Operating Instructions · Edition 10/2007 Control Unit CU240S CU240S DP CU240S DP-F CU240S PN CU240S PN-F Firmware version 3.
Introduction 1 Safety notes 2 SINAMICS Description 3 G120 Control Units CU240S Installing/Mounting 4 Commissioning 5 Communication 6 Operation 7 Troubleshooting 8 Service and maintenance 9 Operating Instructions Valid for • CU240S, CU240S DP, CU240S DP-F with FW 3.0 • CU240S PN, CU240S PN-F with FW 3.
Safety Guidelines 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.
Table of contents 1 Introduction................................................................................................................................................ 9 1.1 Documents for the Inverter ............................................................................................................9 1.2 Description of Document Classes................................................................................................10 2 Safety notes......................................
Table of contents 6 6 5.5.4 5.5.4.1 5.5.4.2 5.5.4.3 5.5.5 5.5.5.1 5.5.5.2 5.5.5.3 5.5.5.4 5.5.5.5 5.5.5.6 5.5.5.7 5.5.6 Further Settings for Commissioning............................................................................................ 66 Calculating the Motor and Control Data...................................................................................... 66 Commissioning the Application...................................................................................................
Table of contents 7 8 6.5.3 6.5.4 6.5.4.1 PROFINET Communication Parameters ...................................................................................170 PROFInet Configuration Example with SIMATIC S7 .................................................................173 Read Parameters.......................................................................................................................176 6.6 6.6.1 6.6.2 6.6.3 6.6.4 6.6.5 6.6.6 6.6.7 Communication via USS .....................
Introduction 1.1 1 Documents for the Inverter Available technical documentation Comprehensive information and support tools are available from the Service and Support internet site ● http://support.automation.siemens.
Introduction 1.2 Description of Document Classes 1.2 Description of Document Classes Description of the documents The following section describes the available document types for your inverter: Brochure The Brochure is advertising literature designed to introduce the product to the marketplace. It contains a basic outline of the product with a brief overview of the technical capabilities of the product.
Safety notes 2 Safety Instructions The following Warnings, Cautions and Notes are provided for your safety and as a means of preventing damage to the product or components in the connected machines. This section lists Warnings, Cautions and Notes, which apply generally when handling the inverter, classified as General, Transport and Storage, Commissioning, Operation, Repair and Dismantling and Disposal.
Safety notes General WARNING This equipment contains dangerous voltages and controls potentially dangerous rotating mechanical parts. Non-compliance with the warnings or failure to follow the instructions contained in this manual can result in loss of life, severe personal injury or serious damage to property. Protection in case of direct contact by means of SELV / PELV is only permissible in areas with equipotential bonding and in dry indoor rooms.
Safety notes CAUTION Children and the general public must be prevented from accessing or approaching the equipment! This equipment may only be used for the purpose specified by the manufacturer. Unauthorized modifications and the use of spare parts and accessories that are not sold or recommended by the manufacturer of the equipment can cause fires, electric shocks and injuries. NOTICE Keep this manual within easy reach of the equipment and make it available to all users.
Safety notes Operation WARNING The SINAMICS G120 inverters operate at high voltages. When operating electrical devices, it is impossible to avoid applying hazardous voltages to certain parts of the equipment. Emergency Stop facilities according to EN 60204, IEC 204 (VDE 0113) must remain operative in all operating modes of the control equipment. Any disengagement of the Emergency Stop facility must not lead to an uncontrolled or an undefined restart of the equipment.
3 Description The SINAMICS G120 range The SINAMICS G120 inverter has been designed for the accurate and efficient control of the speed and torque for three-phase motors. The SINAMICS G120 system comprises two basic modules, the Control Unit (CU) and the Power Module (PM). The Control Units are divided into the following: ● Standard CUs (CUs without fail-safe functions) – CU240E economic version of the CU240 control units (e.g.
Description 3.1 Accessories for the CU240S 3.1 Accessories for the CU240S The following options are available for the CU240S control units. ● BOP (Basic Operator Panel) ● PC connection kit ● MMC (Micro Memory Card) ● CU Screen termination kit A description how to use the individual options or spare parts is part of the option package itself. Ordering information and a brief functional description is given in the SINAMICS G120 catalog.
Description 3.2 Features and Functions of the CU240S 3.
Description 3.
Description 3.3 Layout and Block diagram 3.3 Layout and Block diagram Layout characteristics of the CU240S The figure below shows the various interfaces of the different types of Control Units.
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Description 3.4 Interfaces of the Control Units 3.
Description 3.4 Interfaces of the Control Units CU240S; CU240S DP; CU240S PN CU240S DP-F CU240S PN-F Terminal Designation Function 9 U24V OUT Isolated output +24 V – max. 100 mA x x 10 AI1+ Analog input 1 positive x x 11 AI1- Analog input 1 negative x x 12 AO0+ Analog output 0 positive (0/4 mA … 20 mA, max 500 Ω, switch via P0776 to 0/2 V … 10 V min.
Description 3.4 Interfaces of the Control Units Terminal Designation Function CU240S; CU240S DP; CU240S PN CU240S DP-F CU240S PN-F 73 ENC BN Channel B inverting input x x 74 ENC ZP Channel 0 (zero) non-inverting input x x 75 ENC ZN Channel 0 (zero) inverting input x x The control terminals have a maximum tighten torque of 0.25 Nm (2.2 lbf.in) and a nominal cross section of 1.5 mm2 (AWG 14) for cable.
Description 3.5 Factory Settings of the Control Unit 3.5 Factory Settings of the Control Unit Factory settings for command and setpoint source P0700 = 0 is the same as P0700 = 2 or 6 dependent on type of Control Unit. Note Setting P0700 = 6 (command source via fieldbus communication) and P1000 = 6 (setpoint source via fieldbus communication) are not possible with a CU240S.
Description 3.5 Factory Settings of the Control Unit Table 3-4 Command sources and their BICO connections with default settings of P0700 Function CU240S (P0700 = 2) CU240S DP (P0700 = 6) CU240S DP-F (P0700 = 6) CU240S PN (P0700 = 6) CU240S PN-F (P0700 = 6) Parameter BICO source Parameter BICO source P0840 = 722.0 DI0 P0840 = 2090.0 CW1, Bit 0 ON reverse/OFF1 (not active per default) P0842 = 0.0 --- P0842 = 0.0 --- First OFF2 source: Coast stop P0844 = 1.0 --- P0844 = 2090.
Description 3.
Installing/Mounting 4 Installing the Control Unit The CU controls the functions of the PM. The CU cannot be used without a PM, also the PM cannot be used without a CU. WARNING An inverter can be switched on unintentionally if the installation is not performed correctly. The inverter must be started-up by personnel who are qualified and trained in installing systems of this type. 4.
Installing/Mounting 4.1 Fitting the CU to the PM Figure 4-1 Fitting the control unit to the power module 24 V power supply Normally the CU is supplied with 24 V from Power Module. But it is also possible to use an external DC 24 V supply (20.4 V … 28.8 V, 0.5 A). It must be connected to the Control Unit terminals 31 (+ 24 V In) and 32 (0 V In).
Installing/Mounting 4.2 Connecting a CU240S via Terminals 4.2 Connecting a CU240S via Terminals Description To have access to the control terminals, the terminal cover must be removed, as shown in the figure below. The control terminals have a maximum tighting torque of 0.25 Nm (2.2 lbf.in) and a nominal cable cross section of 1.5 mm2. Figure 4-2 Removing the Control Unit terminal cover The terminals of the CU240 control units are combined to terminal blocks.
Installing/Mounting 4.2 Connecting a CU240S via Terminals Figure 4-3 Removing the two-part connectors with a CU240S DP as example After all the wiring of the control unit is completed - ensure that the terminal cover is replaced. Terminal wiring examples for the Control Unit CU240S Note To control the CU240S DP, CU240S DP-F or CU240S PN via terminals is also possible, but in this case the parameter settings for command and setpoint source have to be changed.
Installing/Mounting 4.2 Connecting a CU240S via Terminals Control with the default settings When shipped from the factory the G120 inverter (Control Unit and Power Module) must not be operated before the values depending on the specific PM are read into the CU. This can be done via: ● Downloading a valid parameter set (by MMC, STARTER, or BOP) ● Quick commissioning ● A factory reset To operate the inverter with the basic settings (e.g.
Installing/Mounting 4.2 Connecting a CU240S via Terminals 4.2.1 Frequency setpoint via terminals Description As a source for both the frequency setpoint and the additional frequency setpoint the analog input terminals can be used. Depending on the customer's needs it can be used as voltage or as current inputs. By default the AI0 and AI1 are set as voltage input terminals. AI0 and AI1 used as voltage inputs To use it as voltage inputs the following must be performed: 1.
Installing/Mounting 4.2 Connecting a CU240S via Terminals AI0 and AI1 used as current inputs To use it as current inputs the following must be performed: 1. DIP switch settings: Set the analog input dip switches to ON-position 2 refers to AI1) (DIP switch 1 refers to AI0, DIP switch 2.
Installing/Mounting 4.3 Connecting a CU240S via USS on RS485 4.3 Connecting a CU240S via USS on RS485 Socket The Control Units CU240S have a 9-pin female sub-D socket for connecting the inverter via an RS485 interface.
Installing/Mounting 4.3 Connecting a CU240S via USS on RS485 Cable Lengths and number of devices Table 4-3 Max. number of devices and max.
Installing/Mounting 4.4 Connecting a CU240S DP or CU240S DP-F via PROFIBUS DP 4.4 Connecting a CU240S DP or CU240S DP-F via PROFIBUS DP Description The function of the PROFIBUS DP interface is to provide a PROFIBUS DP-based link between inverters of the SINAMICS G120 product range and higher-level automation systems e.g. SIMATIC S7. 4.4.
Installing/Mounting 4.4 Connecting a CU240S DP or CU240S DP-F via PROFIBUS DP Table 4-5 Permissible cable length for one segment Baud rate Max. cable lengths for one segment 9.6 kbaud … 187.5 kbaud 1000 m (3280 ft)* 500 kbaud 400 m (1312 ft)* 1.5 Mbaud 200 m (656 ft)* 3 Mbaud … 12 Mbaud 100 m (328 ft)* ∗ Repeaters can be installed to increase the length of a segment. Cable installation rules During installation the bus cable must not be: ● twisted ● stretched or ● compressed.
Installing/Mounting 4.4 Connecting a CU240S DP or CU240S DP-F via PROFIBUS DP PROFIBUS terminator Each bus segment must have a resistor network at both ends as shown in the figure below.
Installing/Mounting 4.4 Connecting a CU240S DP or CU240S DP-F via PROFIBUS DP R on off A1 B1 A2 B2 Figure 4-5 Removing a bus connector 4.4.2 Screening the bus cable and EMC precautions R on off A1 B1 A2 B2 Description The following EMC-related precautions must be taken to ensure interference-free PROFIBUS DP operation. Screening The screen of the PROFIBUS DP cable must be connected in the bus connector.
Installing/Mounting 4.4 Connecting a CU240S DP or CU240S DP-F via PROFIBUS DP Equipotential bonding Differences in potential (for example, due to different mains supplies) between the inverters and the PROFIBUS DP master must be avoided. ● Recommended equipotential bonding cables: – 16 mm2 Cu for equipotential bonding cables up to 200 m long – 25 mm2 Cu for equipotential bonding cables of over 200 m long.
Installing/Mounting 4.5 Connecting a CU240S PN via PROFINET 4.5 Connecting a CU240S PN via PROFINET Socket The Control Units CU240S PN and CU240S PN-F are equipped with a two port ethernet switch, carried out as RJ45 female sockets. Connection to optical nets is achieved by using switches with both electrical and optical ports, the drive is then connected to an electrical port. Therefore, no power supply for an external electrical/optical inverter is provided.
Installing/Mounting 4.5 Connecting a CU240S PN via PROFINET Industrial Ethernet Cables and cable length The CU240S PN provides all Ethernet-cables. As well 1:1 cables as crossover-cables can be used. Table 4-9 Recommended PROFINET cables Max.
Installing/Mounting 4.6 Installation Check List (6 67$57(5 3% Figure 4-8 352),1(7 &RQWUROOHU 6,1$0,&6 * 3% 352),1(7 352),1(7 866 Topology 3: Routing Note Pay attention to the following restrictions: • A ring-type topology is not permissible. • SINAMICS does not support routing from PROFIBUS to PROFINET and vice versa. See also Assembly Instructions RJ45 Plug (http://support.automation.siemens.com/WW/view/en/23175326/130000) 4.
Commissioning 5 Overview A G120 inverter is composed of the Power Module and the Control Unit. After snapping the Control Unit on to the Power Module for the first time, the devices must identify each other. To indicate, that the Power Module and the Control Unit are not yet identified, F0395 is displayed. For further information to the message F0395, refer to section "Message F00395".
Commissioning 4.
Commissioning 5.1 Single Commissioning 5.1 Single Commissioning Overview For single commissioning, you set the parameter of the inverter manually. You use BOP (Basic Operator Panel) or STARTER (Commissioning software via PC) for commissioning. Note We recommend commissioning via STARTER. The commissioning process using STARTER is driven by dialog boxes and will not be interpreted in this manual. This manual describes the parameter related commissioning via BOP.
Commissioning 5.2 Series Commissioning 5.2 Series Commissioning 5.2.1 Common Information to Series commissioning Description Series commissioning means transferring the parameter set from one inverter into a number of other inverters. This provides fast commissioning for identical applications, e. g. series machines or group inverters. Components for series commissioning Commissioning the G120 inverter can be done in different ways.
Commissioning 5.2 Series Commissioning WARNING For series commissioning, all of the communication interfaces as well as also the digital and analog interfaces are re-initialized. This results in a brief communications failure or causes the digital outputs to switch. Potentially hazardous loads must be carefully secured before starting a series commissioning.
Commissioning 5.2 Series Commissioning NOTICE After upload and download of parameters between differing Control Units, the parameter settings must be checked. Parameter download from a different CU might fail with F0063 if parameters cannot be downloaded (Check P949 for the (first) parameter number which cannot be downloaded). If F0061 or F0063 occurs during startup it cannot be cleard except via a power cycle. 5.2.
Commissioning 5.2 Series Commissioning CAUTION Parameter download between different types of control units and of different firmware versions is not recommended. Basically, it is possible to download parameter sets off different CU types, however, as the parameter sets might differ, the user is fully responsible for the consistency of the downloaded parameter set. Therefore, the user has to take the responsibility in case of an automatic download by acknowledging F0395.
Commissioning 5.2 Series Commissioning Automatic download An automatic download needs a MMC to be performed. It is not possible to perform an automatic download from a PC or from the BOP. The automatic download runs as follows according to the settings in P8458 after power cycle or a after a swap (see "Start-up behavior" in this section).
Commissioning 5.3 Common Commissioning Information 5.3 Common Commissioning Information Prerequisites Before commissioning is started, the following data must be available: ● Line supply frequency ● Motor rating plate data ● Command/setpoint sources ● Min./max. frequency or ramp-up/ramp-down time ● Control mode An example for a rating plate is shown in the figure below. The precise definition and explanation of this data is defined in DIN EN 60034-1. 3~Mot.
Commissioning 5.4 Message F00395 5.4 Message F00395 Description The message F00395 is displayed to prompt you to check the parameter set. In case of standard CUs you accept the responsibility for a parameter set by confirming F00395. In case of fail-safe CUs you have to carry out an acceptance test. F00395 does not indicate an inverter fault.
Commissioning 5.5 Commissioning using the BOP 5.5 Commissioning using the BOP 5.5.1 The Basic Operator Panel (BOP) The Basic Operator Panel (BOP) is used for effective parameterizing and control of the inverter. The control signals and speed reference can easily be set by pressing the appropriate buttons. The BOP has the ability to upload and download parameter sets from an inverter to another inverter.
Commissioning 5.5 Commissioning using the BOP 5.5.1.1 Function Keys of the BOP Basic Operator Panel - function keys Table 5-3 BOP keys and their functions Basic Operator Panel Key Function Effects Status display The LCD indicates the settings which the drive inverter is presently using. The display reports faults and alarms. Start motor The inverter is started by pressing the key. This key is deactivated in the default setting.
Commissioning 5.5 Commissioning using the BOP 5.5.1.2 Changing Parameters via BOP Changing parameter with the BOP The description below serves as an example that shows how to change any parameter using the BOP. Table 5-4 Changing P0003 - parameter access level Step Result on display 1 Press 2 Press until P0003 is displayed 3 Press to display the parameter value 4 Press or 5 Press to confirm and store the value 6 All level 1 to level 3 parameters are now visible to the user.
Commissioning 5.5 Commissioning using the BOP 5.5.
Commissioning 5.5 Commissioning using the BOP 5.5.3 Basic Commissioning 5.5.3.1 Quick Commissioning V/f mode For applications using V/f (P1300 = 0 [default]) or Flux Current Control (FCC) (P1300 = 1 or 6), quick commissioning can be accomplished by setting the following parameters: Table 5-6 Quick commissioning - V/f mode Parameter Description P0003 = 3 User access level* 1: Standard: Allows access into most frequently used parameters (default)2: Extended: Allows extended access e.g.
Commissioning 5.
Commissioning 5.5 Commissioning using the BOP Vector Control mode For applications using Vector Control (P1300 = 20 … 23), quick commissioning should be performed as described in the following table: Parameters designated with an "*" offer more settings than are actually shown here. Refer to the Parameter list for additional settings.
Commissioning 5.5 Commissioning using the BOP Parameter Description Setting P1000 = 2 Selection of frequency setpoint* 0: No main setpoint 1: MOP setpoint 2: Analog setpoint (Default for CU240S) 3: Fixed frequency 4: USS on RS232 5: USS on RS485 6: Fieldbus (Default for DP and PN variants) 7: Analog setpoint 2 P1080 = … Minimum frequency Enter the lowest motor frequency (in Hz) to which the motor operates independently of the frequency setpoint.
Commissioning 5.5 Commissioning using the BOP Next to "Quick Commissioning" Next to "Quick Commissioning" the "Motor Data Identification" and additionally in case of vector mode (P1300 = 20/21) the "Speed Control Optimization" should be performed. Both need an ON command to start. 5.5.3.2 Motor Data Identification Parameter settings WARNING The motor data identification routine MUST not be used for loads which are potentially hazardous (for example, suspended loads for crane applications).
Commissioning 5.5 Commissioning using the BOP 5.5.3.3 Speed Control Optimization Parameter settings Parameter Description P0010 = 0 Commissioning parameter filter* Check if P0010 = 0 (Ready) P1960 = 1 Speed control optimization 0: Disable (default) 1: Enable ON command Start Speed control optimization In case of vector mode (P1300 = 20 or 21) Speed Control Optimization is recommended. Once P1960 = 1, alarm A0542 is generated, that states, the next ON command will initiate the optimization.
Commissioning 5.5 Commissioning using the BOP Performing the calculation of motor and control data via BOP Parameter Description P0340 = 1 Calculation of motor parameters This parameter is required during commissioning in order to optimize the operating behavior of the inverter. For the complete parameterization (P0340 = 1), in addition to the motor/control parameters, parameters are pre-assigned which refer to the rated motor data (e.g. torque limits and reference quantities for interface signals).
Commissioning 5.5 Commissioning using the BOP 5.5.4.2 Commissioning the Application Overview After the motor - inverter combination has been commissioned using quick commissioning, the following parameters should be set according to the requirements of the specific application.
Commissioning 5.5 Commissioning using the BOP Note If P0014=0 it is possible to transfer all parameter values from RAM into EEPROM via P0971. The duration of the data transfer depends on the number of changed parameters. The data transfer can last up to 3 minutes. During the data transfer, BOP displays "bUSY".
Commissioning 5.5 Commissioning using the BOP Temperature calculation without sensor In the vector control mode (P1300 = 20/21/22/23) Temperature calculations is possible without sensor. The following parameters have to be set.
Commissioning 5.
Commissioning 5.
Commissioning 5.5 Commissioning using the BOP Frequency setpoint via analog input (AI) (P1000 = 2) Parameter Description P0756 = 0 AI type Defines the type of the analog input and also enables analog input monitoring.
Commissioning 5.5 Commissioning using the BOP Frequency setpoint via fixed frequency (P1000 = 3) Parameter Description P1016 = 1 Fixed frequency mode, defines the selection method for fixed frequencies. The fixed frequency can be selected via four digital inputs (default DI3 … DI6). 1: direct selection (default) 2: binary coded With the default settings additional combinations as follows are possible: P1001 = 0 Fixed frequency 1, (FF1) Value given in Hz.
Commissioning 5.
Commissioning 5.5 Commissioning using the BOP JOG frequency Parameter Description P1057 = 1 JOG Enable P1057 = 0 JOG-function disabled P1057 = 1 JOG-function enabled (default) P1058 = 5 JOG frequency right Frequency in Hz when the motor is being jogged in the clockwise direction. P1059 = 5 JOG frequency left Frequency in Hz when the motor is being jogged in the counter-clockwise direction. P1060 = 45 JOG ramp-up time Ramp-up time in seconds from 0 to the maximum frequency (P1082).
Commissioning 5.5 Commissioning using the BOP Skip Frequency Parameter Description P1091 = 7.5 Skip frequency 1 (entered in Hz) Avoids mechanical resonance effects and suppresses (skips) frequencies in the range around the skip frequency ± P1101 (skip frequency bandwidth). P1092 = 0.0 Skip frequency 2 P1093 = 0.0 Skip frequency 3 P1094 = 0.0 Skip frequency 4 P1101 = 1.
Commissioning 5.5 Commissioning using the BOP Further parameters to set before finishing the application commissioning The following parameters should be configured for each application. Parameter Description P1800 = 4 Pulse frequency (kHz) The pulse frequency can be changed in 2 kHz steps. The range extends from 4 kHz up to 16 kHz. The complete inverter output current at 50 °C is reached with 4 kHz. The maximum output frequency depends on the pulse frequency.
Commissioning 5.5 Commissioning using the BOP 5.5.4.3 Reset Parameters to Factory Settings Overview With a factory reset via P0970 the initial state of the all the inverter parameters can be reestablished. The factory setting values are designated as "Factory setting" in the Parameter Manual. For further information, refer to the section "Factory Settings of the Control Unit" in this manual. Note When resetting the parameters to the factory setting, the communications memory is reinitialized.
Commissioning 5.5 Commissioning using the BOP 5.5.5 Commissioning the Fail-Safe Functions Available fail-safe functions ● Safe Torque Off (STO) ● Safe Stop 1 (SS1) ● Safely Limited Speed (SLS) Command source for fail-safe functions As command source for the fail-safe signals STO, SS1 and SLS either the fail-safe terminals (60 … 63) or PROFIsafe can be used (see p9603 and p9803). WARNING PROFIsafe address To run PROFIsafe, the PROFIsafe address (P9810) must be set first.
Commissioning 5.5 Commissioning using the BOP When a parameter is modified, the relevant value is transmitted to the relevant processor in the CU. The value is transmitted back to the user interface and can be checked by the processor and the user for correctness. To complete commissioning of fail-safe functions use setting P3900 = 10, which accepts all the changes to the fail-safe parameters.
Commissioning 5.5 Commissioning using the BOP 5.5.5.1 Parameters For Fail-Safe Functions Description The following table gives an overview of all parameters for fail-safe functions. Fail-safe parameters have access level 3 (P0003 = 3). To modify values of fail-safe parameters a password is required (P9761). A detailed description is given in the parameter list.
Commissioning 5.5 Commissioning using the BOP Parameter Description Unit Default Min. value value Max. value 2 Communication processor P9801 SI enable parameter - 2 P9802 SI enable safe brake monitoring - 0 0 1 P9803 SI Selection of safety command source - 0 0 128 P9850 SI Safe Digital Input debounce delay time s 0.050 0.000 2.000 P9851 SI Safe Digital Input filter delay time s 0.005 0.000 0.100 P9880 SI braking ramp delay s 0.250 0.010 99.
Commissioning 5.5 Commissioning using the BOP 5.5.5.3 Checksums Description All parameters for fail-safe functions are verified by the use of checksums. These checksums ensure the integrity of the data held within the drive processors memory. There are four checksum, two for each of the processors, these are: ● r9798 – actual checksum for P1. ● P9799 – reference checksum for P1. ● r9898 – actual checksum for P2. ● P9899 – reference checksum for P2. 5.5.5.
Commissioning 5.5 Commissioning using the BOP 5.5.5.5 Common Step-by-Step Descriptions For Fail-Safe Functions Change password Parameter Description P9761 SI input password Unit Default Min. Max. - 0 1000 99999 - 0 1000 99999 - 0 1000 99999 The safety password is entered in this parameter to get access to change the fail-safe parameters. P9762 SI change password Enter the new password. The password must have 5 digits but no leading zero (0).
Commissioning 5.5 Commissioning using the BOP Select fail-safe command source Parameter Description P9603 = … SI Selection of safety command source Unit Default Min. Max. - 0 0 128 - 0 0 128 Fail-safe parameter for selection of the fail-safe input signals. As source for the fail-safe functions the fail-safe digital inputs or PROFIsafe can be used. Selects either safe digital inputs or PROFIsafe .
Commissioning 5.5 Commissioning using the BOP Test stop interval setting Parameter Description P9659 = … SI maximum time until test stop* Unit Default Min. Max. h 8.0 0.1 8760.0 The time interval between test stops is specified in this parameter. The remaining time until a test stop is required is shown in r9660. When r9660 reaches zero, the time interval has expired and warning A1699 is activated. The warning solely informs that a test stop is required.
Commissioning 5.5 Commissioning using the BOP Safe Stop 1 setting Parameter Description Unit Default Min. Max. P9680 = … SI braking ramp delay ms 250 10 99000 s 0.250 0.010 99.000 ms 10000 100 99000 s 10.000 0.100 99.000 Hz 5.0 2.0 20.0 kHz 0.005 0.002 0.020 Time [in ms] between selecting the safe braking ramp (SBR) and the activation of the monitoring ramp. The output frequency is compared to the frequency of the monitoring ramp when the SBR is active.
Commissioning 5.5 Commissioning using the BOP Safely-limited Speed Parameter Description Unit Default Min. Max. P9690 SI setpoint for SLS Hz 10.0 2.0 300.0 kHz 0.010 0.002 0.300 Hz 13.0 5.0 302.0 kHz 0.013 0.005 0.302 - 1 0 2 - 1 0 2 Speed setpoint that is used when the safely limited speed (SLS) is selected. Depending on the setting in P9692/P9892 the frequency of P9690/P9890 may also serve as a speed threshold instead of a setpoint (see P9692).
Commissioning 5.5 Commissioning using the BOP 5.5.5.
Commissioning 5.5 Commissioning using the BOP 5.5.5.7 Acceptance Test and Acceptance Log Description In order to verify the parameter settings for the fail-safe functions, an acceptance test must be carried-out after the following operations: ● Commissioning ● Safety reset ● Automatic download of a parameter set via MMC This acceptance test must be appropriately logged and documented. An example for an appropriate acceptance log is included in the appendix.
Commissioning 5.5 Commissioning using the BOP Contents of a complete acceptance test Documentation Documentation of the machine including the fail-safe functions. ● Machine description and overview/block diagram ● Fail-safe functions for each drive ● Description of the fail-safe devices/equipment. Function test Checking the individual fail-safe functions that are used. ● "Safe Torque Off" (STO) ● "Safe Stop 1" (SS1) ● "Safely-Limited Speed" (SLS) ● "Safe Brake Control" (SBC).
Commissioning 5.5 Commissioning using the BOP 5.5.6 Series commissioning using the BOP Upload and download a parameter set with a BOP With a BOP a single parameter set can be uploaded from an inverter and then downloaded into another inverter. To copy a parameter set from one inverter to another, the following procedure should be performed.
Commissioning 5.5 Commissioning using the BOP Download a parameter set with a BOP Prerequisites ● Supply voltage is active for the download inverter ● The download inverter is in "Ready to Run". Parameter Description Setting Fit the BOP to the inverter and perform the download according the flow chart. P0003 = 3 User access level* 1: Standard: Allows access to the most frequently used parameters (default) 2: Extended: Allows extended access e.g.
Commissioning 5.6 Commissioning with STARTER 5.
Commissioning 5.6 Commissioning with STARTER 5.6.1 Single Commissioning with STARTER STARTER projects Using STARTER either a new project can be created or an already existing project can be opened. To create a new project in STARTER one of the following methods can be used: ● Search inverter ● Wizard ● Select inverter When opening an existing project or creating a new project STARTER is in the offline mode. has to be pressed.
Commissioning 5.6 Commissioning with STARTER 5.6.2 Series Commissioning with STARTER Upload a parameter set with STARTER Prerequisites ● An inverter with an apropriate parameter set is available (upload inverter) ● STARTER is installed on the PC used for series commissioning ● Supply voltage is active for the upload inverter ● The upload inverter is in "Ready to Run".
Commissioning 5.7 Commissioning with the MMC 5.7 Commissioning with the MMC 5.7.1 Parameter Download via MMC Overview A G120 inverter can be parameterized by downloading a parameter set from the MMC to the inverter. The download can be performed as ● Manual Download ● Automatic Download A detailed download description can be found in the section "Upload and Download of Parameter Sets". Note The file format for the MMC is FAT.
Commissioning 5.7 Commissioning with the MMC 5.7.2 Series commissioning with MMC Inserting and removing the MMC Before upload or download can be performed an MMC has to be fitted. How to fit and remove the MMC see the following figure: 6,1$0,&6 6,1$0,&6 Figure 5-3 Fitting and Removing the MMC WARNING When inserting an MMC during operation Alarm A0564 appears if P8458 is set to 0. This is a hint that with P8458 = 0 no Automatic Download will be performed at startup.
Commissioning 5.7 Commissioning with the MMC Upload a parameter set with an MMC Prerequisites To upload a parameter set the following important conditions must be fulfilled: ● An inverter with an appropriate parameter set is available (upload inverter). ● An MMC Type 6SL3254-0AM00-0AA0 is available. ● Supply voltage is active for the upload inverter. ● The upload inverter is in "Ready to Run"". ● The parameters are copied from RAM to EEPROM.
Commissioning 5.7 Commissioning with the MMC Manual Download of a parameter set with an MMC Prerequisites ● Supply voltage is active for the download inverter ● The download inverter is in "Ready State" ● On the MMC the following folder structure must be available: /USER/SINAMICS/DATA/clonexx.bin Procedure Note The following important conditions must be fulfilled when using the download procedure: • During the download the inverter will not react to any commands.
Commissioning 5.7 Commissioning with the MMC Note If P0014 = 0, you can always transfer all parameter values from RAM into EEPROM via P0971. The duration of the data transfer depends on the number of changed parameters. The data transfer can last up to 3 minutes. During the data transfer, BOP displays "bUSY". Automatic Download The Automatic Download at start-up is controlled via P8458.
Commissioning 5.7 Commissioning with the MMC Successful Automatic Download After a successful Automatic Download, F0395 will be displayed. Clearing F00395 is described in the section "Message F00395". WARNING The user is responsible for ensuring that the parameters held in the CU are the correct parameters for their application. Acceptance test On CUs with integrated fail-safe functions it is necessary to do an acceptance test (refer to the "Fail-safe functions" section in this manual).
Commissioning 5.8 Commissioning the Encoder 5.8 Commissioning the Encoder Description WARNING Before installing and commissioning, please read these safety instructions and warning carefully and all the warning labels attached to the equipment. Make sure that the warning labels are kept in a legible condition and replace missing or damaged labels. This equipment contains dangerous voltages and controls potentially dangerous rotating mechanical parts.
Commissioning 5.8 Commissioning the Encoder CAUTION Use of unscreened cables is possible, however we recommend the use of screened cables, in order to fulfill the EMC requirements for the CE marking and fail-safe products (CU240S DP-F). Note The cable from the encoder to the Encoder Module should be one complete length. TTL-encoder specific If the encoder type is a TTL differential and a long cable length is required (>50 m), DIP switches 5, 6, and 7 may be set to ON.
Commissioning 5.8 Commissioning the Encoder 5.8.1 Parameterizing the Encoder Interface Encoder parameterization To enable the encoder to function correctly with the inverter, the parameters in the table below, must be modified.
Commissioning 5.8 Commissioning the Encoder Parameter Name Comment P0492[3] Allowed speed difference This parameter defines the frequency threshold for the loss of the encoder signal (fault F0090). The threshold is used both for low as well as also high frequencies. 1.
Commissioning 5.8 Commissioning the Encoder Table 5-14 Monitoring parameters Parameter Name Comment r0061 CO: Rotor speed Indicates the speed of the rotor. Used to check that the system is working correctly. r0090 CO: Act. rotor angle Indicates the current angle of the rotor. This function is not available on single input channel encoders.
Commissioning 5.8 Commissioning the Encoder 5.8.2 Encoder Fault Codes Description The Encoder Interface has only one fault code, – F0090. This condition occurs when the allowed frequency rate of change, set in P0492[3] is exceeded or when low speed encoder loss is detected. Note The reason for the encoder loss will be given in the level 3 parameter r0949: r0949 = 1 means encoder loss of channel A or channel B, or encoder loss due to high speed (shaft speed > P0492).
Commissioning 5.9 Parameters 5.9 Parameters Overview of parameters The inverter is adapted to a particular application using the corresponding parameters. This means that each parameter is identified by a parameter number and specific attributes (e.g. monitoring parameter, write parameter, BICO attribute, group attribute etc.). Within any one particular inverter system, the parameter number is unique.
Commissioning 5.9 Parameters 5.9.2 Monitoring parameters Description Parameters which can only be monitored are indicated by the prefix "r". These parameters are used to display internal quantities, for example states and actual values. Notation examples: 5.9.3 r0002 monitoring parameter 2 r0052.3 monitoring parameter 52, bit 03 r0947[2] monitoring parameter 947 index 2 r0964[0 ...
Commissioning 5.9 Parameters Indexed parameters are used, for example: ● Drive Data Sets (DDS) ● Command Data Sets (CDS) ● Sub functions. BICO The following types of connectable parameters are available. A description of BICO technology is given in the section "BICO Technology".
Commissioning 5.9 Parameters Can be changed "P" parameters can only be changed depending on the inverter state. The parameter value is not accepted if the instantaneous state is not listed in the parameter attribute "Can be changed". For instance, the quick commissioning parameter P0010 with the attribute "CT" can only be changed in quick commissioning "C" or ready "T" but not in operation "U".
Commissioning 5.9 Parameters Grouping The parameters are sub-divided into groups according to their functionality. This increases the transparency and allows a quicker and more efficient search for specific parameters. Furthermore, parameter P0004 can be used to control the specific group of parameters that are displayed on the BOP.
Commissioning 5.9 Parameters Quick commissioning This parameter attribute identifies as to whether the parameter is included in the quick commissioning (QC) (P0010 = 1).
Commissioning 5.10 Start-up and Swap Behavior of the Inverter 5.10 Start-up and Swap Behavior of the Inverter Overview When starting-up the inverter checks, whether an MMC is plugged in or not. If it is plugged and no swap has been taken place the start-up runs according the "Normal start-up behavior". If a component (CU or PM) has been replaced, this is called a swap and the start-up will be performed according the "Swap behavior" of the inverter. 5.10.
Commissioning 5.10 Start-up and Swap Behavior of the Inverter Successful automatic download After a successful automatic download, F0395 will be displayed. ● In case of a standard CU a confirmation is necessary. ● In the case of CUs with fail-safe functions, an acceptance test must be performed. Confirmation On standard CUs the current parameter set needs to be checked and its correctness confirmed by clearing F0395.
Commissioning 5.10 Start-up and Swap Behavior of the Inverter NOTICE After upload and download of parameters between differing Control Units, the parameter settings must be checked. Parameter download from a different CU might fail with F0063 if parameters cannot be downloaded (Check r0949 for the (first) parameter number which cannot be downloaded). If F0061 or F0063 occurs during startup it cannot be cleared except via a power cycle. 5.10.
Commissioning 5.10 Start-up and Swap Behavior of the Inverter PM swap (CU externally powered) Constraints: MMC with valid Parameter set plugged ● Swap detected, Parameter MMC -> RAM/EEPROM, inverter runs into F00395 ● Confirmation for standard CU or acceptance test in case of fail-safe CU required Constraints: no MMC ● Swap detected, Parameter EEPROM -> RAM, inverter runs into F00395 ● If the parameters, already held in the EEPROM are ok there is no commissioning necessary.
Commissioning 5.10 Start-up and Swap Behavior of the Inverter Swap fault A swap fault is indicated if the automatic download fails. In this case, the CU will return to the parameter set previously held in the EEPROM and F00395 as well as one of F00061, F00062 and F00063 will be generated. On standard CUs the current parameter set needs to be checked and its correctness confirmed by clearing F00395. This can be done via: ● Digital input or PLC signal (depends on the settings of P0700) ● Setting P7844 = 0.
Commissioning 5.10 Start-up and Swap Behavior of the Inverter CU Swap The following procedure is given as a guide to perform a swap of a CU. CAUTION Data set compatibility To ensure complete data set compatibility, it is recommended to perform an upload of the parameter set from the CU to a new MMC prior to swapping the CU. Before performing a CU swap take care of the following: 1. The PM is powered-down and disconnected. 2. Wait 5 minutes to allow the unit to discharge after switching off the line supply.
Communication 6.1 PROFIdrive Profile V4.1 6.1.1 Use Data Structure as Defined in PROFIdrive Profile V4.1 6 Introduction The SINAMICS G120 range of inverters can be controlled through the cyclical PROFIBUS DP channel or the acyclic DPV1 channel. The structure of use data for the cyclic/acyclic channel for is defined in the PROFIdrive Profile, version V4.1.
Communication 6.1 PROFIdrive Profile V4.1 Parameter channel Process data area (PZD) PKE IND PWE PZD01 STW1 ZSW1 1st word 2nd word 3rd word 4th 1st word word PZD: Process data PKE: Parameter identifier IND: Index PWE: Parameter value STW: Control word 1 ZSW: Status word 1 HSW: Main setpoint HIW: Main actual value 6.1.
Communication 6.1 PROFIdrive Profile V4.1 Parameter identifier (PKE), 1st word The parameter identifier (PKE) is always a 16-bit value. 3DUDPHWHU FKDQQHO 3.( VW ZRUG ,1' QG ZRUG 3:( UG DQG WK ZRUG 630 $. 318 Figure 6-2 PKE structure ● Bits 0 to 10 (PNU) contain the remainder of the parameter number (value range 1 to 61999).
Communication 6.1 PROFIdrive Profile V4.
Communication 6.1 PROFIdrive Profile V4.1 Parameter index (IND) 2nd word The array subindex is in the PROFIdrive Profile referred to simply as "subindex". Structure for acyclical communication 3DUDPHWHU FKDQQHO 3.
Communication 6.1 PROFIdrive Profile V4.1 Regulation for the parameter range The bit for parameter page selection functions as follows: If it is set to 1, an offset of 2000 is applied in the inverter to the parameter number (PNU) transferred in the parameter channel request before it is passed on.
Communication 6.1 PROFIdrive Profile V4.1 Parameter value (PWE) 3rd and 4th word In case of PROFIBUS or PROFINET communication the parameter value (PWE) is always transmitted as a double word (32-bit). Only one parameter value at a time can be transferred in a telegram. A 32-bit parameter value comprises PWE1 (high-order word, 3rd word) and PWE2 (loworder word, 4th word). A 16-bit parameter value is transferred in PWE2 (low-order word, 4th word).
Communication 6.2 Cyclic Communication 6.2 Cyclic Communication Telegrams The selection of a telegram via P0922 determines on the drive unit side which process data is transferred between master and slave. From the perspective of the slave, there are receive words and send words.
Communication 6.
Communication 6.2 Cyclic Communication 6.2.
Communication 6.2 Cyclic Communication 6.2.3 PROFIsafe Telegram Structure Description The fail-safe functions can be triggered via the fail-safe digital inputs FDI0 and FDI1 or via PROFIsafe signals (see P9603 and 9803). To use PROFIsafe for triggering the fail-safe functions the G120 GSD file must be installed in the control system e.g. SIMATIC S7.
Communication 6.2 Cyclic Communication 6.2.4 Switch over behavior of Communication telegram Overview When switching over the communication telegram, a number of paramaters values is changed simultanously.
Communication 6.2 Cyclic Communication Table 6-11 P0922 = Switch over behavior of telegram structures, Part 2 20 → 1/353 if P0700 = 20 → 350 if P0700 = 1, 2, 4 6 20 → 352/354 if P0700 = 1, 2, 4 6 20 → 999 if P0700 = 1, 2, 4 6 1, 2, 4 6 P0820 = 0.0 0.0 no change 2091.4 8891.4 0.0 0.0 no change no change P0821 = no change no change no change 2091.5 8891.5 no change no change no change no change P1035 = no change 2090.13 8890.13 no change 2090.13 8890.13 no change 2090.
Communication 6.2 Cyclic Communication Table 6-14 P0922 = Switch over behavior of telegram structures, Part 5 353 → 20 if P0700 = 353 → 350 if P0700 = 1, 2 4 6 1, 2, 4 6 1, 2, 4 353 → 999/1 if P0700 = 6 1, 2, 4 6 P0820 = no change 2013.15 no change 2091.4 8891.4 no change no change no change no change P0821 = no change no change no change no change 2091.5 8891.5 no change no change no change no change P1035 = 19.13 19.13 19.13 no change 2090.13 8890.13 no change 2090.13 8890.
Communication 6.2 Cyclic Communication 6.2.5 Control and status words Description The control and status words comply with the specifications for PROFIdrive Profile, version 4.1 for "Closed-loop speed control mode". Control word 1 (STW1) Control word 1 (bits 0 … 10 as per PROFIdrive Profile and VIK/NAMUR, bits 11 … 15 specific to SINAMICS G120). Table 6-17 Assignment control word 1 Bit Val.
Communication 6.2 Cyclic Communication Bit Val. Meaning comment P0922 = 20 (VIK/NAMUR) P0922 = 1 / 350 / 352 / 353 / 354 (PROFIdrive Profile) 8 0 JOG 1 OFF Drive brakes as quickly as possible. P1055 = 2090:8 P1055 = 2090:8 1 JOG 1 ON The drive runs up as quickly as possible to jogging setpoint (direction of rotation: CW). 0 JOG 2 OFF Drive brakes as quickly as possible.
Communication 6.2 Cyclic Communication An example In the remote control operating mode the commands and target values come from a superior control system to the inverter by means of a PROFIBUS. By switching to local operation, the command and target value source is switched and operation is now performed locally on the system by means of digital inputs and the analog target values.
Communication 6.2 Cyclic Communication Status word 1 (ZSW1) Status word 1 (bits 0 to 10 as per PROFIdrive Profile and VIK/NAMUR, bits 11 to 15 specific to SINAMICS G120). Table 6-19 Bit assignments status word 1 (for all PROFIdrive and VIK/NAMUR telegrams) Bit Value Meaning Remarks 0 1 Ready to switch on Power supply is switched on, electronics initialized, pulses disabled.
Communication 6.2 Cyclic Communication Status word 2 (ZSW2) Status word 2 has the following default assignment: This can be modified using BICO. Table 6-20 Assignment status word 2 (for VIK/NAMUR not defined) Bit Value Meaning Description 0 1 DC Braking Active DC current brake active 1 1 n_act < P2167 Drive inverter frequency < Shutdown limit 2 1 n_act ≧ P1080 Actual frequency > min.
Communication 6.3 Acyclic Communication 6.3 Acyclic Communication Overview of Acyclic communication The content of the transferred data block corresponds to the structure of the acyclic parameter channel according to PROFIdrive Profile, version 4.1 (http://www.profibus.com/organization.htm (Page 130)) Acyclic data transfer mode allows in general: ● Large quantities of use data (up to 240 bytes) to be exchanged. A parameter request/response must fit in a data block (max. 240 byte).
Communication 6.3 Acyclic Communication Acyclic communication via PROFInet (Base mode parameter access) In the base mode parameter access, the requests and the replies are transmitted acyclically by use of the "Acyclic Data Exchange" mechanism of the Communication System. It allows simultaneous accessing by other PROFInet IO Supervisors (e.g. start-up tool).
Communication 6.3 Acyclic Communication ● Parameter address Addressing of a parameter. If several parameters are accessed, there are correspondingly many parameter addresses. The parameter address appears only in the request, not in the response. ● Parameter value Per addressed parameter, there is a segment for the parameter values. Depending on the request ID, parameter values appear only either in the request or in the reply.
Communication 6.3 Acyclic Communication Description of fields in parameter request and response Table 6-23 Description of fields in parameter request Field Data type Values Request reference Unsigned8 0x01 … 0xFF Request ID Note Unique identification of the request/response pair for the master. The master changes the request reference with each new request. The slave mirrors the request reference in its response. Unsigned8 0x01 0x02 Read request Write request Specifies the type of request.
Communication 6.
Communication 6.3 Acyclic Communication Table 6-24 Description of fields in parameter response Field Data type Request reference See Table above Response ID Unsigned8 Values Note 0x01 0x02 0x81 0x82 Read request (+) Write request (+) Read request (–) Write request (–) Request positive, status ok Request negative, fault status Mirrors the request identifier and specifies whether request execution was positive or negative. Negative means: Cannot execute part or all of request.
Communication 6.3 Acyclic Communication Error values in DPV1 parameter responses Table 6-25 148 Explanation of error values in parameter responses Error value Description Remarks Extra info 0x00 Illegal parameter number Access to a parameter which does not exist. – 0x01 Parameter value cannot be changed Modification access to a parameter value which Subindex cannot be changed. 0x02 Lower or upper value limit exceeded Modification access with value outside value limits.
Communication 6.4 Communication via PROFIBUS 6.4 Communication via PROFIBUS 6.4.1 General Information About PROFIBUS for SINAMICS General information PROFIBUS is an open international field bus standard for a wide range of production and process automation applications. The following standards ensure open, multi-vendor systems: ● International standard EN 50170 ● International standard IEC 61158 PROFIBUS is optimized for high-speed, time-critical data communication at field level.
Communication 6.4 Communication via PROFIBUS 6.4.2 Communication Settings PROFBUS DP Setting the PROFIBUS DP address Prior to using the PROFIBUS DP interface, the address of the node (inverter) must be set. There are two methods for setting the PROFIBUS DP address: ● Using the seven DIP-switches on the Control Unit ● Using parameter "P0918" CAUTION If changing the PROFIBUS DP address, a power cycle is necessary for the Control Unit CU240S to make the new PROFIBUS DP address setting effective.
Communication 6.4 Communication via PROFIBUS The PROFIBUS DP address can be set between 1 and 125, as shown in the table below.
Communication 6.4 Communication via PROFIBUS P0918 PROFIBUS Address ● If address 0 is set on the DIP-switches of the Control Unit (default setting), then the PROFIBUS DP address can be changed in parameter P0918. Valid settings are 1 to 125 (default = 3). ● DIP-switch address settings have priority to P0918 settings. That means if a valid PROFIBUS DP address is set via DIP-switches, the settings of P0918 will be ignored.
Communication 6.4 Communication via PROFIBUS Table 6-30 PROFIBUS DP functions Parameter Meaning Value range P2041.01 OP parameter in EEPROM: Modifications to parameter settings via SIMATIC HMI are stored permanently in the EEPROM or as volatile data in the RAM. 0: Permanent (EEPROM) 1: Volatile (RAM) P2041.03 Select displayed diagnostics screen.
Communication 6.4 Communication via PROFIBUS P0927 Modification source for parameters This parameter defines the interface through which parameters can be modified. Bit Description Index 0 Fieldbus (PROFIBUS DP/PROFINET IO) 0: No 1 BOP 0: No 1: Yes 2 PC Connection Kit (STARTER) 0: No 1: Yes 3 RS485 (only CU240S) 0: No 1: Yes 1: Yes The default setting for all bits is 1, i.e. parameters can be modified from all sources.
Communication 6.4 Communication via PROFIBUS 6.4.3 PROFIBUS Configuration Example with SIMATIC S7 Installing a G120 GSD file The inverter can be integrated into a higher level control device, e.g. SIMATIC S7 via the GSD file. It can be downloaded from the internet via: http://support.automation.siemens.com/WW/view/de/23450835 The GSD file must be installed in HW Config of SIMATIC S7 as shown in the example below. Figure 6-8 Installing the G120 GSD in HW config SIMATIC S7 Install the *.
Communication 6.4 Communication via PROFIBUS Setting the telegram addresses Note The inverters are able to operate with different telegram types. The telegram, selected in the inverter via P0922, must be identical to the type selected in HW Config. The addresses can be changed by opening the properties dialog via double click. Set the addresses to the appropriated values or accept the ones, the system offers and confirm your settings with OK.
Communication 6.4 Communication via PROFIBUS PROFIsafe Parameters The PROFIsafe parameters are shown in the following dialog box (to be opened eg. via left mouse double click on PROFIsafe module).
Communication 6.4 Communication via PROFIBUS Only the following parameters can be changed ● F_Dest_Add: PROFIsafe address ● F_WD_Time: control time for the fail-safe functions CAUTION F_WD_Time In conjunction with the sync/freeze function, the watchdog-time should be increased. A more detailed description can be downloaded from http://support.automation.siemens.com/WW/view/en/23646766. Once all inverters with their telegrams are added, save the project and compile.
Communication 6.4 Communication via PROFIBUS 6.4.3.1 Read Parameters Requirements ● The PROFIBUS master has been commissioned and is fully operational. ● PROFIBUS communication between master and slave is operational. ● The master can read and write data sets in conformance with PROFIBUS DPV1. Task description Following the occurrence of at least one fault (ZSW1.3 = 1) the first 8 active fault codes must be read from the fault buffer r0947[0] … r0947[7].
Communication 6.4 Communication via PROFIBUS Information about the parameter request: ● Request_reference: The value is selected at random from the valid value range. The request reference establishes the relationship between request and response. ● Request_ID: 0x01 --> This identifier is required for a read request. ● Drive_object_ID: 0x00 -> Device-Representative. ● No_of_parameters: 0x02 --> Two parameters are read. ● Attribute_parameter_01: 0x10 --> The parameter values are read.
Communication 6.4 Communication via PROFIBUS Create a response data block e.g. DB2 for the response Figure 6-10 Response data block e.g.
Communication 6.4 Communication via PROFIBUS Information about the parameter response: ● Request_reference_mirror: This response belongs to the request with request reference 0x01. ● Response_ID: 0x01 --> Read request positive, values stored as 1st value. ● Drive_object_ID_mirrored: The values correspond to the values from the request. ● No_of_parameters: The values correspond to the values from the request. ● Format_parameter_1: 0x06 --> Parameter values are in Unsigned16 format.
Communication 6.
Communication 6.4 Communication via PROFIBUS 6.4.3.2 Write Parameters Requirements ● The PROFIBUS master has been commissioned and is fully operational. ● PROFIBUS communication between master and slave is operational. ● The master can read and write data sets in conformance with PROFIBUS DPV1. Task description (multiple parameter request) The maximum frequency (parameter P1082) shall change from 50 Hz (default value) to 100 Hz. Procedure Create a request data block e.g.
Communication 6.4 Communication via PROFIBUS Information about the parameter request: ● Request_reference: The value is selected at random from the valid value range. The request reference establishes the relationship between request and response. ● Request_ID: 0x02 --> This identifier is required for a write request. ● Drive_object_ID: 0x00 -> Device-Representative (for G120 inverters = 0). ● No_of_parameters: 0x01 --> One parameter request. ● Attribute: 0x10 -> The parameter value are to be written.
Communication 6.5 Communication via PROFINET 6.5 Communication via PROFINET General information PROFINET IO is an open Industrial Ethernet standard for a wide range of production and process automation applications. PROFINET IO is based on Industrial Ethernet and observes TCP/IP and IT standards. The following standards ensure open, multi-vendor systems: ● International standard IEC 61158 PROFINET IO is optimized for high-speed, time-critical data communication at field level.
Communication 6.5 Communication via PROFINET 6.5.1 Real-Time (RT) Communication Real-time communication If supervisors are involved in communication, this can result in excessively long runtimes for the production automation system. When communicating time-critical IO use data, PROFINET therefore uses its own real time channel, rather than TCP/IP. Definition: Real Time (RT) and determinism Real time means that a system processes external events over a defined period.
Communication 6.5 Communication via PROFINET IP address assignment The TCP/IP protocol is a prerequisite for establishing a connection and parameterization. This is the reason that an IP address is required. The IP addresses of IO devices can be assigned by the IO controller and have always the same sub-network mask as the IO controller. The IP addresses can be consecutively assigned from the IP address of the IO controller. If the IP address is set by the IO controller, it is saved in a volatile fashion.
Communication 6.5 Communication via PROFINET Module ID A drive unit can be represented by a slot model. The slot model of the CU240S PN provides modules and sub-modules. The module-ID is the ID of a slot module or slot sub-module in this model. The module ID has four digits and is assigned by the system. The slot model of the CU240S PN provides two main module ID: ● Module ID of slot 0, device access point (DAP) This module ID is used as a representative of the device.
Communication 6.5 Communication via PROFINET Default router If data needs to be forwarded by means of TCP/IP to a partner located outside the subnetwork, this is carried out via the default router. In the properties dialog in STEP 7 (Properties of Ethernet interface > Parameters > Network transfer), the default router is described as the router. STEP 7 assigns the local IP address to the default router. 6.5.
Communication 6.5 Communication via PROFINET Table 6-34 Parameters for flexible interconnection of process data Telegram PZD1 STW/ZS W PZD2 HSW/HI W PZD3 PZD4 PZD5 PZD5 Link values for setpoints master to inverter r8850.00 r8850.01 r8850.02 r8850.0 3 r8850.0 4 r8850.0 5 Link parameters for actual values inverter to master P8851.0 0 P8851.0 1 P8851.0 2 P8851. 03 P8851. 04 P8851.
Communication 6.5 Communication via PROFINET CAUTION Shutdown on faults can only take place if both monitoring functions are activated! When the PROFINET interface is in operation, parameter P8840 should also be set to a value of > 0. The process data monitoring function is thus activated/deactivated solely using the PROFIBUS process data monitoring function. The monitoring time then corresponds to the process data monitoring time setting plus the time set in P8840.
Communication 6.5 Communication via PROFINET 6.5.4 PROFInet Configuration Example with SIMATIC S7 Prerequisites To integrate a SINAMICS G120 inverter in SIMATIC S7 control system, the following requirements should be fulfilled: Prerequisites for standard inverters ● STEP 7 V5.4, SP1 is installed on the engineering station ● In HW Config, the following components are disposed: – One of the following CPUs CPU 315-2 PN/DP with firmware at least 2.5.1 CPU 317-2 PN/DP with firmware at least 2.5.
Communication 6.5 Communication via PROFINET Adding a SINAMICS G120 inverter to HW Config To add the SINAMICS G120 inverter as a PROFINET IO device, perform the following steps: 1. Select the PROFINET sub-network in HW config. 2. Open "PROFINET IO > Drives > SINAMICS > GSD" in the hardware catalog. 3. Double click onto e.g. "SINAMICS G120 CU240S PN F" to add the G120 inverter as I/O device to the subnet.
Communication 6.5 Communication via PROFINET 3. With a double click on the telegram you open the properties dialog. Enter a name for the telegram or accept the one, the systems offers. 4. Confirm your setting with OK. Setting the telegramm addresses Addresses can be set by opening the dialog box via double click for: ● Parameter access point ● Profisafe telegram ● Selected telegram type Set the addresses to the appropriated values or accept the ones, the system offers and confirm your settings with OK.
Communication 6.5 Communication via PROFINET 6.5.4.1 Read Parameters Requirements ● The PROFInet IO controller and supervisor have been commissioned and are fully operational. ● Communication between supervisor, controller and device is operational. ● The supervisor can read and write data sets in conformance with Base mode parameter access.
Communication 6.5 Communication via PROFINET Create request/response Data block, e.g.
Communication 6.6 Communication via USS 6.6 Communication via USS 6.6.1 Universal serial interface (USS) Data Parameter range: P2010 … r2037 Warnings: – Faults: F0071, F0072 Function chart number: FP2500, FP2510, FP2600, FP2610 Description Using the Universal Serial Interface (USS) protocol, a user can establish a serial point-topoint data link (RS232 interface) and a serial bus data link between a higher-level master system and several slave systems (RS485 interface). Master systems can be e.
Communication 6.6 Communication via USS 7HUPLQDWLRQ UHVLVWRU 2)) &8 6 68% ' 2)) 68% ' )LQDO 56 VODYH * * &8 6 56 VODYH * 56 VODYH 56 0DVWHU &8 6 21 68% ' 6FUHHQLQJ Figure 6-15 USS network via RS485 CAUTION A difference in earth potential between master and the slaves in an RS485 network can cause damage to the Control Unit of the Inverter. Care must be taken to ensure that the master and slaves all have the same ground level. 6.6.
Communication 6.6 Communication via USS Connector A standard 9 pin sub-D connector can be used for USS connection via RS485. Table 6-38 Technical data of standard 9-pin sub-D connector for RS485 Standard 9 pin sub D connector PG socket No Max. baud rate 115200 baud Outgoing cable unit 180° Bus termination The RS485 termination can be activated via switches on the housing of the SINAMICS G120.
Communication 6.6 Communication via USS 6.6.3 Structure of a USS Telegram Description The following figure shows the structure of a typical USS telegram. Header STX n use data LGE 6WDUW 'HOD\ Figure 6-16 ADR 1. 2. ::: Trailer n. BCC 866 IUDPH Structure of USS telegram Variable length telegrams and fixed length telegrams can both be used. This can be selected using parameters P2012 and P2013 to define the PZD and PKW lengths.
Communication 6.6 Communication via USS STX The STX field is a single byte ASCII STX character (0x02) used to indicate the start of a message. LGE The LGE is a single byte field, indicating the number of bytes which follow this in the telegram. It is defined as the sum of ● use data characters (quantity n) ● address byte (ADR) ● block check character (BCC) The actual total telegram length will of course be two bytes longer as STX and LGE itself are not counted in the LGE.
Communication 6.6 Communication via USS 6.6.4 Use data area of USS telegram Basic USS parameters General rule: Index[0] for USS on RS485, Index[1] for USS on RS232. P2010 USS Baudrate [2400 … 115200] baud P2011 USS Slave Address: [0 … 30] P2012 USS PZD Length: [0 … 2 … 8] words P2013 USS parameter channel length: [0, 3 (3 words), 4 (4 words), 127 (variable length)] P2014 USS Telegram Off-Time: [0 … 65535] ms.
Communication 6.6 Communication via USS The length of the parameter channel is determined by parameter P2013, that for the process data by parameter P2012. If either no parameter channel or no PZD is required, the corresponding parameters can be set to zero ("PKW only" or "PZD only" respectively). It is not possible to transmit "PKW only" and "PZD only" alternatively. If both channels are required they must be transferred together. 6.6.
Communication 6.6 Communication via USS 6.6.6 Timeouts and other errors Telegram Timeouts For the timeout monitoring, the character run time is important: Table 6-41 Character run time Baudrate in bit/s Transfer time per character (= 11 bit) Transfer time per bit Character run time 9600 1.146 ms 104.170 us 1.146 ms 19200 0.573 ms 52.084 us 0.573 ms 38400 0.286 ms 26.042 us 0.286 ms 115200 0.059 ms 5.340 us 0.
Communication 6.6 Communication via USS Character delay time timeout between characters and must be smaller than 2 time the character run time but can be zero Start delay timeout between USS messages. Must be > 2 * character run time Response delay Processing time of the slave. Must be < 20 ms, but larger than the start delay! Residual run time < 1.
Communication 6.6 Communication via USS Process Timeouts Parameter P2014 determines the timeout in ms. A value of zero disables the timeout check. Parameter P2014 checks the cyclic refresh of Bit10 in control word 1. When USS is configured as command source of the drive and P2014 is not zero, Bit10 of the received control word 1 is examined. If the bit is not set, an internal timeout counter is incremented. If the threshold of p2014 is reached, a process timeout fault is set by the drive.
Communication 6.6 Communication via USS 6.6.7 USS Process Data Channel (PZD) Description In this area of the telegram, process data (PZD) are continually exchanged between the master and slaves. Dependent of the direction the process data channel contains data for a request to the USS slaves or for a response to the USS master. In the requests are control words and setpoints for the slaves and in the responses are status words and actual values for the master.
7 Operation 7.1 ON/OFF Commands The G120 inverter provides the following ON/OFF commands: ● ON / OFF (ON/OFF1) ● Coast stop (OFF2) ● Quick stop (OFF3) Description ON / OFF (ON/OFF1) The ON/OFF1 function is an inter-coupled command. When the ON command is withdrawn, then OFF1 is directly activated. ● Frequency setpoint = 0 The inverter ramps down to standstill in the period of time set in P1121. ● If parameterized, the motor holding brake is closed (P1215) when zero speed is detected.
Operation 7.1 ON/OFF Commands Quick stop (OFF3) ● Frequency setpoint = 0 ● The inverter ramps down to standstill in the period of time set in P1135. ● If parameterized, the motor holding brake is closed, when zero speed is detected. When the brake application time (P1217) expires, the pulses are suppressed. Zero speed is detected, if one of the following events occur: – The actual speed drops below the Switch-off frequency (P2167).
Operation 7.1 ON/OFF Commands Sources for ON/OFF command For standard Control Units (CU240S), the command source for ON/OFF is the digital input 0 (DI0). For PROFINET or PROFIBUS Control Units, the communication interface is used as command source for ON/OFF. In addition the following sources are selectable via P0700: ● Digital inputs (P0700 = 2) ● BOP (P0700 = 1) ● STARTER (P0700 = 4) ● A higher-level control system (P0700 = 6) Refer to Commissioning section for details.
Operation 7.2 Operation States Displayed via LED 7.2 Operation States Displayed via LED 7.2.1 LED Display Status display The SINAMICS G120 provides LEDs to show the operating states for standard or fail-safe inverters.
Operation 7.2 Operation States Displayed via LED Behavior of the status LED CU240S CU240S DP CU240S DP-F CU240S PN CU240S PN-F System-Fault (SF) • ON: A general system error either software or hardware related is indicated. • Flashing: Download from MMC runs x x x x x Ready (RDY) • ON: The inverter is ready to run or running.
Operation 7.
Operation 7.
Troubleshooting 8.1 8 Faults and Alarms Description The inverter indicates unfavourable states as faults and alarms. ● Alarms Alarms are not displayed via the LEDs on the Control Unit. Alarms require no acknowledgement and cause no systems reaction. The alarm number is displayed on STARTER or a higher-level control system. ● Faults Faults indicate a severe unfavourable state. If a fault occurs, the inverter powers off and the LED "SF" on the Control Unit is active.
Troubleshooting 8.1 Faults and Alarms Alarms For alarm handling, regard the following parameter: ● Stored in parameter r2110 under their code number and can be read out, e. g. A0503 = 503. The value 0 indicates, that no warning is applied. Via the index, you have access to the two actual alarms and the last two historical alarms. Display Faults and alarms are displayed on the following components: ● BOP The status display of the BOP indicates the occurring faults and alarms.
Troubleshooting 8.2 Diagnostics Display 8.2 Diagnostics Display Overview The G120 inverter provides the following types of diagnostic display: ● LEDs on the Control Unit A detailed overview on the LED states is given in section "Operation States displayed via LED" in this manual. ● Alarm and fault numbers You use the alarm and fault numbers for troubleshooting via BOP and STARTER. For details for troubleshooting with STARTER, refer to the respective online help.
Troubleshooting 8.3 Troubleshooting with the BOP 8.3 Troubleshooting with the BOP Diagnostics using alarm and fault numbers The BOP must be fitted to the Control Unit. If an alarm or fault condition occurs, the BOP displays appropriate alarm or fault number. If an alarm occurs the alarm number is displayed and the inverter will continue to run, although it is possible that it may run in an unexpected manner depending upon the alarm condition.
Troubleshooting 8.3 Troubleshooting with the BOP Motor failure without fault or warning message If the motor fails to start when the ON command has been given: ● Check that P0010 = 0. ● Check the inverter state via r0052. ● Check command and setpoint source (P0700 and P1000). ● Check, if the motor data relate to the inverter data power range and voltage. Note For troubleshooting, pay regard to the "Installation Check List" in the chapter "Installation" of this manual.
Troubleshooting 8.4 Troubleshooting via the Control System 8.4 Troubleshooting via the Control System Diagnostics using diagnostic parameters The following diagnostic parameters are set via a higher-level control system. This function is provided by Control Units, which communicate via PROFINET or PROFIBUS. Identification of the communications components The read-only parameter r2053 shows the information by which the various firmware components of the PROFIBUS DP interface can be identified.
Troubleshooting 8.4 Troubleshooting via the Control System Table 8-4 Parameter accessing error numbers Number Cause Remedy 0 … 199: Parameter access has been converted to a parameter channel request. Error detected in the inverter. Additional information is in r2054.05 and r2054.
Troubleshooting 8.
Service and maintenance 9 A&D Technical support 24-hour technical support is provided by four main centres worldwide. A&D Global service and support Europe/Africa (Erlangen) Tel: +49 (180) 5050 222 Fax: +49 (180) 5050 223 Email: adsupport@siemens.com America (Johnson City) Tel: +1 (423) 262 2552 Fax: +1 (423) 262 2589 Email: simatic.hotline@sea.siemens.com Asia/Pacific (Beijing) Tel: +86 (1064) 757 575 Fax: +86 (1064) 747 474 Email: adsupport.asia@siemens.
Service and maintenance China (Beijing) Tel: +86 (1064) 71 9990 Fax: +86 (1064) 71 9991 Email: adscs.china@siemens.com Online Service and support Comprehensive information and support tools are available from the Service and Support internet site at: http://support.automation.siemens.
10 Technical data 10.1 CU240S Performance ratings SINAMICS G120 Control Unit 240 (CU240) Table 10-1 CU240 Performance ratings Feature Specification Operating voltage 24 V DC from Power Module or External 24 V DC (20.4 V … 28.8 V, 0.
11 Spare parts/Accessories 11.1 Basic Operation Panel Basic Operator Panel (BOP) The BOP is a parameterization tool that is fitted directly to the SINAMICS G120 inverter via the option port. It can also be used for up and download of parameter sets. For a detailed description refer to chapter "Commissioning using the BOP".
Spare parts/Accessories 11.2 PC Connection Kit 11.2 PC Connection Kit PC Connection Kit The PC connection kit consists of a PC inverter connector module with a 9-pin sub-D socket and a null modem cable allowing connection to a PC running STARTER software.
A Appendix A.1 Electromagnetic Compatibility Electromagnetic compatibility All manufacturers/assemblers of electrical apparatus which "performs a complete intrinsic function and is placed on the market as a single unit intended for the end user" must comply with the EMC directive EC/89/336.
Appendix A.2 Definition of the EMC Environment and Categories A.2 Definition of the EMC Environment and Categories Classification of EMC performance The EMC environment and categories are defined within the EMC Product Standard EN 61800-3, as follows: First Environment An environment that includes domestic premises and establishments that are connected directly to a public low-voltage power supply network without the use of an intermediate transformer.
Appendix A.3 EMC Overall Performance A.3 EMC Overall Performance EMC Emissions The SINAMICS G120 drives have been tested in accordance with the emission requirements of the category C2 (domestic) environment. Table A-1 Conducted & Radiated Emissions EMC Phenomenon Standard Level Conducted Emissions EN 55011 Class A Radiated Emissions EN 55011 Class A Note To achieve this performance the default switching frequency should not be exceeded.
Appendix A.
Appendix A.4 Standards ((PM240)) A.4 Standards ((PM240)) European Low Voltage Directive The SINAMICS G120 product range complies with the requirements of the Low Voltage Directive 73/23/EEC as amended by Directive 98/68/EEC.
Appendix A.5 Acceptance Log A.5 Acceptance Log A.5.1 Documentation of acceptance test Overview Acceptance test No. Date Person carrying-out Table A-4 Machine description and overview/block diagram Designation Type Serial No.
Appendix A.5 Acceptance Log Table A-5 Drive No.
Appendix A.5 Acceptance Log Table A-6 Drive No. 218 Description of the fail-safe equipment/devices Example: Wiring of the STO terminals (protective door, EMERGENCY STOP), grouping of the STO terminals, etc.
Appendix A.5 Acceptance Log A.5.2 Function test of the acceptance test Description The function test must be carried-out separately for each individual drive (assuming that the machine permits this to be done). Executing the test First commissioning Please mark Series commissioning Function test "Safe Torque Off" (STO) This test comprises the following steps: Table A-7 "Safe Torque Off" function (STO) No. Description 1.
Appendix A.5 Acceptance Log Function test "Safe Stop 1" (SS1) This test comprises the following steps: Table A-8 220 "Safe Stop 1" function (SS1) No. Description 1. Initial state • Drive is "Ready to Run" (P0010 = 0) • No safety faults and alarms • r9772.0 = r9772.1 = 0 (STO de-selected and inactive) • r9772.2 = r9772.3 = 0 (SS1 de-selected and inactive) Status 2. Operate the drive 3. Check that the expected drive operates 4. Select SS1 while issuing the traversing command 5.
Appendix A.5 Acceptance Log Function test "Safely-Limited Speed" (SLS) This test comprises the following steps: Table A-9 "Safely-Limited Speed" function (SLS) No. Description 1. Initial state • Drive is "Ready to Run" (P0010 = 0) • No safety faults and alarms • r9772.4 = r9772.5 = 0 (SLS de-selected and inactive) 2. Operate the drive (if the machine permits it, at a higher speed than the parameterized safely-limited speed) 3. Check that the expected drive operates 4.
Appendix A.5 Acceptance Log A.5.3 Completing the acceptance log Parameters of the fail-safe functions Specified value checked? Yes No Control unit Checksums Drive Name 222 Checksums Drive No.
Appendix A.5 Acceptance Log Data back-up/archiving Memory medium Type Designation Saved where Date Parameters PLC program Circuit diagrams Signatures Commissioning engineer Confirms that the above listed tests and checks have been correctly carried-out. Date Name Company/department Signature Machinery construction OEM Confirms the correctness of the parameterization documented above.
B List of abbreviations B.
List of abbreviations B.
List of abbreviations B.
List of abbreviations B.
List of abbreviations B.
Index A E A&D Technical support, 205 America (Johnson City), 205 Asia/Pacific (Beijing), 205 China (Beijing), 206 Europe/Africa (Erlangen), 205 Online Service and support, 206 Acceptance test, 91 Accessories Basic Operator Panel (BOP), 209 PC Connection Kit, 210 Electromagnetic compatibility, 211 EMC precautions, 41 EMC Standards, 211 European EMC Directive, 215 European Low Voltage Directive, 215 European Machinery Directive, 215 B BOP, 52, 93, 100 C Calculating the motor/control data, 66 Changing par
Index Parameter attribute Access level, 112 Active, 114 BICO, 112 Can be changed, 113 Data type, 113 Grouping, 114 Quick commissioning, 115 Unit, 113 Value range, 115 Parameter channel, 124 Parameters Data sets, 115 PM Swap, 121 Power Modules Fitting the Control Unit to the, 29 PROFIBUS DP Conversion of extended functionality, 142 Setting the address, 150 Switch over behavior, 134 PROFIBUS DP parameters, 151 PROFIBUS terminator, 40 PROFINET parameters, 170 PROFIsafe Parameters, 157 PROFIsafe telegram struc
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