Siemens SINAMICS G120D User manual

SINAMICS G120D converter with control
units CU240D-2 and CU250D-2
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SINAMICS
SINAMICS G120D
SINAMICS G120D converter with
control units CU240D-2 and
CU250D-2
Getting Started
Edition 04/2014, firmware V4.7
04/2014, FW V4.7
A5E34262374B AA
Fundamental safety
instructions
1
Introduction
2
Installation
3
Commissioning
4
Troubleshooting
5

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBER
G
GERMANY
A5E34262374B AA
Ⓟ
05/2014 Subject to change
Copyright © Siemens AG 2012 - 2014.
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 G120D converter with control units CU240D-2 and CU250D-2
Getting Started, 04/12014, FW V4.7, A5E34262374B AA 5
Table of contents
1 Fundamental safety instructions.............................................................................................................. 7
1.1 General safety instructions ............................................................................................................7
1.2 Safety instructions for electromagnetic fields (EMF) ...................................................................11
1.3 Handling electrostatic sensitive devices (ESD) ...........................................................................11
1.4 Industrial security .........................................................................................................................12
1.5 Residual risks of power drive systems.........................................................................................13
2 Introduction........................................................................................................................................... 15
2.1 SINAMICS G120D converter .......................................................................................................15
2.2 Commissioning tools....................................................................................................................17
3 Installation ............................................................................................................................................ 19
3.1 Fitting the CU to the PM...............................................................................................................19
3.2 Drill pattern SINAMICS G120D....................................................................................................20
3.3 Overview of the interfaces ...........................................................................................................22
3.4 Electrical data...............................................................................................................................23
3.5 Basic EMC Rules .........................................................................................................................24
3.6 Connections and cables...............................................................................................................25
3.7 Default settings of inputs and outputs..........................................................................................39
3.8 Settings PROFIBUS DP address with DIP switches ...................................................................41
3.9 Connecting the PROFINET interface...........................................................................................42
3.10 Grounding converter and motor ...................................................................................................42
3.11 Connections and interference suppression .................................................................................44
3.12 Equipotential bonding ..................................................................................................................44
4 Commissioning ..................................................................................................................................... 47
4.1 Default settings for the SINAMICS G120D ..................................................................................47
4.2 Commissioning with the IOP........................................................................................................48
4.3 Commissioning the application ....................................................................................................53
4.4 Reset Parameters to Factory Settings.........................................................................................54
5 Troubleshooting .................................................................................................................................... 55
5.1 List of alarms and faults ...............................................................................................................55
5.2 Status LED overview....................................................................................................................61
5.3 Further information.......................................................................................................................63

Table of contents
SINAMICS G120D converter with control units CU240D-2 and CU250D-2
6Getting Started, 04/12014, FW V4.7, A5E34262374B AA
Objective of these instructions
This Getting Started describes how you install an inverter and commission and operate it
using the IOP operator panel.
The functions and properties of the IOP are described in detail in the "SINAMICS IOP"
operating instructions and are only explained here to an extent that is necessary to
understand the described functions.
Additional information on SINAMICS G120
All manuals for the inverter can be downloaded from the Internet and are additionally
available on DVD. See also Section: Further information (Page 63).
What is the meaning of the symbols in the manual?
An operating instruction starts here.
This concludes the operating instruction.
Firmware upgrade and downgrade
Options for upgrading and downgrading the firmware can be found on the Internet at
http://support.automation.siemens.com/WW/view/de/67364620
(http://support.automation.siemens.com/WW/news/en/67364620).
Transferring license terms of the OSS code to a PC
Procedure
To transfer the OSS license terms from the inverter to a PC, proceed as follows:
1. Switch off the inverter power supply.
2. Insert an empty memory card into the card slot of the inverter. Also see Section:Overview
of the interfaces (Page 22)
3. Switch on the inverter power supply.
4. When you have switched on the power supply, wait 30 seconds.
During this time, the inverter writes the "Read_OSS.ZIP" file onto the memory card.
5. Switch off the inverter power supply.
6. Remove the card from the inverter.
7. Use a card reader and load the file to a PC.
You have then transferred the OSS license terms from the inverter to a PC.

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
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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 G120D converter with control units CU240D-2 and CU250D-2
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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
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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 G120D converter with control units CU240D-2 and CU250D-2
10 Getting Started, 04/12014, FW V4.7, A5E34262374B AA
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).

Fundamental safety instructions
1.2 Safety instructions for electromagnetic fields (EMF)
SINAMICS G120D converter with control units CU240D-2 and CU250D-2
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1.2
Safety instructions for electromagnetic fields (EMF)
WARNING
Danger to life from electromagnetic fields
Electromagnetic fields (EMF) are generated by the operation of electrical power equipment
such as transformers, converters or motors.
People with pacemakers or implants are at a special risk in the immediate vicinity of these
devices/systems.
•Ensure that the persons involved are the necessary distance away (minimum 2 m).
1.3
Handling electrostatic sensitive devices (ESD)
Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules
or devices that may be damaged by either electric fields or electrostatic discharge.
NOTICE
Damage through electric fields or electrostatic discharge
Electric fields or electrostatic discharge can cause malfunctions through damaged
individual components, integrated circuits, modules or devices.
•Only pack, store, transport and send electronic components, modules or devices in their
original packaging or in other suitable materials, e.g conductive foam rubber of
aluminum foil.
•Only touch components, modules and devices when you are grounded by one of the
following methods:
–Wearing an ESD wrist strap
–Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring
•Only place electronic components, modules or devices on conductive surfaces (table
with ESD surface, conductive ESD foam, ESD packaging, ESD transport container).

Fundamental safety instructions
1.4 Industrial security
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1.4
Industrial security
Note
Industrial security
Siemens provides pro
ducts and solutions with industrial security functions that support the
secure operation of plants, solutions, machines, equipment and/or networks. They are
important components in a holistic industrial security concept. With this in mind, Siemens’
product
s and solutions undergo continuous development. Siemens recommends strongly
that you regularly check for product updates.
For the secure operation of Siemens products and solutions, it is necessary to take suitable
preventive action (e.g. cell protection c
oncept) and integrate each component into a holistic,
state
-of-the-art industrial security concept. Third-party products that may be in use should
also be considered. For more information about industrial security, visit Hotspot
-Text
(
http://www.siemens.com/industrialsecurity).
To stay informed about product updates as they occur, sign up for a product
-specific
newsletter. For more information, visit Hotspot
-Text
(
http://support.automation.siemens.com).
WARNING
Danger as a result of unsafe operating states resulting from software manipulation
Software manipulation (e.g. by viruses, Trojan horses, malware, worms) can cause unsafe
operating states to develop in your installation which can result in death, severe injuries
and/or material damage.
•Keep the software up to date.
You will find relevant information and newsletters at this address
(http://support.automation.siemens.com).
•Incorporate the automation and drive components into a holistic, state-of-the-art
industrial security concept for the installation or machine.
You will find further information at this address
(http://www.siemens.com/industrialsecurity).
•Make sure that you include all installed products into the holistic industrial security
concept.

Fundamental safety instructions
1.5 Residual risks of power drive systems
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1.5
Residual risks of power drive systems
The control and drive components of a drive system are approved for industrial and
commercial use in industrial line supplies. Their use in public line supplies requires a
different configuration and/or additional measures.
These components may only be operated in closed housings or in higher-level control
cabinets with protective covers that are closed, and when all of the protective devices are
used.
These components may only be handled by qualified and trained technical personnel who
are knowledgeable and observe all of the safety instructions on the components and in the
associated technical user documentation.
When assessing the machine's risk in accordance with the respective local regulations (e.g.,
EC Machinery Directive), the machine manufacturer must take into account the following
residual risks emanating from the control and drive components of a drive system:
1. Unintentional movements of driven machine components during commissioning,
operation, maintenance, and repairs caused by, for example,
–Hardware and/or software errors in the sensors, control system, actuators, and cables
and connections
–Response times of the control system and of the drive
–Operation and/or environmental conditions outside the specification
–Condensation/conductive contamination
–Parameterization, programming, cabling, and installation errors
–Use of wireless devices/mobile phones in the immediate vicinity of the control system
–External influences/damage
2. In the event of a fault, exceptionally high temperatures, including an open fire, as well as
emissions of light, noise, particles, gases, etc. can occur inside and outside the inverter,
e.g.:
–Component failure
–Software errors
–Operation and/or environmental conditions outside the specification
–External influences/damage
Inverters of the Open Type/IP20 degree of protection must be installed in a metal control
cabinet (or protected by another equivalent measure) such that contact with fire inside
and outside the inverter is not possible.

Fundamental safety instructions
1.5 Residual risks of power drive systems
SINAMICS G120D converter with control units CU240D-2 and CU250D-2
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3. Hazardous shock voltages caused by, for example,
–Component failure
–Influence during electrostatic charging
–Induction of voltages in moving motors
–Operation and/or environmental conditions outside the specification
–Condensation/conductive contamination
–External influences/damage
4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a
risk to people with a pacemaker, implants or metal replacement joints, etc., if they are too
close
5. Release of environmental pollutants or emissions as a result of improper operation of the
system and/or failure to dispose of components safely and correctly
Note
The components must be protected against conductive contamination (e.g. by installing them
in a control cabinet with degre
e of protection IP54 according to IEC 60529 or NEMA 12).
Assuming that conductive contamination at the installation site can definitely be excluded, a
lower degree of cabinet protection may be permitted.
For more information about residual risks of the components in a drive system, see the
relevant sections in the technical user documentation.

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Introduction
2
2.1
SINAMICS G120D converter
Overview
The SINAMICS G120D is a range of converters for controlling the speed of three-phase
motors. The converter consists of two parts, the Control Unit and the Power Module.
Table 2- 1 Control Units of the SINAMICS G120D converter
Designation
Order number
Encoder type
Field bus
CU240D-2 DP
6SL3544-0FB20-1PA0
HTL Encoder PROFIBUS
CU240D-2 DP-F
6SL3544-0FB21-1PA0
CU250D-2 DP-F 6SL3546-0FB21-1PA0 HTL Encoder
SSI Absolute Encoder
CU240D-2 PN
6SL3544-0FB20-1FA0
HTL Encoder PROFINET,
EtherNet/IP
CU240D-2 PN-F
6SL3544-0FB21-1FA0
CU250D-2 PN-F 6SL3546-0FB21-1FA0 HTL Encoder
SSI Absolute Encoder
CU240D-2 PN-F PP
Push-Pull connections
6SL3544-0FB21-1FB0 HTL Encoder
CU240D-2 PN-F FO
Fibre optic connections
6SL3544-0FB21-1FC0
CU250D-2 PN-F PP
Push-Pull connections
6SL3546-0FB21-1FB0 HTL Encoder
SSI Absolute Encoder
CU250D-2 PN-F FO
Fibre optic connections
6SL3546-0FB21-1FC0

Introduction
2.1 SINAMICS G120D converter
SINAMICS G120D converter with control units CU240D-2 and CU250D-2
16 Getting Started, 04/12014, FW V4.7, A5E34262374B AA
Table 2- 2 PM250D Power Modules for the SINAMICS G120D converter
Frame
size
Rated output
power
Rated output
current
Order number
based on High Overload (HO)
FSA
0.75 kW
2.2 A
6SL3525-0PE17-5AA1
1.5 kW 4.1 A 6SL3525-0PE21-5AA1
FSB 3.0 kW 7.7 A 6SL3525-0PE23-0AA1
FSC
4.0 kW
10.2 A
6SL3525-0PE24-0AA1
5.5 kW
13.2 A
6SL3525-0PE25-5AA1
7.5 kW 19.0 A 6SL3525-0PE27-5AA1

Introduction
2.2 Commissioning tools
SINAMICS G120D converter with control units CU240D-2 and CU250D-2
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2.2
Commissioning tools
Figure 2-1 Commissioning tools - PC or IOP Handheld Kit

Introduction
2.2 Commissioning tools
SINAMICS G120D converter with control units CU240D-2 and CU250D-2
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Table 2- 3 Components and tools for commissioning
Component or tool
Order number
Operator Panel
IOP Handheld
6SL3255-0AA00-4HA0
STARTER Commissioning tool (PC
software)
You obtain STARTER on a DVD
(Order number: 6SL3072-
0AA00-0AG0)
and it can be downloaded:
STARTER Download
(http://support.automation.sieme
ns.com/WW/view/en/26233208)
PC Connection Kit
Comprising USB cable (3 m).
6SL3255-0AA00-2CA0

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Installation
3
3.1
Fitting the CU to the PM
Fitting the Control Unit to the Power Module
The inverter is delivered as two separate components - the Power Module (PM) and the
Control Unit (CU). The CU must be fitted to the PM prior to any further commissioning taking
place.
CAUTION
Seals fitted correctly
It is important that when assembling the Power Module and the Control Unit that all the
seals are fitted correctly to ensure IP65 rating.
TN and TT mains supplies
The SINAMICS PM250D Power Module with the Class A integrated mains filter is only
suitable for operation on TN and TT mains supplies.
The CU is fitted to the PM as shown in the diagram below.
Figure 3-1 Fitting the Control Unit to the Power Module

Installation
3.2 Drill pattern SINAMICS G120D
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3.2
Drill pattern SINAMICS G120D
Drill pattern and dimensions
The inverter has an identical drill pattern for all frame sizes. The drill pattern, depth and
tightening torques are shown in the diagram below.
Figure 3-2 SINAMICS G120D drill pattern