Siemens ZTH User manual

Converters with CU250S-2 Control Units
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SINAMICS
SINAMICS G120
Converters with CU250S-2
Control Units
Getting Started
Edition 10/2013, Firmware V4.6
10/2013, FW V4.6
A5E32899990B AA
Safety information
1
Design of the frequency
converter
2
Installing
3
Commissioning
4
More information
5

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E32899990B AA
Ⓟ
09/2013 Technical data subject to change
Copyright © Siemens AG 2013.
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.

Converters with CU250S-2 Control Units
Getting Started, 10/2013, FW V4.6, A5E32899990B AA 5
Table of contents
1 Safety information ................................................................................................................................... 7
1.1 General safety instructions ............................................................................................................7
1.2 Safety instructions for electromagnetic fields (EMF) ...................................................................11
1.3 Handling electrostatic sensitive devices (ESD) ...........................................................................11
1.4 Residual risks of power drive systems.........................................................................................12
2 Design of the frequency converter......................................................................................................... 15
2.1 Identifying the converter...............................................................................................................15
2.2 Overview of Control Units ............................................................................................................16
2.3 Power Module ..............................................................................................................................16
2.4 Assembling frequency converter components.............................................................................18
3 Installing ............................................................................................................................................... 19
3.1 Installing the Power Module.........................................................................................................19
3.1.1 Connecting up the Motor and Power Module ..............................................................................20
3.2 Installing Control Unit...................................................................................................................22
3.2.1 Overview of the interfaces ...........................................................................................................22
3.2.2 Terminal blocks............................................................................................................................24
3.2.3 Finding a suitable setting for the interfaces .................................................................................25
3.2.4 Wiring the terminal strip ...............................................................................................................29
3.3 Installing encoders .......................................................................................................................31
3.3.1 Permissible encoders...................................................................................................................31
3.3.2 Sensor Module.............................................................................................................................32
3.4 Description files for fieldbuses .....................................................................................................32
4 Commissioning ..................................................................................................................................... 33
4.1 Tools to commission the converter ..............................................................................................33
4.2 Commissioning with STARTER ...................................................................................................34
4.2.1 Generating a STARTER project...................................................................................................34
4.2.2 Transfer inverters connected via USB into the project ................................................................34
4.2.3 Configuring a drive.......................................................................................................................36
4.2.4 Adapting the encoder data...........................................................................................................39
4.2.5 Loading the configured data into the drive...................................................................................40
4.2.6 Identifying motor data ..................................................................................................................40
5 More information ................................................................................................................................... 43
5.1 Manuals for your inverter .............................................................................................................43
5.2 Product support............................................................................................................................44

Safety information
Converters with CU250S-2 Control Units
6Getting Started, 10/2013, FW V4.6, A5E32899990B AA
This manual describes how you install a SINAMICS G120 converter with CU250S-2 Control
Unit and commission it.
What is the meaning of the symbols in the manual?
An operating instruction starts here.
This concludes the operating instruction.
Firmware upgrade and downgrade
Options for upgrading and downgrading the firmware can be found on the Internet at
http://support.automation.siemens.com/WW/view/de/67364620
(http://support.automation.siemens.com/WW/news/en/67364620).
Transferring license terms of the OSS code to a PC
The inverter contains open-source software (OSS). The OSS license terms are saved in the
inverter.
Procedure
To transfer the OSS license terms from the inverter to a PC, proceed as follows:
1. Switch off the inverter power supply.
2. Insert an empty memory card into the card slot of the inverter. See also the sections:
–Tools to commission the converter (Page 33)
–Overview of the interfaces (Page 22)
3. Switch on the inverter power supply.
4. When you have switched on the power supply, wait 30 seconds.
During this time, the inverter writes the "Read_OSS.ZIP" file onto the memory card.
5. Switch off the inverter power supply.
6. Remove the card from the inverter.
7. Use a card reader and load the file to a PC.
You have then transferred the OSS license terms from the inverter to a PC.

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Safety information
1
Use for the intended purpose
The inverter described in this manual is a device for controlling an induction motor or a
synchronous motor. The inverter is designed for installation in electrical installations or
machines.
It has been approved for industrial and commercial use on industrial networks. Additional
measures have to be taken when connected to public grids.
The technical specifications and information about connection conditions are indicated on
the rating plate and in the operating instructions.
1.1
General safety instructions
DANGER
Danger to life due to live parts and other energy sources
Death or serious injury can result when live parts are touched.
•Only work on electrical devices when you are qualified for this job.
•Always observe the country-specific safety rules.
Generally, six steps apply when establishing safety:
1. Prepare for shutdown and notify all those who will be affected by the procedure.
2. Disconnect the machine from the supply.
–Switch off the machine.
–Wait until the discharge time specified on the warning labels has elapsed.
–Check that it really is in a no-voltage condition, from phase conductor to phase
conductor and phase conductor to protective conductor.
–Check whether the existing auxiliary supply circuits are de-energized.
–Ensure that the motors cannot move.
3. Identify all other hazardous energy sources, e.g. compressed air, hydraulic systems,
water.
4. Isolate or neutralize all hazardous energy sources, e.g. by closing switches, grounding
or short-circuiting or closing valves.
5. Secure the energy sources against switching on again.
6. Make sure that the machine is completely locked ... and that you have the right
machine.
After you have completed the work, restore the operational readiness in the inverse
sequence.

Safety information
1.1 General safety instructions
Converters with CU250S-2 Control Units
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WARNING
Danger to life through a hazardous voltage when connecting an unsuitable power supply
Death or serious injury can result when live parts are touched in the event of a fault.
•Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV-
(Protective Extra Low Voltage) output voltages for all connections and terminals of the
electronics modules.
WARNING
Danger to life when live parts are touched on damaged devices
Improper handling of devices can cause damage.
Hazardous voltages can be present at the housing or exposed components on damaged
devices.
•Ensure compliance with the limit values specified in the technical data during transport,
storage and operation.
•Do not use any damaged devices.
WARNING
Danger to life through electric shock due to unconnected cable shields
Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected
cable shields.
•Connect cable shields and unused conductors of power cables (e.g., brake conductors)
at least on one side to the grounded housing potential.
WARNING
Danger to life due to electric shock when not grounded
For missing or incorrectly implemented protective conductor connection for devices with
protection class I, high voltages can be present at open, exposed parts, which when
touched, can result in death or severe injury.
•Ground the device in compliance with the applicable regulations.

Safety information
1.1 General safety instructions
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WARNING
Danger to life due to electric shock when opening plug connections in operation
When opening plug connections in operation, arcs can result in severe injury or death.
•Only open plug connections when the equipment is in a no-voltage state, unless it has
been explicitly stated that they can be opened in operation.
WARNING
Danger to life due to fire spreading if housing is inadequate
Fire and smoke development can cause severe personal injury or material damage.
•Install devices without a protective housing in a metal control cabinet (or protect the
device by another equivalent measure) in such a way that contact with fire inside and
outside the device is prevented.
•Additionally, select the installation site so that an uncontrolled spreading of smoke can
be avoided in the case of a fire.
•Ensure that smoke can escape via designated paths.
WARNING
Danger to life through unexpected movement of machines when using mobile wireless
devices or mobile phones
Using mobile wireless devices or mobile phones with a transmitter power > 1 W closer than
approx. 2 m to the components may cause the devices to malfunction and influence the
functional safety of machines, therefore putting people at risk or causing material damage.
•Switch the wireless devices or mobile phones off in the immediate vicinity of the
components.
WARNING
Danger to life due to the motor catching fire in the event of insulation overload
There is a greater load on the motor insulation through a ground fault in an IT system. A
possible result is the failure of the insulation with a risk for personnel through smoke
development and fire.
•Use a monitoring device that signals an insulation fault.
•Correct the fault as quickly as possible so the motor insulation is not overloaded.

Safety information
1.1 General safety instructions
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WARNING
Danger to life due to fire if overheating occurs because of insufficient ventilation clearances
Inadequate ventilation clearances can cause overheating with a risk for personnel through
smoke development and fire. This can also result in increased downtime and reduced
service lives for devices / systems.
•Ensure compliance with the specified minimum clearance as ventilation clearance for
the respective component. They can be found in the dimension drawings or in the
"Product-specific safety instructions" at the start of the respective section.
WARNING
Danger of an accident occuring due to missing or illegible warning labels
Missing or illegible warning labels can result in death or serious injury.
•Check the warning labels are complete based on the documentation.
•Attach any missing warning labels to the components, in the national language if
necessary.
•Replace illegible warning labels.
WARNING
Danger to life when safety functions are inactive
Safety functions that are inactive or that have not been adjusted accordingly can cause
operational faults on machines that could lead to serious injury or death.
•Observe the information in the appropriate product documentation before
commissioning.
•Carry out a safety inspection for functions relevant to safety on the entire system,
including all safety-related components.
•Ensure that the safety functions used in your drives and automation tasks are adjusted
and activated through appropriate parameterizing.
•Run a function test.
•Only put your plant into live operation once you have guaranteed that the functions
relevant to safety are running correctly.
Note
Important safety notices for safety functions
If you want to use safety functions, you must observe the safety notices in the safety
manuals.

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

Safety information
1.4 Residual risks of power drive systems
Converters with CU250S-2 Control Units
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1.4
Residual risks of power drive systems
The control and drive components of a drive system are approved for industrial and
commercial use in industrial line supplies. Their use in public line supplies requires a
different configuration and/or additional measures.
These components may only be operated in closed housings or in higher-level control
cabinets with protective covers that are closed, and when all of the protective devices are
used.
These components may only be handled by qualified and trained technical personnel who
are knowledgeable and observe all of the safety instructions on the components and in the
associated technical user documentation.
When assessing the machine's risk in accordance with the respective local regulations (e.g.,
EC Machinery Directive), the machine manufacturer must take into account the following
residual risks emanating from the control and drive components of a drive system:
1. Unintentional movements of driven machine components during commissioning,
operation, maintenance, and repairs caused by, for example:
–Hardware defects and/or software errors in the sensors, controllers, actuators, and
connection technology
–Response times of the controller and drive
–Operating and/or ambient conditions outside of the specification
–Condensation / conductive contamination
–Parameterization, programming, cabling, and installation errors
–Use of radio devices / cellular phones in the immediate vicinity of the controller
–External influences / damage
2. In the event of a fault, exceptionally high temperatures, including an open fire, as well as
emissions of light, noise, particles, gases, etc. can occur inside and outside the inverter,
e.g.:
–Component malfunctions
–Software errors
–Operating and/or ambient conditions outside of the specification
–External influences / damage
Inverters of the Open Type / IP20 degree of protection must be installed in a metal control
cabinet (or protected by another equivalent measure) such that the contact with fire inside
and outside the inverter is not possible.

Safety information
1.4 Residual risks of power drive systems
Converters with CU250S-2 Control Units
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3. Hazardous shock voltages caused by, for example:
–Component malfunctions
–Influence of electrostatic charging
–Induction of voltages in moving motors
–Operating and/or ambient conditions outside of the specification
–Condensation / conductive contamination
–External influences / damage
4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a
risk to people with a pacemaker, implants or metal replacement joints, etc. if they are too
close.
5. Release of environmental pollutants or emissions as a result of improper operation of the
system and/or failure to dispose of components safely and correctly.
Note
The components must be protected against conductive contamination (e.g. by installing them
in a control cabinet with degree of
protection IP54 according to IEC 60529 or NEMA 12).
Assuming that conductive contamination at the installation site can definitely be excluded, a
lower degree of cabinet protection may be permitted.
For more information about residual risks of the components in a drive system, see the
relevant sections in the technical user documentation.

Safety information
1.4 Residual risks of power drive systems
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Design of the frequency converter
2
2.1
Identifying the converter
Main components of the converter
Each SINAMICS G120 converter comprises a
Control Unit and Power Module.
•
The Control Unit controls and monitors the
Power Module and the connected motor.
•
The Power Modules are available for motors
with a power range of between 0.37
kW and
250 kW.
The following data is provided on the Power Module type plate (①):
●
Designation:
e.g. Power Module 240
●
Technical data:
Voltage, current and power
●
Order number:
e.g. 6SL3224-0BE13-7UA0
●
Version:
e.g. A02
The following data can be found on the Control Unit type plate (②
):
●
Designation:
e.g. CU250S-2 DP Control Unit
●
Order number:
e.g. 6SL3246-0BA22-1PA0
●
Version:
e.g. 02 (hardware) 4.6 (firmware)

Design of the frequency converter
2.2 Overview of Control Units
Converters with CU250S-2 Control Units
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2.2
Overview of Control Units
The Control Units CU250S-2 differ with regard to the type of fieldbus.
Designation
Order number
Fieldbus
CU250S-2 6SL3246-0BA22-1BA0 USS,
Modbus RTU
CU250S-2 DP 6SL3246-0BA22-1PA0 PROFIBUS DP
CU250S-2 PN 6SL3246-0BA22-1FA0 PROFINET IO,
EtherNet/IP
CU250S-2 CAN 6SL3246-0BA22-1CA0 CANopen
2.3
Power Module
You may operate the Control Unit with the following Power
Modules:
•
PM240 (3 AC 400 V for standard applications with dynamic
braking)
•
PM240-2 (3 AC 400 V for standard applications with
dynamic braking, 2nd generation)
in degree of protection IP20 and Push Through (PT)
•
PM340 (1 AC 200 V with dynamic braking)
•
PM250 (3 AC 400 V with energy recovery)
•
PM260 (3 AC 690 V with energy recovery),
PM340, 1 AC 200 V - Standard areas of application
The PM340 Power Module is available without a filter or with an integrated class A line filter
with degree of protection IP20. The PM340 allows dynamic braking via an external braking
resistor.
Order number range: 6SL3210-1SB1…
Frame size
FSA
FSB
FSC
FSD
FSE
FSF
FSGX
Power range (kW)
0.12 … 0.75
--
--
--
--
--
---

Design of the frequency converter
2.3 Power Module
Converters with CU250S-2 Control Units
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PM240, 3 AC 400 V - Standard areas of application
The PM240 Power Module is available without a filter or with an integrated class A line filter
with degree of protection IP20. The PM240 allows dynamic braking via an external braking
resistor.
Order number range: 6SL3224-0BE… and 6SL3224-0XE…
Frame size
FSA
FSB
FSC
FSD
FSE
FSF
FSGX
Power range (kW)
0.37 … 1.5
2.2 … 4
7.5 … 15
18.5 … 30
37 … 45
55 … 132
160 … 250
PM240-2, 3 AC 400 V - standard areas of application, 2nd generation
The PM240-2 Power Module is available without a filter or with an integrated class A line
filter. The PM240-2 permits dynamic braking via an external braking resistor.
Range of order numbers:
•
IP20:
•
Push-through
6SL3210
-1PE…
6SL3211
-1PE…
Frame size
FSA
Power range (kW), IP20
0.55 … 3
Power range (kW), PT
2.2 … 3
PM250, 3 AC 400 V - Application areas with line regeneration
The PM250 Power Module is available without a filter or with an integrated class A line filter
with degree of protection IP20. The PM250 permits dynamic braking with energy feedback
into the line supply.
Order number range, IP20: 6SL3225-0BE …
Frame size
FSC
FSD
FSE
FSF
Power range (kW)
7.5 … 15
18.5 … 30
37 … 45
55 … 90
PM260, 3 AC 690 V - Application areas with line regeneration
The PM260 Power Module is available without a filter or with an integrated class A line filter
with degree of protection IP20. A sine-wave filter is fitted to the motor. The PM260 permits
dynamic braking with energy feedback into the line supply.
Order number range, IP20: 6SL3225-0BH…
Frame size
FSD
FSF
Power range (kW)
11 … 18.5
30 … 55

Design of the frequency converter
2.4 Assembling frequency converter components
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Inverter accessories
Inverter with accessories (example)
The following accessories are available for the inverter:
•
Operator Panel for commissioning and diagnostics
(Basic Operator Panel BOP-2 or Intelligent Operator
Panel IOP).
•
Memory cards for the following tasks:
–Back up the inverter settings on an
interchangeable data storage device.
–Licensing of the "Extended safety functions" and
"Basic positioner" functions.
•
Shield connection kit for optimum shield support of
the connected cables.
•
Line filter for achieving a higher radio interference
suppression class.
•
Line reactor for protecting the inverter in harsh
industrial networks.
•
Output reactor for protecting the inverter when motor
cables > 50 m (shielded) or > 100 m (unshielded)
are used.
•
Sine-wave filter for protecting motors which are not
suitable for inverter operation and for motor cables
up to 300 m.
•
Braking resistor for dynamic braking of the motor.
•
Brake Relay for controlling a motor holding brake.
2.4
Assembling frequency converter components
Attaching the CU Removing the CU Attaching the Operator
Panel

Installing
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Installing
3
3.1
Installing the Power Module
WARNING
Danger of death caused by high leakage currents when the external protective conductor is
interrupted
The inverter conducts high leakage currents > 3.5 mA via the protective conductor. When
the protective conductor is interrupted, touching live components can result in electric
shock, which can lead to death or serious injuries.
•Connect a protective conductor, which satisfies at least one of the following conditions,
to the inverter:
–The protective conductor is routed so that it is protected against mechanical damage.
Cables routed in control cabinets or enclosed machine enclosures are considered to
be adequately protected.
–The protective conductor routed as an individual conductor has a cross-section of
≥10 mm² Cu.
–In a multi-core cable the protective conductor has a cross-section of ≥ 2.5 mm² Cu.
–Two parallel protective conductors with the same cross-section are installed.
–The protective conductor corresponds to the local regulations for equipment with
increased leakage current.

Installing
3.1 Installing the Power Module
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3.1.1
Connecting up the Motor and Power Module
Connecting the Power Module to the motor and power supply
Figure 3-1 Connecting the PM240 and PM240-2 3AC Power Modules
Figure 3-2 Connecting the PM340 1AC Power Module