Siemens SINAMICS S150 NEMA User manual

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SINAMICS
SINAMICS S150 NEMA
Enclosed Drives
Operating Instructions
Firmware version V5.2
12/2018
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
Ⓟ
01/2019 Subject to change
Copyright © Siemens AG 2015 - 2018.
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, 12/2018, 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

Preface
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4Operating Instructions, 12/2018, A5E36652151A
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.
●
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)

Preface
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Operating Instructions, 12/2018, A5E36652151A 5
Siemens Support for on the move
With the "Siemens Industry Online Support" App, you can access more than 300,000
documents relating to Siemens Industry products – any time and from anywhere.
The App supports you in the following areas:
●Resolving problems when executing a project
●Troubleshooting when faults develop
●Expansion of a plant or a new plant
Further, you have access to the Technical Forum and other articles that our experts have
drawn-up:
●FAQs
●Application examples
●Manuals
●Certificates
●Product announcements and much more
The "Siemens Industry Online Support" App is available for Apple iOS and Android.
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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6Operating Instructions, 12/2018, A5E36652151A
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
Web sites of third-party companies
This document includes hyperlinks to web sites of third-party companies Siemens accepts
no responsibility for the content of these web sites, nor does it use these web sites and their
content for its own use, as Siemens cannot check these web sites and is also not
responsible for the content and information provided on them. The user uses these web sites
at his own risk.
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.
Compliance with the General Data Protection Regulation
Siemens respects the principles of data protection, in particular the data minimization rules
(privacy by design).
For this product, this means:
The product does not process or store any person-related data, only technical function data
(e.g. time stamps). If the user links this data with other data (e.g. shift plans) or if he/she
stores personal data on the same data medium (e.g. hard disk), thus personalizing this data,
he/she has to ensure compliance with the applicable data protection stipulations.

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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....................................................................................28
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 .......................................................................................................................... 41
3.1 Chapter content ......................................................................................................................41
3.2 Transportation and storage.....................................................................................................41
3.3 Installation...............................................................................................................................43
3.3.1 Mechanical installation: checklist............................................................................................44
3.3.2 Preparation .............................................................................................................................45
3.3.2.1 Requirements for installation location.....................................................................................45
3.3.2.2 Requirements on the levelness of the floor ............................................................................45
3.3.2.3 Shipping and handling monitors .............................................................................................46
3.3.2.4 Unpacking ...............................................................................................................................48
3.3.2.5 Required tools.........................................................................................................................48
3.3.3 Installation...............................................................................................................................49
3.3.3.1 Lifting the cabinet off the transport pallet................................................................................49
3.3.3.2 Removing the crane transport aids.........................................................................................50
3.3.3.3 Connection to the foundation..................................................................................................52
3.3.4 Changing the enclosure type, options M23 and M54 .............................................................52
3.3.5 Line connection from above (option M13), motor connection from above (option M78) ........53

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4 Electrical installation ............................................................................................................................. 55
4.1 Chapter content...................................................................................................................... 55
4.2 Checklist for electrical installation .......................................................................................... 56
4.3 Important safety precautions.................................................................................................. 62
4.4 Introduction to EMC ............................................................................................................... 63
4.5 EMC-compliant design........................................................................................................... 65
4.6 Power connections................................................................................................................. 67
4.6.1 Cable lugs .............................................................................................................................. 68
4.6.2 Connection cross-sections, cable lengths ............................................................................. 69
4.6.3 Connecting shielded three-phase current cables .................................................................. 70
4.6.4 Connecting the motor and power cables ............................................................................... 70
4.6.5 Adjusting the fan voltage (-G1-T10, -T1-T10)........................................................................ 74
4.6.6 Adjusting the internal power supply (-T10) ............................................................................ 76
4.6.7 Removing the connection clip to the basic interference suppression module for
operation on an ungrounded supply system (IT system)....................................................... 77
4.6.8 Setting the circuit breaker ...................................................................................................... 82
4.7 External supply of the auxiliary incoming supply from a protected supply system................ 84
4.7.1 115 V AC auxiliary incoming supply....................................................................................... 85
4.8 Signal connections ................................................................................................................. 85
4.8.1 CU320-2 DP Control Unit....................................................................................................... 85
4.8.2 Customer terminal block ...................................................................................................... 102
4.8.2.1 Customer interface / shield connection................................................................................ 102
4.8.2.2 Customer terminal block (-A60) ........................................................................................... 104
4.8.2.3 Customer terminal block (-X65) (with option G65)............................................................... 106
4.8.2.4 Terminal descriptions........................................................................................................... 108
4.9 Additional connections ......................................................................................................... 114
4.9.1 Infeed module rated one level lower (option L04)................................................................ 115
4.9.2 dv/dt filter plus Voltage Peak Limiter (option L10) ............................................................... 120
4.9.3 Feeder for external auxiliaries / motor blower (option L17) ................................................. 124
4.9.4 Line filter monitoring (option L40) ........................................................................................ 125
4.9.5 Enclosure light with service socket (option L50).................................................................. 126
4.9.6 Enclosure space heater (option L55)................................................................................... 127
4.9.7 ALL STOP, coast to stop (option N55) ................................................................................ 128
4.9.8 EMERGENCY OFF category 0; 115 V AC or 24 V DC (option N57) .................................. 128
4.9.9 EMERGENCY STOP category 1; 115 V AC (option N59)................................................... 130
4.9.10 EMERGENCY STOP category 1; 24 V DC (option L60) ..................................................... 131
4.9.11 25 kW braking unit (option L61/L64); 50 kW braking unit (option L62/L65)......................... 132
4.9.11.1 Installing the braking resistor ............................................................................................... 132
4.9.11.2 Commissioning..................................................................................................................... 136
4.9.11.3 Diagnosis and duty cycles ................................................................................................... 137
4.9.11.4 Threshold switch .................................................................................................................. 137
4.9.12 Line-side surge arrester (option L96)................................................................................... 142
4.9.13 Insulation monitor (option L87) ............................................................................................ 142
4.9.14 Control power supply, 120 V AC, 5 A (option N70) ............................................................. 144
4.9.15 CBC10 CAN Communication Board (option G20) ............................................................... 146
4.9.16 Communication Board Ethernet CBE20 (option G33) ......................................................... 149

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4.9.17 TM150 Temperature Sensor Module (option G51, G52)......................................................152
4.9.17.1 Description ............................................................................................................................152
4.9.17.2 Connecting............................................................................................................................153
4.9.17.3 Connection examples ...........................................................................................................156
4.9.18 SMC10 Sensor Module Cabinet-Mounted (option K46) .......................................................158
4.9.18.1 Description ............................................................................................................................158
4.9.18.2 Connection............................................................................................................................159
4.9.18.3 Connection example .............................................................................................................161
4.9.19 SMC20 Sensor Module Cabinet-Mounted (option K48) .......................................................163
4.9.19.1 Description ............................................................................................................................163
4.9.19.2 Connection............................................................................................................................164
4.9.19.3 Connection example .............................................................................................................166
4.9.20 SMC30 Sensor Module Cabinet-Mounted (option K50) .......................................................168
4.9.20.1 Description ............................................................................................................................168
4.9.20.2 Connection............................................................................................................................172
4.9.20.3 Connection examples ...........................................................................................................176
4.9.21 Voltage Sensing Module for determining the actual motor speed and the phase angle
(option K51) ..........................................................................................................................177
4.9.22 Additional SMC30 Sensor Module (option K52) ...................................................................178
4.9.23 Additional customer terminal block TM31 (option G61)........................................................178
4.9.24 TM31 wired to customer terminal block (option G65)...........................................................179
4.9.25 Additional TM31 (option G61) wired to customer terminal block (option G66).....................179
4.9.26 Safety license for 1 axis (option K01) ...................................................................................179
4.9.27 Terminal module for activation of "Safe Torque Off" and "Safe STOP 1" (option K82)........180
4.9.28 Terminal Module TM54F (option K87) ..................................................................................181
4.9.29 Safe Brake Adapter SBA 230 V AC (option K88) .................................................................183
4.9.30 Control Unit CU320-2 PN (option K95).................................................................................184
5 Commissioning ................................................................................................................................... 199
5.1 Chapter content ....................................................................................................................199
5.2 The STARTER commissioning tool ......................................................................................200
5.2.1 Installing the STARTER commissioning tool ........................................................................202
5.2.2 Layout of the STARTER user interface ................................................................................202
5.3 Procedure for commissioning with STARTER......................................................................203
5.3.1 Creating the project...............................................................................................................203
5.3.2 Configuring the drive unit......................................................................................................211
5.3.3 Transferring the drive project................................................................................................239
5.3.4 Commissioning with STARTER via Ethernet........................................................................241
5.4 The AOP30 operator panel...................................................................................................247
5.5 Initial commissioning with the AOP30...................................................................................248
5.5.1 First commissioning ..............................................................................................................248
5.5.2 Basic commissioning ............................................................................................................250
5.6 Status after commissioning...................................................................................................259
5.7 Commissioning an encoder with gear factor ........................................................................260
5.8 Parameter reset to factory settings.......................................................................................261

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6 Operation.............................................................................................................................................263
6.1 Chapter content.................................................................................................................... 263
6.2 General information about command and setpoint sources ................................................ 264
6.3 Basic information about the drive system ............................................................................ 265
6.3.1 Parameters........................................................................................................................... 265
6.3.2 Drive objects ........................................................................................................................ 268
6.3.3 Data sets .............................................................................................................................. 269
6.3.4 BICO technology: Interconnecting signals........................................................................... 275
6.3.5 Propagation of faults ............................................................................................................ 281
6.4 Command sources............................................................................................................... 282
6.4.1 "PROFIdrive" default setting ................................................................................................ 282
6.4.2 "TM31 terminals" default setting .......................................................................................... 284
6.5 Setpoint sources .................................................................................................................. 286
6.5.1 Analog inputs ....................................................................................................................... 286
6.5.2 Motorized potentiometer ...................................................................................................... 288
6.5.3 Fixed speed setpoints .......................................................................................................... 289
6.6 Control via the operator panel.............................................................................................. 291
6.6.1 Operator panel (AOP30) overview and menu structure....................................................... 291
6.6.2 Menu: Operation screen ...................................................................................................... 293
6.6.3 Parameterization menu........................................................................................................ 294
6.6.4 Fault/alarm memory menu ................................................................................................... 295
6.6.5 Commissioning/service menu.............................................................................................. 296
6.6.5.1 Drive commissioning............................................................................................................ 296
6.6.5.2 Device commissioning ......................................................................................................... 297
6.6.5.3 Drive diagnostics.................................................................................................................. 297
6.6.5.4 AOP settings ........................................................................................................................ 299
6.6.5.5 AOP diagnostics................................................................................................................... 307
6.6.6 Sprachauswahl/Language selection .................................................................................... 309
6.6.7 Operation via the operator panel (LOCAL mode) ................................................................ 309
6.6.7.1 LOCAL/REMOTE key .......................................................................................................... 310
6.6.7.2 ON key / OFF key ................................................................................................................ 310
6.6.7.3 Switching between clockwise and counter-clockwise rotation............................................. 311
6.6.7.4 Jog ....................................................................................................................................... 311
6.6.7.5 Increase setpoint / decrease setpoint .................................................................................. 311
6.6.7.6 AOP setpoint ........................................................................................................................ 312
6.6.7.7 Lock AOP LOCAL mode ...................................................................................................... 313
6.6.7.8 Acknowledge error from the AOP ........................................................................................ 313
6.6.7.9 CDS setting via AOP............................................................................................................ 313
6.6.7.10 Operator input inhibit / parameterization inhibit ................................................................... 314
6.6.8 Faults and alarms................................................................................................................. 315
6.6.9 Saving the parameters permanently.................................................................................... 317
6.6.10 Parameterization errors ....................................................................................................... 317
6.7 Communication according to PROFIdrive ........................................................................... 318
6.7.1 General information ............................................................................................................. 318
6.7.2 Application classes .............................................................................................................. 320
6.7.3 Cyclic communication .......................................................................................................... 322
6.7.3.1 Telegrams and process data ............................................................................................... 323
6.7.3.2 Structure of the telegrams.................................................................................................... 325
6.7.3.3 Overview of control words and setpoints ............................................................................. 326

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6.7.3.4 Overview of status words and actual values.........................................................................326
6.7.4 Acyclic communication..........................................................................................................327
6.7.4.1 Structure of requests and responses....................................................................................329
6.7.4.2 Determining the drive object numbers ..................................................................................335
6.7.4.3 Example 1: Reading parameters ..........................................................................................335
6.7.4.4 Example 2: Writing parameters (multi-parameter request)...................................................337
6.7.5 Diagnostic channels..............................................................................................................341
6.7.5.1 Diagnostics via PROFINET ..................................................................................................342
6.7.5.2 Diagnostics via PROFIBUS ..................................................................................................344
6.7.6 Further information about PROFIdrive communication ........................................................348
6.8 Communication via PROFIBUS DP......................................................................................349
6.8.1 PROFIBUS port ....................................................................................................................349
6.8.2 General information about PROFIBUS DP...........................................................................353
6.8.2.1 General information about PROFIBUS DP for SINAMICS...................................................353
6.8.2.2 Sequence of DOs in the telegram.........................................................................................355
6.8.3 Control via PROFIBUS .........................................................................................................356
6.8.4 Monitoring: Telegram failure .................................................................................................358
6.8.5 Creating an S150 in SIMATIC Manager ...............................................................................359
6.8.6 Further information about communication via PROFIBUS DP.............................................362
6.9 Communication via PROFINET IO .......................................................................................362
6.9.1 Activating online operation: STARTER via PROFINET IO ...................................................362
6.9.2 General information about PROFINET IO ............................................................................366
6.9.2.1 General information about PROFINET IO for SINAMICS ....................................................366
6.9.2.2 Real-time (RT) and isochronous real-time (IRT) communication .........................................367
6.9.2.3 Addresses .............................................................................................................................368
6.9.2.4 Dynamic IP address assignment ..........................................................................................371
6.9.2.5 DCP flashing .........................................................................................................................372
6.9.2.6 Data transmission .................................................................................................................373
6.9.2.7 Communication channels .....................................................................................................374
6.9.3 Communication with CBE20 .................................................................................................375
6.9.3.1 Selecting the CBE20 firmware..............................................................................................375
6.9.3.2 EtherNet/IP ...........................................................................................................................376
6.9.4 PROFINET media redundancy .............................................................................................376
6.9.5 PROFINET system redundancy ...........................................................................................377
6.9.5.1 Overview ...............................................................................................................................377
6.9.5.2 Design, configuring and diagnostics .....................................................................................378
6.9.5.3 Faults, alarms and parameters .............................................................................................379
6.9.6 PROFIenergy ........................................................................................................................380
6.9.6.1 Description ............................................................................................................................380
6.9.6.2 Tasks of PROFIenergy .........................................................................................................381
6.9.6.3 PROFIenergy commands .....................................................................................................382
6.9.6.4 PROFIenergy measured values ...........................................................................................384
6.9.6.5 PROFIenergy energy-saving mode ......................................................................................384
6.9.6.6 PROFIenergy inhibit and pause time....................................................................................385
6.9.6.7 Function diagrams and parameters ......................................................................................385
6.9.7 Support of I&M data sets 1...4 ..............................................................................................386
6.9.8 Further information about communication via PROFINET IO ..............................................388
6.10 Communication via SINAMICS Link .....................................................................................388
6.10.1 Basic principles of SINAMICS Link.......................................................................................388
6.10.2 Topology ...............................................................................................................................390
6.10.3 Configuring and commissioning............................................................................................392

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6.10.4 Example ............................................................................................................................... 396
6.10.5 Communication failure when booting or in cyclic operation................................................. 399
6.10.6 Transmission times for SINAMICS Link............................................................................... 399
6.10.7 Function diagrams and parameters ..................................................................................... 400
6.11 Communication via EtherNet/IP........................................................................................... 401
6.11.1 Overview .............................................................................................................................. 401
6.11.2 Connect drive device to Ethernet/IP .................................................................................... 401
6.11.3 Configuring communication ................................................................................................. 403
6.11.4 Supported objects ................................................................................................................ 404
6.11.5 Integrate the drive device into the Ethernet network via DHCP .......................................... 414
6.11.6 Parameters, faults and alarms ............................................................................................. 415
6.12 Communication via MODBUS TCP ..................................................................................... 417
6.12.1 Overview .............................................................................................................................. 417
6.12.2 Configuring Modbus TCP via interface X150....................................................................... 418
6.12.3 Configuring Modbus TCP via interface X1400..................................................................... 419
6.12.4 Mapping tables..................................................................................................................... 420
6.12.5 Write and read access using function codes ....................................................................... 423
6.12.6 Communication via data set 47............................................................................................ 425
6.12.6.1 Communication details......................................................................................................... 426
6.12.6.2 Examples: Read parameters ............................................................................................... 427
6.12.6.3 Examples: Write parameter ................................................................................................. 428
6.12.7 Communication procedure................................................................................................... 429
6.12.8 Parameters, faults and alarms ............................................................................................. 430
6.13 Communication services and used port numbers................................................................ 431
6.14 Parallel operation of communication interfaces ................................................................... 433
6.15 Engineering Software Drive Control Chart (DCC) ............................................................... 437
7 Setpoint channel and closed-loop control .............................................................................................439
7.1 Section content .................................................................................................................... 439
7.2 Setpoint channel .................................................................................................................. 440
7.2.1 Setpoint addition .................................................................................................................. 440
7.2.2 Direction reversal ................................................................................................................. 441
7.2.3 Skip frequency bands and minimum speed......................................................................... 442
7.2.4 Speed limitation.................................................................................................................... 443
7.2.5 Ramp-function generator ..................................................................................................... 444
7.3 V/f (V/Hz) control.................................................................................................................. 448
7.3.1 Voltage boost ....................................................................................................................... 451
7.3.2 Resonance damping ............................................................................................................ 454
7.3.3 Slip compensation................................................................................................................ 455
7.4 Vector speed/torque control with/without an encoder.......................................................... 457
7.4.1 Vector control without encoder ............................................................................................ 458
7.4.2 Vector control with encoder ................................................................................................. 465
7.4.3 Actual speed value filter....................................................................................................... 466
7.4.4 Speed controller ................................................................................................................... 467
7.4.4.1 Examples of speed controller settings ................................................................................. 470
7.4.4.2 Speed controller pre-control (integrated pre-control with balancing)................................... 471
7.4.4.3 Reference model.................................................................................................................. 474
7.4.4.4 Speed controller adaptation ................................................................................................. 475

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7.4.4.5 Droop Function .....................................................................................................................477
7.4.4.6 Open actual speed value ......................................................................................................479
7.4.5 Closed-loop torque control....................................................................................................481
7.4.6 Torque limiting ......................................................................................................................483
7.4.7 Current setpoint filters...........................................................................................................485
7.4.8 Current controller adaptation ................................................................................................486
7.4.9 Permanent-field synchronous motors ...................................................................................487
8 Output terminals.................................................................................................................................. 491
8.1 Section content .....................................................................................................................491
8.2 Analog outputs ......................................................................................................................492
8.2.1 List of signals for the analog signals.....................................................................................493
8.3 Digital outputs .......................................................................................................................496
9 Functions, monitoring and protective functions .................................................................................... 499
9.1 Section content .....................................................................................................................499
9.2 Active Infeed functions..........................................................................................................500
9.2.1 Line and DC link identification ..............................................................................................500
9.2.2 Harmonics controller .............................................................................................................501
9.2.3 Variable power factor (reactive power compensation) .........................................................502
9.2.4 Settings for the infeed (Active Infeed) under difficult line conditions ....................................503
9.3 Drive functions ......................................................................................................................505
9.3.1 Motor data identification and automatic speed controller optimization.................................505
9.3.1.1 Motor data identification........................................................................................................506
9.3.1.2 Rotating measurement and speed controller optimization ...................................................509
9.3.1.3 Shortened rotating measurement .........................................................................................511
9.3.1.4 Parameters ...........................................................................................................................512
9.3.2 Efficiency optimization ..........................................................................................................513
9.3.2.1 Description ............................................................................................................................513
9.3.2.2 Simple efficiency optimization (method 1) ............................................................................514
9.3.2.3 Advanced efficiency optimization (method 2) .......................................................................515
9.3.2.4 Function diagrams, parameters ............................................................................................515
9.3.3 Fast magnetization for induction motors...............................................................................516
9.3.4 Vdc control ............................................................................................................................519
9.3.5 Automatic restart function .....................................................................................................523
9.3.6 Flying restart .........................................................................................................................526
9.3.6.1 Flying restart without encoder...............................................................................................528
9.3.6.2 Flying restart with encoder....................................................................................................531
9.3.6.3 Parameters ...........................................................................................................................532
9.3.7 Checking for a short-circuit/ground fault at a motor..............................................................533
9.3.8 Motor changeover .................................................................................................................534
9.3.8.1 Description ............................................................................................................................534
9.3.8.2 Example of changing over between two motors...................................................................534
9.3.8.3 Function diagrams ................................................................................................................536
9.3.8.4 Parameters ...........................................................................................................................536
9.3.9 Friction characteristic curve ..................................................................................................537
9.3.10 Armature short-circuit braking, DC braking...........................................................................539
9.3.10.1 General .................................................................................................................................539
9.3.10.2 External armature short-circuit braking.................................................................................539
9.3.10.3 Internal armature short-circuit braking..................................................................................541

Table of contents
Enclosed Drives
14 Operating Instructions, 12/2018, A5E36652151A
9.3.10.4 DC braking ........................................................................................................................... 542
9.3.11 Increasing the output frequency........................................................................................... 544
9.3.11.1 Description ........................................................................................................................... 544
9.3.11.2 Default pulse frequencies .................................................................................................... 545
9.3.11.3 Increasing the pulse frequency ............................................................................................ 545
9.3.11.4 Maximum output frequency achieved by increasing the pulse frequency ........................... 546
9.3.11.5 Parameters........................................................................................................................... 546
9.3.12 Derating behavior at increased pulse frequency ................................................................. 547
9.3.13 Pulse frequency wobbling .................................................................................................... 548
9.3.14 Runtime (operating hours counter) ...................................................................................... 550
9.3.15 Simulation mode .................................................................................................................. 551
9.3.16 Direction reversal ................................................................................................................. 553
9.3.17 Unit changeover ................................................................................................................... 554
9.3.18 Simple brake control ............................................................................................................ 556
9.3.19 Synchronization.................................................................................................................... 559
9.3.20 Energy saving indicator for pumps, fans, and compressors................................................ 560
9.3.21 Write protection .................................................................................................................... 563
9.3.22 Know-how protection ........................................................................................................... 565
9.3.22.1 Description ........................................................................................................................... 565
9.3.22.2 Activating know-how protection ........................................................................................... 567
9.3.22.3 Deactivating know-how protection ....................................................................................... 569
9.3.22.4 Changing the know-how protection password ..................................................................... 570
9.3.22.5 OEM exception list ............................................................................................................... 570
9.3.22.6 Loading data with know-how protection into the file system................................................ 571
9.3.22.7 Overview of important parameters....................................................................................... 574
9.3.23 Essential service mode ........................................................................................................ 574
9.3.24 Web server........................................................................................................................... 579
9.3.24.1 Description ........................................................................................................................... 579
9.3.24.2 Starting the web server ........................................................................................................ 583
9.3.24.3 Web server configuration ..................................................................................................... 585
9.3.24.4 Display areas ....................................................................................................................... 586
9.3.24.5 Overview of important parameters....................................................................................... 588
9.3.25 Tolerant encoder monitoring ................................................................................................ 588
9.3.25.1 General information ............................................................................................................. 588
9.3.25.2 Encoder track monitoring ..................................................................................................... 589
9.3.25.3 Zero mark tolerance............................................................................................................. 590
9.3.25.4 Freezing the actual speed for dn/dt errors........................................................................... 591
9.3.25.5 Adjustable hardware filter .................................................................................................... 591
9.3.25.6 Edge evaluation of the zero mark ........................................................................................ 592
9.3.25.7 Signal edge evaluation (1x, 4x)............................................................................................ 593
9.3.25.8 Setting the measuring time to evaluate speed "0" ............................................................... 594
9.3.25.9 Sliding averaging of the speed actual value ........................................................................ 594
9.3.25.10 Rotor position adaptation ..................................................................................................... 595
9.3.25.11 Pulse number correction for faults ....................................................................................... 595
9.3.25.12 "Tolerance band pulse number" monitoring......................................................................... 596
9.3.25.13 Troubleshooting, causes and remedies............................................................................... 598
9.3.25.14 Tolerance window and correction ........................................................................................ 600
9.3.25.15 Dependencies ...................................................................................................................... 600
9.3.25.16 Overview of important parameters....................................................................................... 602
9.3.26 Position tracking................................................................................................................... 603
9.3.26.1 General information ............................................................................................................. 603
9.3.26.2 Measuring gearbox .............................................................................................................. 604

Table of contents
Enclosed Drives
Operating Instructions, 12/2018, A5E36652151A 15
9.4 Extended functions ...............................................................................................................608
9.4.1 Technology controller............................................................................................................608
9.4.2 Bypass function.....................................................................................................................611
9.4.2.1 Bypass with synchronizer with degree of overlapping (p1260 = 1) ......................................613
9.4.2.2 Bypass with synchronizer without degree of overlapping (p1260 = 2) .................................616
9.4.2.3 Bypass without synchronizer (p1260 = 3).............................................................................618
9.4.2.4 Function diagram ..................................................................................................................620
9.4.2.5 Parameters ...........................................................................................................................620
9.4.3 Extended brake control .........................................................................................................621
9.4.4 Extended monitoring functions .............................................................................................626
9.4.5 Moment of inertia estimator ..................................................................................................628
9.4.6 Position control .....................................................................................................................634
9.4.6.1 Actual position value preparation..........................................................................................635
9.4.6.2 Position controller .................................................................................................................645
9.4.6.3 Monitoring functions..............................................................................................................646
9.4.6.4 Measuring probe evaluation and reference mark search .....................................................648
9.4.7 Basic positioner.....................................................................................................................650
9.4.7.1 Mechanical system ...............................................................................................................652
9.4.7.2 Limitations.............................................................................................................................654
9.4.7.3 Basic positioner and safe setpoint velocity limitation............................................................660
9.4.7.4 Referencing...........................................................................................................................661
9.4.7.5 Referencing with several zero marks per revolution.............................................................672
9.4.7.6 Safely referencing under EPOS............................................................................................675
9.4.7.7 Traversing blocks..................................................................................................................678
9.4.7.8 Traversing to fixed stop.........................................................................................................684
9.4.7.9 Direct setpoint specification (MDI) ........................................................................................687
9.4.7.10 Jog ........................................................................................................................................690
9.4.7.11 Status signals........................................................................................................................690
9.4.8 Parameterizable bandstop filters for the active infeed..........................................................693
9.5 Monitoring functions and protective functions ......................................................................695
9.5.1 Protecting power components ..............................................................................................695
9.5.2 Thermal monitoring and overload responses .......................................................................696
9.5.3 Blocking protection................................................................................................................699
9.5.4 Stall protection (only for vector control) ................................................................................700
9.5.5 Thermal motor protection......................................................................................................701
9.5.5.1 Description ............................................................................................................................701
9.5.5.2 Temperature sensor connection to customer terminal module TM31 (option G60) .............701
9.5.5.3 Temperature sensor connection to a Sensor Module (options K46, K48, K50) ...................702
9.5.5.4 Temperature sensor connection directly at the Control Interface Module............................703
9.5.5.5 Temperature sensor evaluation ............................................................................................704
9.5.5.6 Thermal motor models..........................................................................................................705
9.5.5.7 Function diagrams ................................................................................................................709
9.5.5.8 Parameters ...........................................................................................................................709
9.5.6 Temperature measurement via TM150 (option G51) ...........................................................710
9.5.6.1 Description ............................................................................................................................710
9.5.6.2 Measurement with up to 6 channels .....................................................................................712
9.5.6.3 Measurement with up to 12 channels ...................................................................................712
9.5.6.4 Forming groups of temperature sensors...............................................................................713
9.5.6.5 Evaluation of temperature channels .....................................................................................714
9.5.6.6 Function diagrams ................................................................................................................715
9.5.6.7 Parameters ...........................................................................................................................716

Table of contents
Enclosed Drives
16 Operating Instructions, 12/2018, A5E36652151A
10 Diagnostics / faults and alarms.............................................................................................................717
10.1 Chapter content.................................................................................................................... 717
10.2 Diagnostics........................................................................................................................... 718
10.2.1 Diagnostics via LEDs ........................................................................................................... 718
10.2.2 Diagnostics via parameters.................................................................................................. 728
10.2.3 Indicating and rectifying faults.............................................................................................. 732
10.3 Overview of alarms and faults.............................................................................................. 733
10.3.1 "External alarm 1" ................................................................................................................ 734
10.3.2 "External fault 1"................................................................................................................... 734
10.3.3 "External fault 2"................................................................................................................... 735
10.3.4 "External fault 3"................................................................................................................... 735
11 Maintenance and servicing...................................................................................................................737
11.1 Chapter content.................................................................................................................... 737
11.2 Maintenance......................................................................................................................... 738
11.2.1 Cleaning ............................................................................................................................... 738
11.3 Servicing .............................................................................................................................. 739
11.3.1 Installation device................................................................................................................. 740
11.3.2 Using crane lifting lugs to transport power blocks ............................................................... 741
11.4 Replacing components ........................................................................................................ 743
11.4.1 Replacing the filter mats ...................................................................................................... 743
11.4.2 Replacing the Control Interface Module, frame size FX ...................................................... 744
11.4.3 Replacing the Control Interface Module, frame size GX ..................................................... 746
11.4.4 Replacing the Control Interface Module, frame size HX...................................................... 748
11.4.5 Replacing the Control Interface Module, frame size JX ...................................................... 750
11.4.6 Replacing the power block (frame size FX) ......................................................................... 752
11.4.7 Replacing the power block (frame size GX) ........................................................................ 754
11.4.8 Replacing the power block (frame size HX)......................................................................... 756
11.4.9 Replacing the power block (frame size JX) ......................................................................... 760
11.4.10 Replacing the fan, frame size FX......................................................................................... 762
11.4.11 Replacing the fan, frame size GX ........................................................................................ 764
11.4.12 Replacing the fan, size HX................................................................................................... 766
11.4.13 Replacing the fan, frame size JX ......................................................................................... 770
11.4.14 Replacing the fan in the Active Interface Module (frame size FI) ........................................ 772
11.4.15 Replacing the fan in the Active Interface Module (frame size GI) ....................................... 774
11.4.16 Replacing the fan in the Active Interface Module (frame size HI)........................................ 776
11.4.17 Replacing the fan in the Active Interface Module (frame size JI) ........................................ 778
11.4.18 Replacing the DC fuses in the Active Line Module, Motor Module, frame size HX............. 780
11.4.19 Replacing the DC fuses in the Active Line Module, Motor Module, frame size JX.............. 783
11.4.20 Replacing cylindrical fuses................................................................................................... 785
11.4.21 Replacement of LV HRC fuses with blade contacts ............................................................ 786
11.4.22 Replacement of LV HRC fuses with screw mounting .......................................................... 788
11.4.23 Replacing the cabinet operator panel .................................................................................. 790
11.4.24 Replacing the Backup Battery for the Cabinet Operator Panel ........................................... 790
11.5 Forming the DC link capacitors............................................................................................ 792
11.6 Messages after replacing DRIVE-CLiQ components........................................................... 793
11.7 Upgrading the cabinet unit firmware .................................................................................... 794

Table of contents
Enclosed Drives
Operating Instructions, 12/2018, A5E36652151A 17
11.8 Loading the new operator panel firmware from the PC. .......................................................795
12 Technical specifications ...................................................................................................................... 797
12.1 Chapter content ....................................................................................................................797
12.2 General data .........................................................................................................................798
12.2.1 Derating data ........................................................................................................................799
12.2.1.1 Current derating as a function of the ambient temperature ..................................................799
12.2.1.2 Installation altitudes over 6600 ft and up to 16500 ft above MSL.........................................800
12.2.1.3 Current derating as a function of the pulse frequency..........................................................801
12.2.2 Overload capability ...............................................................................................................803
12.3 Technical specifications........................................................................................................805
12.3.1 Cabinet units, 380 V ... 480 V 3 AC ......................................................................................806
12.3.2 Cabinet units, 500 ... 690 V 3 AC .........................................................................................814
A Appendix............................................................................................................................................. 827
A.1 Environmental compatibility ..................................................................................................827
A.2 List of abbreviations..............................................................................................................828
A.3 Parameter macros ................................................................................................................837
Index................................................................................................................................................... 849

Table of contents
Enclosed Drives
18 Operating Instructions, 12/2018, A5E36652151A