Siemens SINAMICS S150 NEMA User manual

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SINAMICS
SINAMICS S150 NEMA
Converter cabinet units
Operating Instructions
Firmware version V5.1
11/2017
A5E36652151A
Preface
Safety instructions
1
Device overview
2
Mechanical installation
3
Electrical installation
4
Commissioning
5
Operation
6
Setpoint channel and closed-
loop control
7
Output terminals
8
Functions, monitoring and
protective functions
9
Diagnostics / faults and
alarms
10
Maintenance and servicing
11
Technical specifications
12
Appendix
A

Siemens AG
Division Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E36652151A
Ⓟ
04/2018 Subject to change
Copyright © Siemens AG 2015 - 2017.
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.

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Operating Instructions, 11/2017, A5E36652151A 3
Preface
Structure of this documentation
The customer documentation comprises general and individual documentation.
The general documentation describes the topics that apply to all cabinet units:
●
Operating Instructions
The Operating Instructions consist of the following sections:
–Device description
–Mechanical installation
–Electrical installation
–Commissioning guide
–Description of function
–Maintenance instructions
–Technical specifications
●
List Manual
The List Manual consists of the following parts:
–Parameter list
–Function diagrams
–Fault / alarm list
●
Documentation for Drive Control Chart (DCC)
–Programming and Operating Manual: DCC Editor description
–Function Manual: Description of the standard DCC blocks
The individual documentation describes a specific configured cabinet unit and contains the
following:
●
Dimension drawing
The dimension drawing documents the dimensions of the ordered cabinet unit.
●
Layout diagram
The layout diagram shows the components installed in the ordered cabinet unit along with
the equipment identifiers and location designations.
●
Circuit diagram
The circuit diagram shows the electrical components installed in the ordered encoder unit
with the equipment identifiers and location designations, their interconnections, and the
customer interfaces.

Preface
Converter cabinet units
4Operating Instructions, 11/2017, A5E36652151A
●
Terminal diagram
The terminal diagram shows all the customer terminals in the ordered cabinet unit and
the associated internal wiring in the cabinet unit. This diagram documents the line-side
target wiring.
●
Spare parts list
The spare parts list contains all the available spare parts for the ordered cabinet unit.
●
Additional operating instructions
The instructions for supplier components installed in the ordered cabinet unit are included
as original documentation.
Technical support
Technical advice is available at the following address:
●Phone.: [phone] (within USA, toll free)
Tel.: [phone] (outside USA)
●Online request: www.siemens.com/automation/support-request
Customer service, field service, spare parts and repair
●[e-mail]
Tel.: [phone] (within USA, toll free)
Tel.: [phone] (outside USA)
Internet address
Information about SINAMICS can be found on the Internet at the following address:
http://www.siemens.com/sinamics
EMC limits for South Korea
The EMC limits to be observed for Korea correspond to the limits of the EMC product
standard for variable-speed electric drives EN 61800-3 of category C2 or the limit class A,
Group 1 according to EN 55011.
By implementing appropriate additional measures, the limit values according to category C2
or limit value class A, Group 1, are complied with. Additional measures, such as the use of
an additional RFI suppression filter (EMC filter), may be necessary.
In addition, measures for proper plant design to meet EMC requirements are described in
detail in this manual and the "SINAMICS Low Voltage Configuration Manual".

Preface
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Operating Instructions, 11/2017, A5E36652151A 5
Certification
The following manufacturing sites have a UL listing for the manufacture of Industrial Control
Panels and Control Panel Enclosures:
●Siemens Industry Inc.
500 Hunt Valley Rd, New Kensington, PA 15068-7060, USA
UL file # E83449
●Siemens AG
Vogelweiherstrasse 1-15, 90441 Nuremberg, Germany
UL file # E251147
Use of OpenSSL
This product contains software (https://www.openssl.org/) that has been developed by the
OpenSSL project for use in the OpenSSL toolkit.
This product contains cryptographic software (mailto:[e-mail]) created by Eric
Young.
This product contains software (mailto:[e-mail]) developed by Eric Young.

Preface
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6Operating Instructions, 11/2017, A5E36652151A

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Table of contents
Preface ................................................................................................................................................... 3
1 Safety instructions................................................................................................................................. 19
1.1 General safety instructions .....................................................................................................19
1.2 Handling the AOP30 backup battery ......................................................................................24
1.3 Handling electrostatic sensitive devices (ESD) ......................................................................25
1.4 Industrial security ....................................................................................................................26
1.5 Residual risks of power drive systems....................................................................................27
2 Device overview.................................................................................................................................... 29
2.1 Chapter content ......................................................................................................................29
2.2 Applications, characteristics ...................................................................................................29
2.2.1 Field of application ..................................................................................................................29
2.2.2 Features, quality, service........................................................................................................30
2.3 Configuration...........................................................................................................................32
2.4 Wiring principle .......................................................................................................................34
2.5 Rating plate.............................................................................................................................35
3 Mechanical installation .......................................................................................................................... 39
3.1 Content of this chapter............................................................................................................39
3.2 Transportation and storage.....................................................................................................39
3.3 Installation...............................................................................................................................41
3.3.1 Mechanical installation: checklist............................................................................................42
3.3.2 Preparation .............................................................................................................................43
3.3.2.1 Requirements for installation location.....................................................................................43
3.3.2.2 Requirements on the levelness of the floor ............................................................................43
3.3.2.3 Shipping and handling indicators............................................................................................44
3.3.2.4 Unpacking ...............................................................................................................................46
3.3.2.5 Required tools.........................................................................................................................46
3.3.3 Installation...............................................................................................................................47
3.3.3.1 Lifting the enclosure off the transport pallet............................................................................47
3.3.3.2 Disassembling the lifting hardware .........................................................................................49
3.3.3.3 Connection to the foundation..................................................................................................50
3.3.4 Changing the enclosure type, options M23 and M54 .............................................................51
3.3.5 Line connection from above (option M13), motor connection from above (option M78) ........51

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4 Electrical installation ............................................................................................................................. 53
4.1 Content of this chapter........................................................................................................... 53
4.2 Checklist for electrical installation.......................................................................................... 54
4.2.1 Checklist for electrical installation.......................................................................................... 54
4.3 Important safety precautions.................................................................................................. 59
4.4 Introduction to EMC ............................................................................................................... 60
4.5 EMC-compliant design........................................................................................................... 62
4.6 Power connections................................................................................................................. 64
4.6.1 Cable lugs .............................................................................................................................. 65
4.6.2 Connection cross-sections, cable lengths ............................................................................. 66
4.6.3 Connection of shielded three-phase current cables .............................................................. 67
4.6.4 Connecting the motor and power cables ............................................................................... 67
4.6.5 Adjusting the fan voltage (-G1-T10, -T1-T10)........................................................................ 71
4.6.6 Adjusting the internal power supply (-T10) ............................................................................ 73
4.6.7 Removing the connection clip to the basic interference suppression module for
operation on an ungrounded supply system (IT system)....................................................... 74
4.6.8 Setting the circuit breaker ...................................................................................................... 80
4.7 External supply of the auxiliary incoming supply from a protected supply system................ 81
4.7.1 115 V AC auxiliary incoming supply....................................................................................... 82
4.8 Signal connections................................................................................................................. 82
4.8.1 CU320-2 DP Control Unit....................................................................................................... 82
4.8.2 Customer terminal block ........................................................................................................ 97
4.8.2.1 Customer interface / shield connection.................................................................................. 97
4.8.2.2 Customer terminal block (-A60) ............................................................................................. 99
4.8.2.3 Customer terminal block (-X65) (with option G65)............................................................... 101
4.8.2.4 Terminal descriptions........................................................................................................... 103
4.9 Additional connections ......................................................................................................... 109
4.9.1 Infeed module rated one level lower (option L04)................................................................ 110
4.9.2 dv/dt filter plus Voltage Peak Limiter (option L10) ............................................................... 114
4.9.3 Feeder for external auxiliaries / motor blower (option L17) ................................................. 118
4.9.4 Line filter monitoring (option L40) ........................................................................................ 120
4.9.5 Enclosure light with service socket (option L50).................................................................. 121
4.9.6 Enclosure space heater (option L55)................................................................................... 121
4.9.7 ALL STOP, coast to stop (Option N55)................................................................................ 122
4.9.8 EMERGENCY OFF category 0; 115 V AC or 24 V DC (option N57) .................................. 123
4.9.9 EMERGENCY STOP category 1; 115 V AC (option N59)................................................... 124
4.9.10 EMERGENCY STOP category 1; 24 V DC (option L60) ..................................................... 125
4.9.11 25 kW braking unit (option L61/L64); 50 kW braking unit (option L62/L65)......................... 126
4.9.11.1 Installing the braking resistor ............................................................................................... 127
4.9.11.2 Commissioning..................................................................................................................... 130
4.9.11.3 Diagnostics and duty cycles................................................................................................. 131
4.9.11.4 Threshold switch .................................................................................................................. 132
4.9.12 Line-side surge arrester (option L96)................................................................................... 137
4.9.13 Insulation monitor (option L87) ............................................................................................ 137
4.9.14 Control power supply, 120 V AC, 5 A (option N70) ............................................................. 139
4.9.15 CAN Communication Board CBC10 (option G20) ............................................................... 141
4.9.16 PROFINET Communication Board CBE20 (option G33)..................................................... 144
4.9.17 TM150 Temperature Sensor Module (option G51, G52)..................................................... 147

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4.9.17.1 Description ............................................................................................................................147
4.9.17.2 Connecting............................................................................................................................148
4.9.17.3 Connection examples ...........................................................................................................151
4.9.18 SMC10 Sensor Module Cabinet-Mounted (option K46) .......................................................153
4.9.18.1 Description ............................................................................................................................153
4.9.18.2 Connection............................................................................................................................154
4.9.18.3 Connection example .............................................................................................................156
4.9.19 SMC20 Sensor Module Cabinet-Mounted (option K48) .......................................................158
4.9.19.1 Description ............................................................................................................................158
4.9.19.2 Connection............................................................................................................................159
4.9.19.3 Connection example .............................................................................................................161
4.9.20 SMC30 Sensor Module Cabinet-Mounted (option K50) .......................................................163
4.9.20.1 Description ............................................................................................................................163
4.9.20.2 Connection............................................................................................................................168
4.9.20.3 Connection examples ...........................................................................................................172
4.9.21 Voltage Sensing Module for acquiring the motor speed and the phase angle (option
K51).......................................................................................................................................173
4.9.22 Additional SMC30 Sensor Module Cabinet-Mounted (option K52) ......................................174
4.9.23 Additional customer terminal block TM31 (option G61)........................................................174
4.9.24 TM31 wired to customer terminal block (option G65)...........................................................175
4.9.25 Additional TM31 (option G61) wired to customer terminal block (option G66).....................175
4.9.26 Safety license for 1 axis (option K01) ...................................................................................175
4.9.27 Terminal module for activation of "Safe Torque Off" and "Safe Stop 1" (option K82)..........176
4.9.28 TM54F Terminal Module (option K87) ..................................................................................177
4.9.29 Safe Brake Adapter SBA 230 V AC (option K88) .................................................................179
4.9.30 Control Unit CU320-2 PN (option K95).................................................................................180
5 Commissioning ................................................................................................................................... 193
5.1 Chapter content ....................................................................................................................193
5.2 The STARTER commissioning tool ......................................................................................194
5.2.1 Installing the STARTER commissioning tool ........................................................................196
5.2.2 Layout of the STARTER user interface ................................................................................196
5.3 Procedure for commissioning with STARTER......................................................................197
5.3.1 Creating the project...............................................................................................................197
5.3.2 Configuring the drive unit......................................................................................................205
5.3.3 Transferring the drive project................................................................................................234
5.3.4 Commissioning with STARTER via Ethernet........................................................................236
5.4 Operator panel AOP30 .........................................................................................................242
5.5 Initial commissioning with the AOP30...................................................................................243
5.5.1 Initial startup..........................................................................................................................243
5.5.2 Basic commissioning ............................................................................................................245
5.5.3 Status after commissioning...................................................................................................256
5.5.4 Commissioning an encoder with gear factor ........................................................................257
5.5.5 Parameter reset to factory settings.......................................................................................257

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6 Operation.............................................................................................................................................259
6.1 Chapter content.................................................................................................................... 259
6.2 General information about command and setpoint sources ................................................ 260
6.3 Basic information about the drive system ............................................................................ 261
6.3.1 Parameters........................................................................................................................... 261
6.3.2 Drive objects ........................................................................................................................ 264
6.3.3 Data sets .............................................................................................................................. 265
6.3.4 BICO technology: Interconnecting signals........................................................................... 271
6.3.5 Propagation of faults ............................................................................................................ 277
6.4 Command sources............................................................................................................... 278
6.4.1 "PROFIdrive" default setting ................................................................................................ 278
6.4.2 "TM31 terminals" default setting .......................................................................................... 280
6.5 Setpoint sources .................................................................................................................. 282
6.5.1 Analog inputs ....................................................................................................................... 282
6.5.2 Motorized potentiometer ...................................................................................................... 284
6.5.3 Fixed speed setpoints .......................................................................................................... 285
6.6 Control via the operator panel.............................................................................................. 287
6.6.1 Operator panel (AOP30) overview and menu structure....................................................... 287
6.6.2 Operation screen menu ....................................................................................................... 289
6.6.3 Parameterization menu........................................................................................................ 290
6.6.4 Fault/alarm memory menu ................................................................................................... 292
6.6.5 Commissioning/service menu .............................................................................................. 293
6.6.5.1 Drive commissioning............................................................................................................ 293
6.6.5.2 Device commissioning ......................................................................................................... 293
6.6.5.3 Drive diagnostics.................................................................................................................. 294
6.6.5.4 AOP settings ........................................................................................................................ 295
6.6.5.5 AOP diagnostics................................................................................................................... 303
6.6.6 Language selection.............................................................................................................. 305
6.6.7 Operation via the operator panel (LOCAL mode) ................................................................ 305
6.6.7.1 LOCAL/REMOTE key .......................................................................................................... 306
6.6.7.2 ON key / OFF key ................................................................................................................ 306
6.6.7.3 CCW/CW selection .............................................................................................................. 307
6.6.7.4 Jog ....................................................................................................................................... 307
6.6.7.5 Increase setpoint / decrease setpoint .................................................................................. 307
6.6.7.6 AOP setpoint ........................................................................................................................ 308
6.6.7.7 Inhibit AOP LOCAL mode .................................................................................................... 309
6.6.7.8 Acknowledge fault from the AOP ......................................................................................... 309
6.6.7.9 CDS setting via AOP............................................................................................................ 309
6.6.7.10 Operator input inhibit / Parameterization inhibit
................................................................... 310
6.6.8 Faults and alarms................................................................................................................. 311
6.6.9 Saving the parameters permanently .................................................................................... 313
6.6.10 Parameterization errors ....................................................................................................... 313
6.7 Communication according to PROFIdrive ........................................................................... 314
6.7.1 General information ............................................................................................................. 314
6.7.2 Application classes .............................................................................................................. 316
6.7.3 Cyclic communication .......................................................................................................... 317
6.7.3.1 Message frames and process data...................................................................................... 318
6.7.3.2 Structure of the telegrams.................................................................................................... 320
6.7.3.3 Overview of control words and setpoints ............................................................................. 321

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6.7.3.4 Overview of status words and actual values.........................................................................322
6.7.4 Acyclic communication..........................................................................................................322
6.7.4.1 Structure of requests and responses....................................................................................324
6.7.4.2 Determining the drive object numbers ..................................................................................330
6.7.4.3 Example 1: Reading parameters ..........................................................................................330
6.7.4.4 Example 2: Writing parameters (multi-parameter request)...................................................332
6.7.5 Diagnostic channels..............................................................................................................336
6.7.5.1 Diagnostics via PROFINET ..................................................................................................337
6.7.5.2 Diagnostics via PROFIBUS ..................................................................................................339
6.7.6 Further information about PROFIdrive communication ........................................................343
6.8 Communication via PROFIBUS DP......................................................................................344
6.8.1 PROFIBUS port ....................................................................................................................344
6.8.2 Control via PROFIBUS .........................................................................................................348
6.8.3 Monitoring: Message frame failure .......................................................................................350
6.8.4 Creating an S150 in SIMATIC Manager ...............................................................................351
6.8.5 Further information about communication via PROFIBUS DP.............................................353
6.9 Communication via PROFINET IO .......................................................................................354
6.9.1 Activating online operation: STARTER via PROFINET IO ...................................................354
6.9.2 General information about PROFINET IO ............................................................................358
6.9.2.1 General information about PROFINET IO for SINAMICS ....................................................358
6.9.2.2 Real-time (RT) and isochronous real-time (IRT) communication .........................................359
6.9.2.3 Addresses .............................................................................................................................360
6.9.2.4 Data transmission .................................................................................................................362
6.9.2.5 Communication channels .....................................................................................................363
6.9.3 PROFINET media redundancy .............................................................................................364
6.9.4 PROFINET system redundancy ...........................................................................................365
6.9.4.1 Overview ...............................................................................................................................365
6.9.4.2 Design, configuring and diagnostics .....................................................................................366
6.9.4.3 Faults, alarms and parameters .............................................................................................367
6.9.5 Communication with CBE20 .................................................................................................368
6.9.5.1 Selecting the CBE20 firmware..............................................................................................368
6.9.5.2 EtherNet/IP ...........................................................................................................................368
6.9.6 PROFIenergy ........................................................................................................................369
6.9.6.1 Description ............................................................................................................................369
6.9.6.2 Tasks of PROFIenergy .........................................................................................................370
6.9.6.3 PROFIenergy - Properties of the drive system.....................................................................370
6.9.6.4 PROFIenergy - Commands ..................................................................................................
371
6.9.6.5 PROFIenergy - Measurement values ...................................................................................372
6.9.6.6 PROFIenergy - Energy-saving mode....................................................................................372
6.9.6.7 Disabling PROFIenergy and pause time ..............................................................................373
6.9.6.8 PROFIenergy applications....................................................................................................373
6.9.6.9 Function diagrams and parameters ......................................................................................374
6.9.7 Support of I&M data sets 1...4 ..............................................................................................374
6.9.8 Further information about communication via PROFINET IO ..............................................377
6.10 Communication via SINAMICS Link .....................................................................................377
6.10.1 Basic principles of SINAMICS Link.......................................................................................377
6.10.2 Topology ...............................................................................................................................379
6.10.3 Configuring and commissioning............................................................................................381
6.10.4 Example ................................................................................................................................385
6.10.5 Communication failure when booting or in cyclic operation..................................................388
6.10.6 Transmission times for SINAMICS Link................................................................................389

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6.10.7 Function diagrams and parameters ..................................................................................... 390
6.11 Communication via EtherNet/IP........................................................................................... 391
6.11.1 Overview .............................................................................................................................. 391
6.11.2 Connect drive device to Ethernet/IP .................................................................................... 391
6.11.3 Configuring communication ................................................................................................. 392
6.11.4 Supported objects ................................................................................................................ 393
6.11.5 Integrate the drive device into the Ethernet network via DHCP .......................................... 402
6.11.6 Parameters, faults and alarms ............................................................................................. 403
6.12 Communication via MODBUS TCP ..................................................................................... 404
6.12.1 Overview .............................................................................................................................. 404
6.12.2 Configuring Modbus TCP via interface X150....................................................................... 405
6.12.3 Configuring Modbus TCP via interface X1400..................................................................... 406
6.12.4 Mapping tables..................................................................................................................... 407
6.12.5 Write and read access using function codes ....................................................................... 410
6.12.6 Communication via data set 47............................................................................................ 412
6.12.6.1 Communication details......................................................................................................... 413
6.12.6.2 Examples: Read parameters ............................................................................................... 414
6.12.6.3 Examples: Write parameter ................................................................................................. 415
6.12.7 Communication procedure................................................................................................... 416
6.12.8 Parameters, faults and alarms ............................................................................................. 417
6.13 Communication services and used port numbers................................................................ 418
6.14 Parallel operation of communication interfaces ................................................................... 420
6.15 Engineering Software Drive Control Chart (DCC) ............................................................... 424
7 Setpoint channel and closed-loop control .............................................................................................425
7.1 Section content .................................................................................................................... 425
7.2 Setpoint channel .................................................................................................................. 426
7.2.1 Setpoint addition .................................................................................................................. 426
7.2.2 Direction reversal ................................................................................................................. 427
7.2.3 Skip frequency bands and minimum speed......................................................................... 428
7.2.4 Speed limiting....................................................................................................................... 429
7.2.5 Ramp-function generator ..................................................................................................... 430
7.3 V/f (V/Hz) control.................................................................................................................. 434
7.3.1 Voltage boost ....................................................................................................................... 437
7.3.2 Resonance damping ............................................................................................................ 440
7.3.3 Slip compensation................................................................................................................ 441
7.4 Vector speed/torque control with/without an encoder.......................................................... 443
7.4.1 Vector control without an encoder ....................................................................................... 444
7.4.2 Vector control with encoder ................................................................................................. 451
7.4.3 Actual speed value filter....................................................................................................... 452
7.4.4 Speed controller ................................................................................................................... 453
7.4.4.1 Speed controller feedfoward control (integrated feedfoward control with balancing).......... 456
7.4.4.2 Reference model.................................................................................................................. 459
7.4.4.3 Speed controller adaptation ................................................................................................. 460
7.4.4.4 Droop ................................................................................................................................... 462
7.4.4.5 Open actual speed value ..................................................................................................... 464
7.4.5 Torque control ...................................................................................................................... 466
7.4.6 Torque limiting...................................................................................................................... 468

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7.4.7 Current setpoint filter.............................................................................................................470
7.4.8 Current controller adaptation ................................................................................................471
7.4.9 Permanent-magnet synchronous motors..............................................................................472
8 Output terminals.................................................................................................................................. 477
8.1 Section content .....................................................................................................................477
8.2 Analog outputs ......................................................................................................................478
8.2.1 List of signals for the analog signals.....................................................................................479
8.3 Digital outputs .......................................................................................................................482
9 Functions, monitoring and protective functions .................................................................................... 485
9.1 Section content .....................................................................................................................485
9.2 Active Infeed functions..........................................................................................................486
9.2.1 Line and DC link identification ..............................................................................................486
9.2.2 Harmonics controller .............................................................................................................487
9.2.3 Variable power factor (reactive power compensation) .........................................................488
9.2.4 Settings for the infeed (Active Infeed) under difficult line conditions ....................................489
9.3 Drive functions ......................................................................................................................491
9.3.1 Motor data identification and automatic speed controller optimization.................................491
9.3.1.1 Motor data identification........................................................................................................492
9.3.1.2 Rotating measurement and speed controller optimization ...................................................495
9.3.1.3 Shortened rotating measurement .........................................................................................497
9.3.1.4 Parameters ...........................................................................................................................498
9.3.2 Efficiency optimization ..........................................................................................................498
9.3.3 Fast magnetization for induction motors...............................................................................500
9.3.4 VDC control...........................................................................................................................502
9.3.5 Automatic restart function .....................................................................................................506
9.3.6 Flying restart .........................................................................................................................509
9.3.6.1 Flying restart without an encoder..........................................................................................510
9.3.6.2 Flying restart with an encoder...............................................................................................513
9.3.6.3 Parameters ...........................................................................................................................514
9.3.7 Checking for a short-circuit/ground fault at a motor..............................................................515
9.3.8 Motor changeover .................................................................................................................516
9.3.8.1 Description ............................................................................................................................516
9.3.8.2 Example of changing over between two motors...................................................................516
9.3.8.3 Function diagrams ................................................................................................................518
9.3.8.4 Parameters ...........................................................................................................................518
9.3.9 Friction Characteristic ...........................................................................................................518
9.3.10 Armature short-circuit braking, DC braking...........................................................................520
9.3.10.1 General information ..............................................................................................................520
9.3.10.2 External armature short-circuit braking.................................................................................521
9.3.10.3 Internal armature short-circuit braking ..................................................................................522
9.3.10.4 DC braking ............................................................................................................................524
9.3.11 Increasing the output frequency ...........................................................................................526
9.3.11.1 Description ............................................................................................................................526
9.3.11.2 Default pulse frequencies .....................................................................................................527
9.3.11.3 Increasing the pulse frequency.............................................................................................527
9.3.11.4 Maximum output frequency achieved by increasing the pulse frequency ............................528
9.3.11.5 Parameters ...........................................................................................................................528
9.3.12 Derating behavior with increased pulse frequency...............................................................529

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14 Operating Instructions, 11/2017, A5E36652151A
9.3.13 Pulse frequency wobbling .................................................................................................... 530
9.3.14 Runtime (operating hours counter) ...................................................................................... 532
9.3.15 Simulation mode .................................................................................................................. 533
9.3.16 Direction reversal ................................................................................................................. 534
9.3.17 Unit switchover..................................................................................................................... 536
9.3.18 Simple brake control ............................................................................................................ 538
9.3.19 Synchronization.................................................................................................................... 541
9.3.20 Energy savings indicator for pumps, fans, and compressors .............................................. 542
9.3.21 Write protection .................................................................................................................... 545
9.3.22 Know-how protection ........................................................................................................... 547
9.3.22.1 Description ........................................................................................................................... 547
9.3.22.2 Activating know-how protection ........................................................................................... 549
9.3.22.3 Deactivating know-how protection ....................................................................................... 550
9.3.22.4 Changing the know-how protection password ..................................................................... 551
9.3.22.5 OEM exception list ............................................................................................................... 551
9.3.22.6 Memory card copy protection............................................................................................... 552
9.3.22.7 Spare part replacement when know-how protection with copy protection is activated ....... 552
9.3.22.8 Overview of important parameters....................................................................................... 553
9.3.23 Emergency operation........................................................................................................... 554
9.3.24 Web server........................................................................................................................... 558
9.3.24.1 Description ........................................................................................................................... 558
9.3.24.2 Starting the Web server ....................................................................................................... 560
9.3.24.3 Web server configuration ..................................................................................................... 563
9.3.24.4 Display areas ....................................................................................................................... 564
9.3.24.5 Overview of important parameters....................................................................................... 566
9.3.25 Tolerant encoder monitoring ................................................................................................ 566
9.3.25.1 General information ............................................................................................................. 566
9.3.25.2 Encoder track monitoring ..................................................................................................... 567
9.3.25.3 Zero mark tolerance............................................................................................................. 568
9.3.25.4 Freezing the actual speed for dn/dt errors........................................................................... 569
9.3.25.5 Adjustable hardware filter .................................................................................................... 569
9.3.25.6 Edge evaluation of the zero mark ........................................................................................ 570
9.3.25.7 Signal edge evaluation (1x, 4x)............................................................................................ 571
9.3.25.8 Setting the measuring time to evaluate speed "0" ............................................................... 571
9.3.25.9 Sliding averaging of the speed actual value ........................................................................ 572
9.3.25.10 Rotor position adaptation ..................................................................................................... 572
9.3.25.11 Pulse number correction for faults ....................................................................................... 573
9.3.25.12 "Tolerance band pulse number" monitoring......................................................................... 574
9.3.25.13 Troubleshooting, causes and remedies............................................................................... 575
9.3.25.14 Tolerance window and correction ........................................................................................ 577
9.3.25.15 Dependencies ...................................................................................................................... 577
9.3.25.16 Overview of important parameters....................................................................................... 579
9.3.26 Position tracking................................................................................................................... 580
9.3.26.1 General information ............................................................................................................. 580
9.3.26.2 Measuring gearbox .............................................................................................................. 581
9.4 Extended functions .............................................................................................................. 586
9.4.1 Technology controller........................................................................................................... 586
9.4.2 Bypass function.................................................................................................................... 589
9.4.2.1 Synchronized bypass with overlap (p1260 = 1)................................................................... 590
9.4.2.2 Synchronized bypass without overlap (p1260 = 2).............................................................. 594
9.4.2.3 Bypass without synchronization (p1260 = 3) ....................................................................... 596
9.4.2.4 Function diagram ................................................................................................................. 598

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9.4.2.5 Parameters ...........................................................................................................................598
9.4.3 Extended brake control.........................................................................................................599
9.4.4 Extended monitoring functions .............................................................................................604
9.4.5 Moment of inertia estimator ..................................................................................................606
9.4.6 Position control .....................................................................................................................612
9.4.6.1 Position actual value conditioning.........................................................................................613
9.4.6.2 Position controller .................................................................................................................624
9.4.6.3 Monitoring functions..............................................................................................................625
9.4.6.4 Measuring probe evaluation and reference mark search .....................................................627
9.4.7 Basic positioner.....................................................................................................................629
9.4.7.1 Mechanical system ...............................................................................................................631
9.4.7.2 Limitations.............................................................................................................................633
9.4.7.3 Basic positioner and safe setpoint velocity limitation............................................................638
9.4.7.4 Referencing...........................................................................................................................638
9.4.7.5 Referencing with several zero marks per revolution.............................................................648
9.4.7.6 Safely referencing under EPOS............................................................................................651
9.4.7.7 Traversing blocks..................................................................................................................653
9.4.7.8 Travel to fixed stop................................................................................................................659
9.4.7.9 Direct setpoint input (MDI) ....................................................................................................662
9.4.7.10 Jogging .................................................................................................................................665
9.4.7.11 Status signals........................................................................................................................665
9.4.8 Parameterizable bandstop filters for the active infeed..........................................................668
9.5 Monitoring functions and protective functions ......................................................................670
9.5.1 Power unit protection, general ..............................................................................................670
9.5.2 Thermal monitoring and overload responses .......................................................................671
9.5.3 Blocking protection................................................................................................................673
9.5.4 Stall protection (vector control only) .....................................................................................674
9.5.5 Thermal motor protection......................................................................................................675
9.5.5.1 Description ............................................................................................................................675
9.5.5.2 Temperature sensor connection to customer terminal module TM31 (option G60) .............675
9.5.5.3 Temperature sensor connection to a sensor module (option K50) ......................................676
9.5.5.4 Temperature sensor connection directly to the control interface module.............................677
9.5.5.5 Temperature sensor evaluation ............................................................................................678
9.5.5.6 Thermal motor models..........................................................................................................679
9.5.5.7 Function diagrams ................................................................................................................682
9.5.5.8 Parameters ...........................................................................................................................682
9.5.6 Temperature measurement via TM150 (option G51) ...........................................................683
9.5.6.1 Description ............................................................................................................................683
9.5.6.2 Measurement with up to 6 channels .....................................................................................685
9.5.6.3 Measurement with up to 12 channels ...................................................................................685
9.5.6.4 Forming groups of temperature sensors...............................................................................686
9.5.6.5 Evaluation of temperature channels .....................................................................................687
9.5.6.6 Function diagrams ................................................................................................................688
9.5.6.7 Parameters ...........................................................................................................................688
10 Diagnostics / faults and alarms............................................................................................................ 689
10.1 Chapter content ....................................................................................................................689
10.2 Diagnostics ...........................................................................................................................690
10.2.1 Diagnostics via LEDs............................................................................................................690
10.2.2 Diagnostics via parameters ..................................................................................................700
10.2.3 Indicating and rectifying faults ..............................................................................................704

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16 Operating Instructions, 11/2017, A5E36652151A
10.3 Overview of alarms and faults.............................................................................................. 705
10.3.1 "External alarm 1" ................................................................................................................ 706
10.3.2 "External fault 1"................................................................................................................... 706
10.3.3 "External Fault 2" ................................................................................................................. 707
10.3.4 "External fault 3"................................................................................................................... 707
11 Maintenance and servicing...................................................................................................................709
11.1 Chapter content.................................................................................................................... 709
11.2 Maintenance......................................................................................................................... 710
11.2.1 Cleaning ............................................................................................................................... 710
11.3 Servicing .............................................................................................................................. 711
11.3.1 Installation device................................................................................................................. 712
11.3.2 Using lifting lugs to transport power blocks ......................................................................... 713
11.4 Replacing components ........................................................................................................ 715
11.4.1 Replacing the filter mats ...................................................................................................... 715
11.4.2 Replacing the Control Interface Module, frame size FX ...................................................... 716
11.4.3 Replacing the Control Interface Module, frame size GX ..................................................... 718
11.4.4 Replacing the Control Interface Module, frame size HX...................................................... 720
11.4.5 Replacing the Control Interface Module, frame size JX ...................................................... 722
11.4.6 Replacing the power block, frame size FX .......................................................................... 724
11.4.7 Replacing the power block, frame size GX.......................................................................... 726
11.4.8 Replacing the power block, frame size HX .......................................................................... 728
11.4.9 Replacing the power block, frame size JX........................................................................... 732
11.4.10 Replacing the fan, frame size FX......................................................................................... 734
11.4.11 Replacing the fan, frame size GX ........................................................................................ 736
11.4.12 Replacing the fan, size HX................................................................................................... 738
11.4.13 Replacing the fan, frame size JX ......................................................................................... 742
11.4.14 Replacing the fan in the Active Interface Module (frame size FI) ........................................ 744
11.4.15 Replacing the fan in the Active Interface Module (frame size GI) ....................................... 746
11.4.16 Replacing the fan in the Active Interface Module (frame size HI)........................................ 748
11.4.17 Replacing the fan in the Active Interface Module (frame size JI) ........................................ 750
11.4.18 Replacing the DC fuses in the Active Line Module, Motor Module, frame size HX............. 752
11.4.19 Replacing the DC fuses in the Active Line Module, Motor Module, frame size JX.............. 755
11.4.20 Replacing cylindrical fuses................................................................................................... 757
11.4.21 Replacement of LV HRC fuses with blade contacts ............................................................ 758
11.4.22 Replacement of LV HRC fuses with screw mounting .......................................................... 760
11.4.23 Replacing the door-mounted operator panel ....................................................................... 762
11.4.24 Replacing the backup battery for the door-mounted operator panel ................................... 762
11.5 Forming the DC link capacitors............................................................................................ 764
11.6 Messages after replacement of DRIVE-CLiQ components ................................................. 765
11.7 Upgrading the drive firmware............................................................................................... 766
11.8 Downloading new operator panel firmware from the PC ..................................................... 767

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12 Technical specifications ...................................................................................................................... 769
12.1 Chapter content ....................................................................................................................769
12.2 General data .........................................................................................................................770
12.2.1 Derating data ........................................................................................................................771
12.2.1.1 Current derating as a function of the ambient temperature ..................................................771
12.2.1.2 Installation altitudes over 6600 ft and up to 16500 ft above MSL.........................................772
12.2.1.3 Current derating as a function of the pulse frequency..........................................................773
12.2.2 Overload capability ...............................................................................................................775
12.3 Technical specifications ........................................................................................................776
12.3.1 Cabinet units, 380 V ... 480 V 3 AC ......................................................................................777
12.3.2 Cabinet units, 500 ... 690 V 3 AC .........................................................................................785
A Appendix............................................................................................................................................. 797
A.1 Acronyms and abbreviations ................................................................................................797
A.2 Parameter macros ................................................................................................................799
Index................................................................................................................................................... 811

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18 Operating Instructions, 11/2017, A5E36652151A