Siemens sinamics dcp User manual

SINAMICS
SINAMICS DCP
Operating Instructions
05/2016
A5E34382853K
Preface
Introduction
1
Safety notes
2
Description
3
Preparations for use
4
Mounting
5
Electrical connection
6
Commissioning
7
Operation
8
Servicing
9
Spare parts
10
Disposal
11
Service and Support
A
Technical data
B
Quality documents
C
Additional documents
D
Checklists and forms
E
Assembly documents
F
Index
G

Siemens AG
Division Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG
GERMANY
Document order number: A5E34382853K
Ⓟ
05/2016 Subject to change
Copyright © Siemens AG 2014 - 2016.
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury
may
result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by
personnel qualified
for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are 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 DCP
Operating Instructions, 05/2016, A5E34382853K 5
Preface
Device software version
When these Operating Instructions went to print, SINAMICS DCP units were being supplied
from the factory with the software release specified on Page 3. However, these Operating
Instructions can, in principle, also apply to other software versions.
●
Older software versions
It is possible that not all of the functions described here may be available.
●
Newer software versions
It is possible that the SINAMICS DCP may feature additional functions that are not
described in these Operating Instructions. Do not change any parameters that you cannot
find in the List Manual from their factory setting, and do not give parameters any values
that are not specified in the List Manual.
The software release is displayed using r50060[6].
Example:
01010203 displayed on the BOP20 means 01.01.02.03 → Version 1.1, Service Pack 2,
Hotfix 3
Downloading the latest software version
(https://support.industry.siemens.com/cs/ww/en/view/109474935)
SINAMICS DCP documentation available
SINAMICS DCP Operating Instructions
Contains all information on
ordering, installation, connecting, commissioning, maintaining, description of functions,
and service
SINAMICS DCP List Manual
Contains
parameter list, function diagrams, list of faults and alarms
SINAMICS Free Function Blocks, Commissioning Manual
Contains a general description, the list of parameters, the function diagrams as well as
the list of faults and alarms.
SINAMICS DCP DVD Documentation
Contains, among others:
•
All the manuals mentioned above in all the available languages
•
The function diagrams in VISIO format

Preface
SINAMICS DCP
6Operating Instructions, 05/2016, A5E34382853K
Manuals in the Internet
The manuals are also available in the Internet:
Manuals (https://support.industry.siemens.com/cs/ww/en/ps/13302)
The list of general conditions available there include current supplements to the manuals.
The notes included in the general condition lists have a higher priority than the statements
made in the manuals.
Further Internet links
Generic station description file (GSD) for
PROFIBUS (https://support.industry.siemens.com/cs/ww/en/view/98206128)
PROFINET (https://support.industry.siemens.com/cs/at/en/view/98207877)

SINAMICS DCP
Operating Instructions, 05/2016, A5E34382853K 7
Table of contents
Preface ................................................................................................................................................... 5
1 Introduction........................................................................................................................................... 13
2 Safety notes.......................................................................................................................................... 15
2.1 Safety concept ........................................................................................................................17
2.2 Notes on operator protection ..................................................................................................18
2.2.1 Information about electromagnetic fields ................................................................................20
2.3 Notes on plant safety ..............................................................................................................21
2.4 ESD-sensitive components.....................................................................................................22
3 Description............................................................................................................................................ 23
4 Preparations for use.............................................................................................................................. 25
4.1 Device order numbers.............................................................................................................25
4.2 Rating plate.............................................................................................................................26
4.3 Ordering information for options and accessories ..................................................................28
5 Mounting............................................................................................................................................... 31
6 Electrical connection ............................................................................................................................. 35
6.1 EMC-compliant installation .....................................................................................................36
6.1.1 Basic information about EMC .................................................................................................36
6.1.2 EMC-compliant installation of SINAMICS DCP (installation instructions) ..............................38
6.2 Block diagram with connection suggestion.............................................................................40
6.3 Components............................................................................................................................43
6.4 Terminals and connectors ......................................................................................................45
6.5 Additional system components ...............................................................................................57
6.5.1 Option Board: Communication Board EtherNet CBE20 .........................................................57
6.5.1.1 Description ..............................................................................................................................57
6.5.1.2 Safety instructions...................................................................................................................57
6.5.1.3 Interface description................................................................................................................58
6.5.1.4 Meaning of the LEDs ..............................................................................................................59
6.5.1.5 Assembling the 30 kW device.................................................................................................62
6.5.1.6 Assembling the 120 kW device...............................................................................................64
6.5.1.7 Technical data.........................................................................................................................65
6.5.2 Terminal Module Cabinet TMC (option G63)..........................................................................65
7 Commissioning ..................................................................................................................................... 71
7.1 Switching on............................................................................................................................73
7.1.1 BOP20 status display during ramp-up....................................................................................73

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SINAMICS DCP
8Operating Instructions, 05/2016, A5E34382853K
7.2 Commissioning using the BOP20 operator panel.................................................................. 75
7.2.1 Requirements......................................................................................................................... 75
7.2.2 Commissioning steps............................................................................................................. 75
7.3 Commissioning with the STARTER commissioning tool ....................................................... 78
7.3.1 STARTER commissioning tool............................................................................................... 78
7.3.1.1 Description ............................................................................................................................. 78
7.3.1.2 Installing the STARTER commissioning tool ......................................................................... 78
7.3.1.3 Layout of the STARTER user interface ................................................................................. 79
7.3.2 Procedure for commissioning with STARTER ....................................................................... 79
7.3.2.1 Basic procedure when using STARTER................................................................................ 79
7.3.2.2 Creating the project................................................................................................................ 80
7.3.2.3 The STARTER project wizard................................................................................................ 81
7.3.2.4 Configuring a drive unit .......................................................................................................... 88
7.3.2.5 Starting the drive project ........................................................................................................ 95
7.3.2.6 Connection through a serial interface .................................................................................... 99
7.4 Activating function modules ................................................................................................. 102
7.4.1 Activating offline via STARTER ........................................................................................... 102
7.4.2 Activating online via parameters .......................................................................................... 103
8 Operation.............................................................................................................................................107
8.1 Operation ............................................................................................................................. 107
8.1.1 Basics................................................................................................................................... 107
8.1.1.1 Parameters........................................................................................................................... 107
8.1.1.2 Data sets .............................................................................................................................. 110
8.1.1.3 Drive objects ........................................................................................................................ 111
8.1.1.4 Memory card functions......................................................................................................... 113
8.1.1.5 BICO technology: Interconnecting signals........................................................................... 118
8.1.2 Parameter assignment via the BOP20 (Basic Operator Panel 20)...................................... 122
8.1.2.1 General information on the BOP20...................................................................................... 122
8.1.2.2 Display and operation with the BOP20 ................................................................................ 126
8.1.2.3 Displaying faults and alarms................................................................................................ 131
8.1.2.4 Controlling the drive using the BOP20................................................................................. 132
8.2 Inputs/outputs....................................................................................................................... 133
8.2.1 Overview of the inputs/outputs............................................................................................. 133
8.2.2 Digital inputs/outputs............................................................................................................ 133
8.2.3 Analog inputs ....................................................................................................................... 133
8.2.4 Analog outputs ..................................................................................................................... 134
8.3 Communication, IT security ................................................................................................. 135
8.4 Communication according to PROFIdrive ........................................................................... 136
8.4.1 General Information ............................................................................................................. 136
8.4.2 Application classes .............................................................................................................. 138
8.4.3 Cyclic communication .......................................................................................................... 139
8.4.3.1 Telegrams and process data ............................................................................................... 139
8.4.3.2 Description of the control word ............................................................................................ 142
8.4.3.3 Description of the status word.............................................................................................. 143
8.4.3.4 Diagnostics channels for cyclic communication................................................................... 144
8.4.4 Parallel operation of communication interfaces ................................................................... 145

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SINAMICS DCP
Operating Instructions, 05/2016, A5E34382853K 9
8.4.5 Acyclic communication..........................................................................................................148
8.4.5.1 General information about acyclic communication ...............................................................148
8.4.5.2 Structure of requests and responses....................................................................................150
8.4.5.3 Determining the drive object numbers ..................................................................................155
8.4.5.4 Example 1: Read parameter.................................................................................................156
8.4.5.5 Example 2: Writing parameters (multi-parameter request)...................................................158
8.5 Communication via PROFIBUS DP......................................................................................162
8.5.1 PROFIBUS connection .........................................................................................................162
8.5.2 General information about PROFIBUS.................................................................................164
8.5.2.1 General information about PROFIBUS for SINAMICS .........................................................164
8.5.2.2 Example of a telegram structure for acyclic data acquisition ...............................................166
8.5.3 Commissioning PROFIBUS..................................................................................................168
8.5.3.1 Setting the PROFIBUS interface ..........................................................................................168
8.5.3.2 PROFIBUS interface in operation.........................................................................................169
8.5.3.3 Commissioning PROFIBUS..................................................................................................170
8.5.3.4 Diagnostics options...............................................................................................................171
8.5.3.5 SIMATIC HMI addressing .....................................................................................................171
8.5.3.6 Monitoring telegram failure ...................................................................................................172
8.5.4 Direct data exchange............................................................................................................174
8.5.4.1 Direct data exchange ............................................................................................................174
8.5.4.2 Setpoint assignment in the subscriber..................................................................................176
8.5.4.3 Activating/parameterizing direct data exchange...................................................................176
8.5.4.4 Commissioning the PROFIBUS direct data exchange .........................................................178
8.5.4.5 GSD during operation ...........................................................................................................190
8.5.4.6 Diagnosing the PROFIBUS slave-to-slave communication in STARTER ............................191
8.5.5 Messages via diagnostics channels .....................................................................................191
8.6 Communication via PROFINET IO .......................................................................................194
8.6.1 Establishing online operation: STARTER via PROFINET IO ...............................................194
8.6.2 General information about PROFINET IO ............................................................................200
8.6.2.1 Real-time (RT) and isochronous real-time (IRT) communication .........................................201
8.6.2.2 Addresses .............................................................................................................................202
8.6.2.3 Data transfer .........................................................................................................................204
8.6.2.4 Communication channels for PROFINET.............................................................................205
8.6.3 Drive control with PROFINET ...............................................................................................205
8.6.3.1 Media redundancy ................................................................................................................207
8.6.4 RT classes for PROFINET IO...............................................................................................208
8.6.5 PROFINET GSDML ..............................................................................................................214
8.6.6 Communication with CBE20 .................................................................................................214
8.6.7 Messages via diagnostics channels .....................................................................................215
8.7 EtherNet/IP ...........................................................................................................................218
8.7.1 Connection of SINAMICS DCP with EtherNet/IP to EtherNet networks...............................218
8.7.1.1 Connection of SINAMICS DCP with EtherNet/IP to EtherNet networks...............................218
8.7.2 Configuration of SINAMICS DCP for EtherNet/IP ................................................................218
8.7.2.1 Setting the IP address and activating the EtherNet/IP protocol ...........................................218
8.7.3 Configuration of a Rockwell controller with SINAMICS DCP................................................225
8.7.4 Writing and reading parameters with Class 4xx ...................................................................228

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SINAMICS DCP
10 Operating Instructions, 05/2016, A5E34382853K
8.8 Switch on, switch off, enable................................................................................................ 230
8.8.1 Switch on / switch off (ON/OFF1) - control word bit 0.......................................................... 230
8.8.2 OFF2 (disconnection) - control word bit 1............................................................................ 230
8.8.3 OFF3 (quick stop) - control word bit 2.................................................................................. 231
8.8.4 Operation enable (enable) - control word bit 3 .................................................................... 231
8.9 Closed-loop control .............................................................................................................. 232
8.10 Precharging of the DC links ................................................................................................. 240
8.11 Device fan ............................................................................................................................ 243
8.12 Derating................................................................................................................................ 244
8.13 Runtime (operating hours counter) ...................................................................................... 246
8.14 Diagnostics........................................................................................................................... 247
8.14.1 Diagnostic memory .............................................................................................................. 247
8.14.2 Description of the LEDs on the CUD ................................................................................... 247
8.14.3 Faults and alarms................................................................................................................. 251
8.14.3.1 General information ............................................................................................................. 251
8.14.3.2 Buffer for faults and alarms.................................................................................................. 252
8.14.3.3 Configuring messages ......................................................................................................... 255
8.14.3.4 Parameters and function diagrams for faults and alarms .................................................... 257
8.14.3.5 Forwarding faults and alarms............................................................................................... 258
8.15 Drive Control Chart (DCC) for SINAMICS DCP................................................................... 259
8.16 Technological functions ....................................................................................................... 264
8.16.1 MPP Tracker ........................................................................................................................ 264
8.16.2 Battery charging characteristic............................................................................................. 268
8.17 Parallel connection of multiple SINAMICS DCPs ................................................................ 269
9 Servicing..............................................................................................................................................271
9.1 Upgrading software releases ............................................................................................... 272
9.1.1 Upgrading the device software ............................................................................................ 273
9.1.1.1 Backup the configuration ..................................................................................................... 273
9.1.1.2 Update the SINAMICS DCP software.................................................................................. 273
9.1.1.3 Update the STARTER project.............................................................................................. 274
9.1.1.4 Download to target system, RAM to ROM........................................................................... 274
9.2 Replacing the fans ............................................................................................................... 275
9.2.1 Replacing the fan of a 30 kW device ................................................................................... 276
9.2.2 Replacing the fans for the 120 kW device ........................................................................... 277
10 Spare parts ..........................................................................................................................................279
11 Disposal...............................................................................................................................................281
11.1 Environmental compatibility ................................................................................................. 281
A Service and Support ............................................................................................................................283
B Technical data .....................................................................................................................................285
B.1 Ambient conditions............................................................................................................... 285
B.2 Device data .......................................................................................................................... 287
B.3 Standards and certifications................................................................................................. 290

Table of contents
SINAMICS DCP
Operating Instructions, 05/2016, A5E34382853K 11
C Quality documents .............................................................................................................................. 291
D Additional documents.......................................................................................................................... 293
D.1 List of abbreviations..............................................................................................................293
E Checklists and forms........................................................................................................................... 301
F Assembly documents .......................................................................................................................... 303
G Index................................................................................................................................................... 305
Index................................................................................................................................................... 307

Table of contents
SINAMICS DCP
12 Operating Instructions, 05/2016, A5E34382853K

SINAMICS DCP
Operating Instructions, 05/2016, A5E34382853K 13
Introduction
1
The objective of these Operating Instructions is to convey know-how necessary to enable
instructed persons to operate the system professionally and safely.
Knowledge of the Operating Instructions and descriptions of the associated components is
required for all work on the various components. In case of doubt, request support from the
Siemens Customer Support.
Only appropriately trained and instructed personnel is permitted to operate the system.
These Operating Instructions are intended to inform and instruct defined target groups,
safeguard the manufacturer against liability, observe the product, provide traceability and
reproducibility, as well as the long-term or legally required archiving of the relevant
information content.
The individual sections of the Operating Instructions provide information about the product
itself, the handling of the product, and the actions of users.
This document includes safety information and the most important technical details of the
SINAMICS DCP.
Note
SINAMICS DCP is a member of the Sin
amics family of devices. This series of devices
mainly comprises components for electric drives. This is the reason that in these operating
instructions in chapters which are applicable for several SINAMICS components (for
example PROFIBUS), the terms "Dri
ve", "Master/leading drive", "Drive device" or "Drive
system" are used. In these operating instructions, "drive", "drive unit" or "drive system"
always refers to the SINAMICS DCP.

Introduction
SINAMICS DCP
14 Operating Instructions, 05/2016, A5E34382853K

SINAMICS DCP
Operating Instructions, 05/2016, A5E34382853K 15
Safety notes
2
Note
In the interests of cla
rity, these Operating Instructions do not contain full details of all
information for all product types and cannot take into account every possible aspect of
installation, operation, or maintenance.
Should further information be desired or should particul
ar problems arise which are not
covered sufficiently in the Operating Instructions for the purchaser’s purposes, please
contact your local SIEMENS office.
We also draw your attention to the fact that the contents of these Operating Instructions are
not par
t of and do not modify any prior or existing agreement, commitment, or legal
relationship. The Purchase Agreement contains the complete and exclusive obligations of
Siemens, including the warranty provisions. Any statements contained in these Operating
Ins
tructions neither expand nor restrict the scope of these contractual warranty conditions.
WARNING
Note the safety instructions
Operating, servicing, maintaining or installing the SINAMICS DCP may result in property
damage, serious injury, and even death if the safety instructions are not observed.
You must strictly comply with all notes regarding intended use. Different operating modes,
overloads, load cycles, and differing ambient conditions are permitted only after special
arrangement with the manufacturer.
WARNING
Qualified personnel
The system is at a hazardous voltage. Failure to comply with these Operating Instructions
can lead to death, serious injury and material damage.
Only qualified personnel are permitted to work on this system. Such personnel must be
thoroughly acquainted with all the warnings and maintenance procedures referred to in
these Operating Instructions.
Perfect, safe and reliable operation of the system assumes that it has been professionally
transported, stored, mounted and installed as well as correct operation and servicing.
Note
In addition
to the safety instructions stated here, make sure that the safety instructions in the
manuals for the individual devices are also observed and followed at all times when working
with different components.

Safety notes
SINAMICS DCP
16 Operating Instructions, 05/2016, A5E34382853K
DANGER
Grounding the SINAMICS DCP
High voltages that could cause death or serious injury may be still present in the SINAMICS
DCP even after the system has been shut down.
Work on the power units is only permitted when steps have been taken to ensure proper
grounding.

Safety notes
2.1 Safety concept
SINAMICS DCP
Operating Instructions, 05/2016, A5E34382853K 17
2.1
Safety concept
The SINAMICS DCP is subject to a comprehensive safety concept which, when properly
implemented, ensures safe installation, operation, servicing, and maintenance.
The safety concept encompasses safety components and functions to protect the device and
operators.
Safety components for personnel protection
●
External components for the safety concept
Power contactors and fuses
●
Enclosure
The touch protection is ensured according to EN 61800-5-1
Protection and monitoring functions of internal components
●Current converter protection by means of monitoring systems:
–Current monitoring
–Voltage monitoring
–Temperature monitoring of the heat sink
–Monitoring of the surrounding air temperature in the fan block
●Shutdown at a communication failure between the SINAMICS DCP and the higher-level
controller

Safety notes
2.2 Notes on operator protection
SINAMICS DCP
18 Operating Instructions, 05/2016, A5E34382853K
2.2
Notes on operator protection
Note
Qualified personnel
All work associated with the transport, installation, commissioning, operation or maintenance
must be performed by qualified specialist personnel (skilled electricians according to EN
50110
-1 "Operation of electrical installations").
For the purpose of these basic safety instructions, "skilled technical personnel" means
people who are familiar
with the installation, mounting, commissioning and operation of the
product. They must be properly qualified for the tasks with which they are charged.
The personnel must also be thoroughly familiar with all safety
-related instructions and
measures in thi
s documentation.
Read the following information about personal protection.
Safety-relevant instructions for work on SINAMICS DCP devices
The five safety rules:
Operation of electrical installations according to the low-voltage directive 2006/95/EC
This standard applies to the operation of and all work on, with or in the vicinity of electrical
installations.
Observe the five safety rules when performing any work
1. Disconnect the system
2. Protect against reconnection
3. Make sure that the equipment is in a no voltage condition
4. Ground and short-circuit
5. Cover or fence off adjacent components that are still live
WARNING
Dangerous parts
The SINAMICS DCP may have live parts during operation.
Unauthorized removal of required covers, improper use, or incorrect installation or
operation may lead to death and serious injury or property damage.
Always take the appropriate precautions before touching any components.

Safety notes
2.2 Notes on operator protection
SINAMICS DCP
Operating Instructions, 05/2016, A5E34382853K 19
WARNING
Dangerous voltages
High voltages can cause death or serious injury if the safety rules are not observed or if the
equipment is handled improperly.
As soon as the DC link or the battery is connected, dangerous DC voltages are present.
When the SINAMICS DCP is in operation, high voltages occur, and can remain present for
a longer period after the equipment is switched off.
Make sure that work is only carried out by qualified personnel under strict observance of
the five safety rules, the warning notices in this documentation, and the safety-relevant
instructions.
DANGER
Capacitor discharge / dangerous voltages
After disconnection of the supply voltage, voltages are still present in the SINAMICS DCP
devices that could result in death or serious injury.
After you have switched off the power supply, strictly observe the discharge time of the DC
link capacitors of 5 minute before you perform any maintenance work or repair work and do
not touch the device during this period.
Measure the voltage once the discharge time has elapsed.
CAUTION
Hot surfaces
During operation, the temperature of some components increases significantly; for
example, heat sinks, reactors, semiconductor modules etc.
These components can remain very hot for some time after operation. Serious injury
(scalding) may occur if you come into contact with these components.
Do not touch hot components even after you have switched off the SINAMICS DCP.

Safety notes
2.2 Notes on operator protection
SINAMICS DCP
20 Operating Instructions, 05/2016, A5E34382853K
2.2.1
Information about electromagnetic fields
WARNING
Electromagnetic radiation during operation of the plant
Electromagnetic fields are generated during operation of electrical power engineering
equipment, such as transformers, converters, and motors.
Electromagnetic fields can interfere with electronic devices, which could cause them to
malfunction.
For example, the operation of heart pacemakers can be impaired, potentially leading to
damage to a person's health or even death. Steps must be taken, therefore, to ensure that
persons with heart pacemakers cannot enter these areas.
The plant operator is responsible for taking appropriate measures (labels and hazard
warnings) to adequately protect operating personnel and others against any possible risk.
●Observe the relevant nationally applicable health and safety regulations or the applicable
national regulations in the country of installation.
●Display adequate hazard warning notices on the installation.
●Place barriers around hazardous areas.
●Take measures, e.g. using shields, to reduce electromagnetic fields at their source.
●Make sure that personnel are wearing the appropriate protective gear.