!
The equipment contains dangerous voltages and controls potentially dangerous rotating mechanical
parts. Non-compliance with the warnings or failure to follow the instructions contained in the docu-
mentation can result in loss of life, severe personal injury or serious damage to property.
Take particular notice of the general and regional installation and safety regulations regarding work
on dangerous voltage installations (e.g. EN 50178) as well as the relevant regulations regarding the
correct use of tools and personal protective equipment (PPE).
Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Only quali-
fied personnel may commission and operate this equipment. Within the context of the safety notes
in this documentation, qualified persons are defined as persons who are authorized to commission,
ground and label devices, systems and circuits in accordance with established safety practices and
standards.
Liability disclaimer
Depending on the firmware and software version of the Control Unit, operator panel and STARTER,
the masks, symbols and menus may differ. We have reviewed the contents of this publication to
ensure consistency with the hardware and software described. Since deviations cannot be pentirely
ruled out, we cannot guarantee full consistency. However, the information in this publication is
reviewed regularly and any necessary corrections are included in subsequent editions.

6
Welcome to the SINAMICS G120P Tutorial for First Time
Users. This tutorial will help you to simply and quickly
get to know the converter. We’ll take you step by step
through installation, setting parameters and initial
commissioning. We recommend that you work through
all of the chapters.

7
Converter SINAMICS G120P 08– 23
1.1 Components Power Module 12
Control Unit 13
Operator Panel 2 (BOP-2/IOP-2) 14
1.2 Mounting and wiring Power Module 15
Control Unit 18
Wiring the control terminals in the CU230P-2 20
Wiring examples 21
Operator Panels (BOP-2/IOP-2) 22
Operator Panels BOP-2 and IOP-2 24– 57
2.1 Basic functions The BOP-2 display 26
Menu structure 27
2.2 Working with BOP-2 Parameter list / Operating mode 28
Function buttons 31
2.3 Quick commissioning Resetting the converter 32
Setting the control mode / Selecting line frequency 33
Entering motor data 34
Specifying application parameters 35
Saving and restoring data 38
2.4 Intelligent Operator Panel The device 40
Working with IOP-2 41
Basic Commissioning 42
Output Settings 50
Trend View 52
Accessing diagnostics 56
STARTER software and PC 58– 86
3.1 Mounting and preparation Creating a STARTER project 62
STARTER user interface 65
Loading converter data 66
3.2 Parameterization Configuration wizard 70
3.3 Application cases Activating emergency operation 75
Parameterization of the PID 76
Saving data 79
Restoring factory settings 82
Appendix Download overview 87

8
This chapter introduces the low-voltage SINAMICS G120P
converter. You will learn about the main components, its
structure and obtain some practical tips about assem-
bling and wiring of the frequency converter.
1

9
Converter family
SINAMICS G120P
3AC 400V 0,37kW– 90kW (IP55)
3AC 400V 0,37kW– 75kW (IP20)

10
1.1 Components
The SINAMICS G120P converter has a modular design
It comprises three basic components:
1 2
The Power Module supplies
power to the motor
The Control Unit controls and
monitors the Power Module
Converter family SINAMICS G120P: Components

11
3 +
The Basic Operator Panel (BOP-2) or
the Intelligent Operator Panel (IOP-2)
are used to operate and monitor the
converter
With a computer, a USB-cable and the
STARTER commissioning software you
can also set parameters, operate and
monitor the converter
Each Control Unit can be freely
combined with each Power
Module.
NOTE

12
1
2
3
4
5
Power Module
The device is available in several sizes and degrees of protection. It has a power range extending from
0.37 kW up to 90 kW (75kW for IP20). The power modules are available in both IP20 and IP55.
IP20
IP55
Please check the rating plate
to make sure that the power
module also meets your require-
ment specifications.
NOTE
Rating plate
Power connectors
Motor connectors
PE terminals
Equipotential bonding
2
2
4
4 3
3
Converter family SINAMICS G120P: Components
3
2
1
1
5

13
1
2
3
3
16
6
6
4
2
5
9
9
8
9
7
4
5
6
7
8
9
10
Control Unit
There are various designs for the Control Units. They differ primarily in terms of different field bus inter-
faces. This tutorial will use the example of the CU230P-2 HVAC/BT Control Unit. It offers Modbus RTU,
BACnet MS / TP and USS as field bus interfaces.
Always use the CU screening kit in
order to ensure optimal potential
equalization, fixing and screening
of all bus- and signal cables.
NOTE
Rating plate
DIP switch for analog inputs
DIP switch for fieldbus address
Interface for the Operator
Panel (BOP-2 or IOP-2)
Status LEDs
Terminals for digital and
analog inputs and outputs
USB interface for STARTER
Interface to the Power Module
Fastening clips
RS485 connector for Fieldbus
10

14
Basic Operator Panel 2 (BOP-2)
The basic input and display device is used to operate and set parameters for the converter after being
connected to the Control Unit. It is operated by pressing the buttons and can be used to simply commis-
sion a converter thanks to the menu prompting and the 2-line display. The BOP-2 can store one set of
parameters and can be used to clone.
Intelligent Operator Panel (IOP-2)
The Intelligent Operator Panel manages the same functions as the BOP-2 but adds several more options.
The integrated application wizards, full graphical diagnostic overviews and plain text significantly
increase the usability. The IOP-2 can store up to 16 parameter settings and is thus very convenient for series
commissioning.
1
3
4
1
2
3
266
55
4
1
1
6
6
5
5
4 4
3 3
2 2
BOP-2 IOP-2
Seven operating buttons
Display
Release catch
Threaded inserts for door mounting
RS232 connector
Product rating label
Graphic display
Navigation wheel
Five operating buttons
USB connection (for firmware
and language pack updates)
RS232 connector
Product rating label
Converter family SINAMICS G120P: Components

15
Mounting the Power Module in the control cabinet
Please refer to the drilling pattern provided with the Power Module
for the correct drilling centers and clearance distances above and below
the Power Module. The Power Modules can be mounted side-by-side.
However, a 1mm gap is recommended to simplify installation.
1.2 Mounting and wiring
Before starting, check to ensure the following conditions have been met:
• All required components, tools and small parts are available
• All required cables and conductors have been routed/installed in accordance with specifications
• All minimum clearances are complied with
The motor and converter must be
selected so that they match each
other. This is also the case in our
example. Further, the data from
the rating plate of the motor are
important when initially commis-
sioning the converter.
NOTE
The 5 safety regulations when working on a VSD must be strictly observed
• Disconnect
• Lock out against unintentional restart
• Verify that it really is in a no-voltage condition
• Ground and short circuit
• Cover or partition off any adjacent live parts
Example of
drilling pattern
36.5 mm (1.44")
62.3mm (2.45")
6 mm (0.23")
186 mm (7.32")

16
Connecting the Power Module to the motor
Depending on the required EMC class, different cable length limits are applicable for the connection
between the Power Module and motor. Always use shielded cables. If longer cables are needed, make
sure that a sine-wave filter is used.
Wiring the Power Module (motor cable)
• Connect the equipotential bonding conductor to the Power Module (only for IP55. For IP20 ensure
that the cabinet is connected to the equipotential bonding conductor and that the metal heatsink
is properly connected to the rear of the cabinet)
• Connect the phases and the ground conductor to terminals U2, V2, W2 and PE. Make sure that the
cable is properly shielded. For IP55 devices use an EMC gland, route the screen through the cable
gland and connect it inside the housing
1
2
The motor and Power Module are now connected.
Wiring the motor
• Unscrew the cover of the terminal box on the motor (the inside cover of Siemens’ motors
illustrates the wiring for star and the delta connections)
• Remove the jumper bars from the connecting block and loosen the screws
• Place the jumper bars on the terminal block and screw them into place (depending on the
type of connections required – star or delta – in this example, a star connection is shown)
• Insert the cables from the Power Module through the opening of the terminal box to the motor
• Connect the PE connection first
• Introduce the phase conductors into the connections according to the phase assignment
• Replace the terminal box cover and ensure that it is secured with the four screws, tightened to the
required torque
• Use an EMC cable gland on the motor as well and make sure that the cable is properly shielded
inside the cable gland
3
The electrical wiring is now complete.
Wiring the power supply
• Connect the phases and the earth conductor to the terminal clamps L1, L2, L3 and PE
4
Converter family SINAMICS G120P: Mounting and wiring

17
Motor cables are sources of inter-
ference. This means that you
must use shielded cables in order
to meet the corresponding elec-
tromagnetic compatibility specifi-
cations. The cable lengths that are
actually possible depend on the
following:
‒ Operating environment
‒ Converter being used
‒ Reactors and filters used
‒ Shielded or unshielded cable
In order to meet Class A / C2 elec-
tromagnetic compatibility requi-
rements, you need a power
module with integrated filter and
a shielded cable (max. length:
25 meters). To meet Class B/ C1,
a Power Module with Filter B has
to be used (IP55 max. 25m, IP20
max. 50m).
A star connection is shown in the
example. The rating plate provides
information about the correct
circuit data: e.g. 230/400 V ∆/Y
means that you operate the motor
in a Y connection with a 400 V
line supply.
NOTE
42
1
3
3

18
Attaching the Control Unit
Attach the Control Unit to the bottom of the Power Module using the fastening clips and then press
the upper edge of the Control Unit onto the Power Module until the locking device snaps into place.
The terminal cover has to be opened before wiring the control terminals.
General procedure for wiring using the cage clamp mechanism
• Slide the wire into the terminal opening
• The inner clamp opens slightly and holds the wire tightly into place
The wire is now firmly attached.
• To release the wire gently press a screw driver onto the lever
• Remove the wire
• Withdraw the screwdriver from the terminal
Converter family SINAMICS G120P: Mounting and wiring
Wiring example of CU230-P-2

19
Wiring the control terminals in the CU230P-2
The CU230P-2 comes with an extensive range of I/O. 6 digital inputs, 3 digital outputs, 4 analogue
inputs – 2 of those for LG-Ni1000 or Pt1000 Sensors and 2 analogue outputs are standard.
In the factory settings, some of the I/O are preconfigured to adress common
requirements (see diagramm on the next page).
The CU230P-2 has a macro parameter (p0015), which automatically configures the drive to adress com-
mon applications. Using this macro, I/O and functions are automatically configured as well as some
common parameters in some macros. When carrying out the basic commissioning of the drive with
either STARTER, BOP-2 or the IOP-2, you can select the macro most suitable for your particular application.
After a drive has been set-up you, can select another macro at any time by simply activating the com-
missioning mode (P0010=1) and then select the required macro in P0015. After commissioning has
been completed, you can reset P0010 to 0.
Always ensure that all signal- and
bus cables are shielded at the
Control Unit using the shielding kit.
Signal- and bus cables must be
routed the maximum possible dis-
tance away from power and motor
cables, and cross them only at a
90° angle.
NOTE
Your G120P with FW 4.6 comes with the following HVAC specific macros
12: Standard I /O with analog setpoint (factory setting)
101: General purpose application
103: Pump delta P control
104: Stairway pressurization (ESM)
105: Pressure-controlled supply fan
106: Cooling tower fan (active temp. sensor) + hibernation mode
107: Cooling tower fan (LG-Ni1000 temp. sensor) + hibernation mode
108: USS fieldbus
109: Modbus RTU fieldbus
110: BACnet MS/TP fieldbus

20
18 DO 0 NC
19 DO 0 NO
20 DO 0 COM
23 DO 2 NC
24 DO 2 NO
25 DO 2 COM
Wiring the control terminals in the CU230P-2
Converter family SINAMICS G120P: Mounting and wiring
1+10V OUT
2GND
3AI 0+
Analog
in/ out
4AI 0-
12 AO 0+
13 GND
21 DO 1 NO
22 DO 1 COM
14 T1 MOTOR
15 T2 MOTOR
9+24V OUT
28 GND
Digital
in/ out
69 DI COM
5DI 0
6DI 1
7DI 2
8DI 3
16 DI 4
17 DI 5
31 +24V IN
32 GND IN
–
35 +10V OUT
36 GND
50 AI 2+/NI1000
Analog
in/ out
51 GND
52 AI 3+/NI1000
53 GND
–
–
–
–
10 AI 1+
Analog
in/ out
11 AI 1-
26 AO 1+
27 GND