Sinamics g120e Oper Manual 032012

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SINAMICS

SINAMICSG120E Enclosed Drives

1.0 Hp to 200 Hp

Operating Instructions · Edition 03/2012

� G120E Enclosed Drives, 1.0 Hp to 200

�Hp, Firmware V4.3

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SINAMICS

G120E Enclosed Drives, 1.0 Hp to 200 Hp, Firmware V4.3

Operating Instructions

03/2012 A5E03460835A

Preface

Safety Information 1

Product Description 2

Drive Installation and Connection

3

Commissioning 4

Operation 5

Parameter Descriptions 6

Drive Functions 7

Troubleshooting 8

Maintenance, Service, and Support

9

List of Abbreviations A

Legal information

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 with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.

CAUTION without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.

NOTICE indicates that an unintended result or situation can occur if the relevant information is not taken into account.

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.

Siemens industry, Inc. 3333 Old Milton Parkway Alpharetta, GA 30005 USA

A5E03460835A Ⓟ 03/2012 Technical data subject to change

Copyright © Siemens AG 2012. All rights reserved

G120E Enclosed Drives, 1.0 Hp to 200 Hp, Firmware V4.3 Operating Instructions, 03/2012, A5E03460835A 3

Preface

SINAMICS documentation This documentation describes the standard features and the operation of the SINAMICS G120E enclosed drive products.

WARNING Before installing and commissioning the drive, make sure that you read all the safety notes and warnings carefully, including the warning labels on the equipment itself.

Target group This documentation is intended for engineers, commissioning engineers, and maintenance personnel who have a general knowledge of adjustable speed drives. It is recommended that persons using this documentation also have knowledge of SINAMICS drive systems and STARTER software.

Search tools The following guides are provided to help you locate information in this manual:

● Contents

● List of abbreviations

● Index

Scope This manual describes the G120E firmware release V4.3.

The scope of the functionality described in this document may differ from the scope of the functionality of the drive that is actually supplied, depending on the actual customer’s specifications:

● It is possible for other functions not described in this documentation to be executed in the drive.

● Refer to the outline drawing and schematic for detailed information regarding the actual configuration of the drive supplied.

● Product manuals for order engineered functions will be supplied in the main owner’s manual to supplement the standard drive operating instructions.

Preface

G120E Enclosed Drives, 1.0 Hp to 200 Hp, Firmware V4.3 4 Operating Instructions, 03/2012, A5E03460835A

Technical support If you have any questions, please contact us on the following hotline:

Table 1 America (Johnson City, TN):

Internet Support-Request: http://www.siemens.com/automation/support-request Tel: +1 (800) 333-7421 Tel: +1 (423) 262-2522 Fax: +1 (423) 262-2200

Internet address for SINAMICS http://www.sea.siemens.com/US/Products/Drives

Notation The following notation and abbreviations are used in this documentation:

● Notation for parameters (examples):

– p0918 Adjustable parameter 918

– r1024 Visualization parameter 1024

– p1070[1] Adjustable parameter 1070, index 1

– p2098[1].3 Adjustable parameter 2098, index 1, bit 3

– p0099[0…3] Adjustable parameter 99, indices 0 to 3

– r0945[2](3) Visualization parameter 945, index 2 of drive object 3

– p0795.4 Adjustable parameter 795, bit 4

● Notation for faults and alarms (examples):

– F12345 Fault 12345

– A67890 Alarm 67890

Contact/Originator address Siemens Industry, Inc. 3333 Old Milton Parkway Alpharetta, GA 30005 USA


Table of contents

Preface ...................................................................................................................................................... 3

1 Safety Information...................................................................................................................................... 9

1.1 Safety instructions..........................................................................................................................9 1.1.1 Overview ........................................................................................................................................9 1.1.2 General cautions and notes .........................................................................................................10 1.1.3 Components that can be destroyed by electrostatic discharge (ESD) ........................................11

1.2 Information ...................................................................................................................................12 1.2.1 Transport and storage..................................................................................................................12 1.2.2 Commissioning.............................................................................................................................13 1.2.2.1 Mechanical installation.................................................................................................................13 1.2.2.2 Electrical installation ....................................................................................................................14 1.2.3 Operation .....................................................................................................................................15 1.2.4 Repair...........................................................................................................................................16

2 Product Description ................................................................................................................................. 17

2.1 Overview ......................................................................................................................................17

2.2 Features and functions ................................................................................................................18 2.2.1 G120E block diagram ..................................................................................................................18 2.2.2 Drive features...............................................................................................................................19 2.2.3 Drive functions .............................................................................................................................19

2.3 Basic components and options for the G120E ............................................................................21 2.3.1 G120E typical wall-mount enclosure photos with component locations......................................21 2.3.2 G120E typical free-standing enclosure photos with component locations ..................................23 2.3.3 Control unit CU230P-2.................................................................................................................25 2.3.3.1 Variants of CU230P-2 ..................................................................................................................25 2.3.3.2 Interfaces, connectors, switches, control terminals, LEDs on the CU230P-2 .............................26 2.3.4 Control unit CU240E-2.................................................................................................................27 2.3.4.1 Variants of CU240E-2 ..................................................................................................................27 2.3.4.2 Interfaces, connectors, switches, control terminals, LEDs on the CU240E-2 .............................28 2.3.5 Control unit CU240S ....................................................................................................................29 2.3.5.1 Variants of CU240S .....................................................................................................................29 2.3.5.2 Interfaces, connectors, switches, control terminals, LEDs on the CU240S ................................29 2.3.6 Power modules ............................................................................................................................31 2.3.7 Main circuit breaker......................................................................................................................31 2.3.8 Intelligent operator panel (IOP)....................................................................................................31 2.3.9 Standard options..........................................................................................................................32 2.3.9.1 Overview ......................................................................................................................................32 2.3.9.2 Mechanical options ......................................................................................................................33 2.3.9.3 Input options.................................................................................................................................33 2.3.9.4 Output options..............................................................................................................................34

Table of contents


2.3.9.5 Bypass options............................................................................................................................ 34 2.3.9.6 Communication options............................................................................................................... 34 2.3.9.7 Miscellaneous electrical options ................................................................................................. 35

2.4 Technical specifications .............................................................................................................. 36 2.4.1 General technical specifications ................................................................................................. 36 2.4.2 Derating data............................................................................................................................... 37 2.4.2.1 Current derating as a function of the site altitude and ambient temperature.............................. 37 2.4.2.2 Voltage derating as a function of the site altitude ....................................................................... 37 2.4.2.3 Current reduction depending upon pulse frequency................................................................... 38 2.4.3 G120E specifications .................................................................................................................. 39

3 Drive Installation and Connection ............................................................................................................ 45

3.1 Connection .................................................................................................................................. 45 3.1.1 Connection to the power supply.................................................................................................. 45 3.1.1.1 Reforming the capacitors ............................................................................................................ 47 3.1.2 Connection to the motor.............................................................................................................. 48 3.1.3 Customer control terminals ......................................................................................................... 49

3.2 Cable accessibility....................................................................................................................... 49

3.3 Permissible cable length from motor connection to drive ........................................................... 50

3.4 Cooling ........................................................................................................................................ 50

3.5 Installation check list and required tools ..................................................................................... 51

4 Commissioning ........................................................................................................................................ 53

4.1 Preliminary check........................................................................................................................ 53

4.2 Commissioning overview ............................................................................................................ 54 4.2.1 Single commissioning ................................................................................................................. 54 4.2.2 Series commissioning ................................................................................................................. 55 4.2.3 Commissioning with the IOP....................................................................................................... 56 4.2.3.1 Quick commissioning with the IOP ............................................................................................. 56 4.2.3.2 Identifying motor data.................................................................................................................. 57 4.2.3.3 Reset parameters to control unit default settings ....................................................................... 57

4.3 Advanced commissioning with STARTER.................................................................................. 58 4.3.1 STARTER interfaces................................................................................................................... 58 4.3.2 Single commissioning with STARTER ........................................................................................ 58 4.3.3 Series commissioning with STARTER........................................................................................ 59

5 Operation................................................................................................................................................. 61

5.1 Running the drive for the first time .............................................................................................. 61

5.2 Intelligent operator panel............................................................................................................. 62 5.2.1 Overview ..................................................................................................................................... 62 5.2.1.1 Introduction ................................................................................................................................. 62 5.2.1.2 Layout and functions ................................................................................................................... 63 5.2.1.3 Screen icons ............................................................................................................................... 65 5.2.1.4 Menu structure ............................................................................................................................ 66

Table of contents


5.2.2 Control..........................................................................................................................................67 5.2.2.1 Overview ......................................................................................................................................67 5.2.2.2 Setpoint ........................................................................................................................................67 5.2.2.3 Reverse........................................................................................................................................68 5.2.2.4 Jog ...............................................................................................................................................69 5.2.3 Menu ............................................................................................................................................70 5.2.3.1 Overview ......................................................................................................................................70 5.2.3.2 Parameters...................................................................................................................................71 5.2.3.3 Up/Download................................................................................................................................78 5.2.3.4 Extras ...........................................................................................................................................78

5.3 ON/OFF commands.....................................................................................................................82 5.3.1 Overview ......................................................................................................................................82 5.3.1.1 Overview ......................................................................................................................................82 5.3.1.2 ON / OFF (ON/OFF1) command..................................................................................................82 5.3.1.3 Coast stop (OFF2) command ......................................................................................................83 5.3.1.4 Quick stop (OFF3) command.......................................................................................................83 5.3.2 Power ON/OFF ............................................................................................................................83

6 Parameter Descriptions ........................................................................................................................... 85

6.1 Overview of parameters...............................................................................................................85

6.2 Key parameters for operating the drive .......................................................................................86 6.2.1 Parameter attributes ....................................................................................................................86 6.2.2 Monitoring parameters .................................................................................................................91 6.2.3 Write parameters .........................................................................................................................91

6.3 BICO technology, data sets, other parameters............................................................................92 6.3.1 BICO technology overview...........................................................................................................92 6.3.2 Using BICO technology................................................................................................................92 6.3.3 Data sets ......................................................................................................................................96

7 Drive Functions...................................................................................................................................... 103

7.1 Overview of functions.................................................................................................................103

7.2 Overview of the CU230P-2 functions.........................................................................................104

7.3 Overview of the CU240E-2 functions.........................................................................................106

7.4 Overview of CU240S functions ..................................................................................................108

8 Troubleshooting..................................................................................................................................... 111

8.1 Faults and alarms ......................................................................................................................111 8.1.1 Overview of alarms and faults....................................................................................................112

8.2 Diagnostics display ....................................................................................................................113 8.2.1 Introduction ................................................................................................................................113 8.2.2 Diagnostics with the IOP............................................................................................................113

Table of contents


9 Maintenance, Service, and Support ....................................................................................................... 119

9.1 Maintenance.............................................................................................................................. 119 9.1.1 Overview ................................................................................................................................... 119 9.1.2 Maintenance procedure ............................................................................................................ 119 9.1.2.1 Overview ................................................................................................................................... 119 9.1.2.2 Cleaning .................................................................................................................................... 120 9.1.2.3 Inspecting.................................................................................................................................. 121 9.1.2.4 Replacing components.............................................................................................................. 121 9.1.3 Storage requirements................................................................................................................ 123

9.2 Service and support .................................................................................................................. 124

A List of Abbreviations .............................................................................................................................. 127

A.1 List of abbreviations .................................................................................................................. 127

Index...................................................................................................................................................... 133


Safety Information 11.1 Safety instructions

1.1.1 Overview 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 drive, classified as General, Transport and Storage, Commissioning, Operation, Repair and Dismantling and Disposal.

Specific Warnings, Cautions and Notes that apply to particular activities are listed at the beginning of the relevant sections in this manual and are repeated or supplemented at critical points throughout these sections.

Please read the information carefully, since it is provided for your personal safety and will also help prolong the service life of your drive and the equipment to which it is connected.



1.1.2 General cautions and notes

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.

Only suitably qualified personnel should work on this equipment, and only after becoming familiar with all safety notices, installation, operation and maintenance procedures contained in this manual. The successful and safe operation of this equipment is dependent upon its proper handling, installation, operation and maintenance.

A fixed ground connection is required, and the minimum size of the conductor shall comply with National Electric Code, NFPA70.

The power supply, DC and motor terminals, the brake and thermistor cables can carry dangerous voltages even if the inverter is inoperative. Wait at least five minutes to allow the unit to discharge after switching off the line supply before carrying out any installation work.

The output of the drive must never be open-circuited while operating in order to prevent possible damage to the drive.

When connecting the line supply to the Inverter, make sure that the terminal box of the motor is closed.

This equipment is capable of providing internal motor overload protection according to UL508C. Refer to P0610 and P0335, i²t is ON by default.

When changing from the ON to OFF-state of an operation if an LED or other similar display is not lit or active; this does not indicate that the unit is switched-off or powered-down.

The cabinet must always be grounded.

Isolate the line supply and lock out the disconnect before making or changing connections to the unit.

Ensure that the drive is configured for the correct supply voltage. The drive must not be connected to a higher voltage supply.

Static discharges on surfaces or interfaces that are not generally accessible (for example, terminal or connector pins) can cause malfunctions or defects. Therefore, when working with inverters or inverter components, ESD protective measures should be observed.

Take particular notice of the general and regional installation and safety regulations regarding work on dangerous voltage installations as well as the relevant regulations regarding the correct use of tools and personal protective equipment (PPE).



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.

Whenever measuring or testing has to be performed on live equipment, applicable OSHA regulations must be observed. Suitable electronic tools should be used.

Before installing and commissioning, please read these safety instructions and warnings 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.

1.1.3 Components that can be destroyed by electrostatic discharge (ESD)

CAUTION The board contains components that can be destroyed by electrostatic discharge. These components can be easily destroyed if not handled properly. If you do have to use electronic boards, however, please observe the following: You should only touch electronic boards if absolutely necessary. When you touch boards, however, your body must be electrically discharged

beforehand. Boards must not come into contact with highly insulating materials (such as plastic

parts, insulated desktops, articles of clothing manufactured from man-made fibers). Boards must only be placed on conductive surfaces. Boards and components should only be stored and transported in conductive packaging

(such as metalized plastic boxes or metal containers). If the packaging material is not conductive, the boards must be wrapped with a

conductive packaging material (such as conductive foam rubber or household aluminum foil).

Safety Information 1.2 Information


The necessary ESD protective measures are clearly illustrated in the following diagram:

● a = conductive floor surface

● b = ESD table

● c = ESD shoes

● d = ESD overall

● e = ESD wristband

● f = cabinet ground connection

● g = contact with conductive flooring

Figure 1-1 ESD Protective Measures

1.2 Information

1.2.1 Transport and storage

WARNING Correct transport, storage as well as careful operation and maintenance are essential for the proper and safe operation of the equipment.



CAUTION Protect the equipment against physical shocks and vibration during transport and storage. It is important that the equipment is protected from water (rainfall) and excessive temperatures.

1.2.2 Commissioning

WARNING Working on the equipment by unqualified personnel or failure to comply with warnings can result in severe personal injury or serious damage to material. Only suitably qualified personnel trained in the setup, installation, commissioning and operation of the product should carry out work on the equipment.

CAUTION Cable connection

The control cables must be laid separately from the power cables. Carry out the connections as shown in the installation section in this manual, to prevent inductive and capacitive interference from affecting the correct function of the system.

1.2.2.1 Mechanical installation

WARNING To ensure the safe operation of the equipment, it must be installed and commissioned by qualified personnel in full compliance with the warnings laid down in this manual.

Take particular note of the general and regional installation and safety regulations regarding work on dangerous voltage installation as well as the relevant regulations regarding the correct use of tools and personal protective equipment (PPE).



1.2.2.2 Electrical installation

WARNING Power and motor connections

The cabinet must always be grounded. If it is not grounded correctly, extremely dangerous conditions may arise which could prove potentially fatal.

Isolate the mains electrical supply and lock-out the disconnect before making or changing connections to the unit.

The terminals of the drive can carry dangerous voltages even if the drive is inoperative. Wait at least 5 minutes to allow the unit to discharge after switching off the line supply before carrying out any installation work.

When connecting the line supply to the drive, make sure that the terminal box of the motor is closed.


Ensure that the drive is selected for the correct supply voltage range - it must not be connected to networks with nominal voltage outside the range of 460 - 480V (or 380 - 480V with option N75), +/-10%.

The drive short circuit current rating (SCCR) is marked on the drive nameplate. To comply with the requirements of NFPA 70, it must not be connected to a network capable of delivering higher fault currents than the drive SCCR.



1.2.3 Operation

WARNING The inverter operates at high voltages. When operating electrical devices, it is impossible to avoid applying hazardous voltages to certain parts of the equipment.

The power supply, DC and motor terminals can carry dangerous voltages even if the drive is inoperative. Wait five minutes to allow the unit to discharge after switching off the line supply before carrying out any installation work.

Emergency Stop facilities 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.

The mechanical disconnect installed in the drive has a defeat feature that should only be used by qualified personnel with the proper personal protective equipment (PPE).

Certain parameter settings may cause the inverter to restart automatically after an input power failure, for example, the automatic restart function.

Motor parameters must be accurately configured for motor overload protection to operate correctly.

The power modules are components with a high leakage current!

Use of mobile radio device (for example, telephones and walky-talkies) with a transmission power > 1 W in the immediate vicinity of the devices (< 1.5 m) can interfere with the functioning of the equipment!

If an input circuit breaker or fuse trips in a branch circuit, a fault current may have been disconnected. To reduce the risk of fire or electric shock, current-conducting parts and other components in the drive should be inspected and damaged parts replaced. When a protective device trips, the cause of the trip must be identified and rectified.



1.2.4 Repair

WARNING Repairs on equipment may only be carried out by Siemens Service, by repair centers authorized by Siemens or by authorized personnel who are thoroughly acquainted with all the warnings and operating procedures contained in this manual.

Any defective parts or components must be replaced using parts contained in the relevant spare parts list.

Disconnect and lock out the power supply before opening the equipment for access.

Replace any failed fuses with the same class and current rating. Refer to the label installed inside the drive cabinet.


Product Description 22.1 Overview

SINAMICS G120E The SINAMICS G120E is a stand-alone, adjustable speed, enclosed drive for single motor applications with variable or constant torque loads. This compact and quiet drive includes an AC/AC power module with IGBT power semiconductors and an innovative cooling concept. The control can be operated in either Volts/Hertz or sensorless vector modes or closed loop vector control with encoder (depending on the control unit option selected).

The standard drive enclosure is either a wall mount box or a floor standing cabinet, which can be equipped with a variety of options. G120E is delivered with the following standard features:

● SINAMICS G120 converter components

● NEMA 1 enclosure

● UL listed to UL508C

● Circuit breaker disconnect (per NEC requirements for motor branch circuit protection)

● 65 kA SCCR

● Mechanical door interlocks

● Input line reactor (only with power module PM240)

● Intelligent Operator Panel for easy start-up and operation

G120E reference documents This document does not include all of the information for G120E drives. Should further information be desired, please refer to the additional enclosed documents available on the product CD supplied with each drive.

For further information (for example, product manuals, FAQs, and updates), go to the following Internet address and search for SINAMICS G120:

http://support.automation.siemens.com

Product Description 2.2 Features and functions


2.2 Features and functions

2.2.1 G120E block diagram

Figure 2-1 G120E Block Diagram



2.2.2 Drive features

● Modular inverter

● Simple to install

● Signal interconnection possible via BICO technology

● Different data sets selectable

● Fast current limiting (FCL) for trip-free operation

● Easy exchange of Power Module or Control Unit

● Rugged EMC design

● Configurable for a wide range of applications

● Status display via LEDs on the Control Unit

● High pulse frequencies for low noise motor operation

● EM (Electro-Magnetic) brake relay driver

● Built-in braking chopper for dynamic braking

● DC-link voltage controller

● Kinetic buffering

2.2.3 Drive functions

Commissioning functions ● Quick commissioning

● Motor/control data calculation

● Motor data identification

● Application commissioning

● Series commissioning

● Parameter reset to the control unit defaults



Operating functions ● Adjustable setpoint channel

● Adjustable ramp-function generator (RFG)

● JOG mode

● Free function blocks (FFB)

● Fast free function blocks (Fast FFB)

● Automatic restart (WEA)

● Flying restart

● Motorized potentiometer

● Fixed and skip frequencies

● PID controller

● Current limiting

● Slip compensation

● Motor holding brake (MHB)

● Wobble generator

Control functions ● V/Hz control with different characteristics

● SLVC (Sensorless vector control mode) speed and torque

● VC (Vector control mode with encoder) speed and torque (only with CU240S)

Protective functions ● Motor protective functions

● Inverter protective functions

● Plant / system protective functions

Maintenance functions ● Monitoring function

● Fault log

● Alarm log

Product Description 2.3 Basic components and options for the G120E


2.3 Basic components and options for the G120E

2.3.1 G120E typical wall-mount enclosure photos with component locations

Figure 2-2 G120E 60HP Front View



Figure 2-3 G120E 60HP Interior View



2.3.2 G120E typical free-standing enclosure photos with component locations

Figure 2-4 G120E 200HP Front View



Figure 2-5 G120E 200HP Interior View



2.3.3 Control unit CU230P-2

2.3.3.1 Variants of CU230P-2 ● CU230P-2 HVAC (standard version of the CU230P-2 control units): This basic unit has

integrated technology functions for pumps, fans, and compressor applications. Specific functions include the following:

– Emergency operation

– Multi-zone controller

– Motor staging

– Hibernation

– Bypass

The CU230P-2 HVAC has an available RS485 interface for the following:

– USS

– Modbus RTU

– BACnet MS/TP communication

● CU230P-2 DP (CU230P-2 plus PROFIBUS DP interface (PROFIdrive Profile V4.1)): This control unit has all of the functionality of the basic CU230P-2 with the addition of a PROFIBUS DP communication interface.



2.3.3.2 Interfaces, connectors, switches, control terminals, LEDs on the CU230P-2

Figure 2-6 CU230P-2 User Interfaces



2.3.4 Control unit CU240E-2

2.3.4.1 Variants of CU240E-2 ● CU240E-2 (standard version of the CU240E-2): This basic unit has a minimum number of

inputs and outputs for general industrial applications. It also has an available RS485 interface for USS or Modbus RTU communication.

● CU240E-2 DP (CU240E-2 plus PROFIBUS DP interface (PROFIdrive Profile V4.1)): This control unit has all of the functionality of the basic CU240E-2 with the addition of a PROFIBUS DP communication interface.

● CU240E-2 F (CU240E-2 plus safety-integrated functions): This control unit has all of the functionality of the basic CU240E-2 with the addition of an extra fail-safe digital input for implementing basic safety functions.

● CU240E-2 DP-F (CU240E-2 DP plus safety-integrated functions): This control unit has all of the functionality of the CU240E-2 DP with the addition of an extra fail-safe digital input for implementing basic safety functions.



2.3.4.2 Interfaces, connectors, switches, control terminals, LEDs on the CU240E-2

Figure 2-7 CU240E-2 User Interfaces



2.3.5 Control unit CU240S

2.3.5.1 Variants of CU240S ● CU240S (standard version of the CU240 control units): This basic unit utilizes USS protocol

for external network communication. It is provided on G120E drives with other industry standard communication requirements, such as Modbus, Modbus Plus, Ethernet IP, or Modbus TCP/IP.

● CU240S DP (CU240S plus PROFIBUS DP interface (PROFIdrive Profile V4.1)): This control unit has all of the functionality of the basic CU240S with the addition of a PROFIBUS DP communication interface.

● CU240S PN (CU240S plus PROFINET interface (PROFIdrive Profile V4.1)): This control unit has all of the functionality of the basic CU240S with the addition of a PROFINET communication interface.

● CU240S DP-F (CU240S DP plus safety-integrated functions): This control unit has all of the functionality of the CU240S DP with the addition of two extra fail-safe digital inputs for implementing basic safety functions.

● CU240S PN-F (CU240S PN plus safety-integrated functions): This control unit has all of the functionality of the CU240S PN with the addition of two extra fail-safe digital inputs for implementing basic safety functions.

2.3.5.2 Interfaces, connectors, switches, control terminals, LEDs on the CU240S The following interfaces are provided on the Control Unit:

● Terminals for the input and output signals

● Card slot to upload and download inverter settings

● Connector to communicate with higher-level controls

● DIP switches to configure the speed encoder, the analog inputs and, if required, to set the PROFIBUS address.

● LEDs for diagnostics



All of these interfaces are shown in the following diagram:

Figure 2-8 CU240S User Interface



2.3.6 Power modules

Overview The following are the types of SINAMICS G120 series power modules available for applications.

● PM240 power modules with braking capability (resistor braking):

– 380 V … 480 V, IP20, Frame size A 1.0 HP… 2.0 HP

– 380 V … 480 V, IP20, Frame size B 3.0 HP… 5.0 HP

– 380 V … 480 V, IP20, Frame size C 10 HP… 20 HP

– 380 V … 480 V, IP20, Frame size D 25 HP… 40 HP

– 380 V … 480 V, IP20, Frame size E 50 HP… 60 HP

– 380 V … 480 V, IP20, Frame size F 75 HP… 200 HP

● PM250 power modules with regenerative braking capability:

– 380 V … 480 V, IP20, Frame size D 25 HP… 40 HP

– 380 V … 480 V, IP20, Frame size E 50 HP… 60 HP

– 380 V … 480 V, IP20, Frame size F 75 HP… 125 HP

2.3.7 Main circuit breaker The main circuit breaker is a three-pole, automatically-operated, molded-case circuit breaker designed to provide NEC branch circuit protection for overload or short circuit. It has an extra high interrupting rating of 65kA and can be reset manually to resume normal operation. A flange-mounted disconnect handle is installed onto the breaker and mechanically interlocked with the cabinet to ensure that the incoming power supply is disconnected before the cabinet door can be opened. The handle provides a mechanism to lock-out the drive from operation.

2.3.8 Intelligent operator panel (IOP)

Description The IOP has been designed to enhance the interface and communication capabilities of the SINAMICS G120E drives. The IOP can be used for commissioning, operation, and diagnostic purposes.

The IOP connects to the CU230P-2 or CU240E-2 control unit through an RS232 interface. It is designed to automatically recognize the specific control unit type.



Structure The IOP has a back-lit display and push-wheel that allows simple progression through its menu system. The IOP provides support using a USB connection for downloading of wizards and additional languages. The panel is installed in the cabinet door.

2.3.9 Standard options

2.3.9.1 Overview Pre-designed standard options are available to tailor the G120E to customer specifications, whilst maintaining short ex factory delivery times. Please consult your local Siemens Sales Representative for additional options.

Note

It is a mandatory requirement that a control unit be selected from the control unit options list.

Table 2- 1 Standard options

Option Code Description Control Unit (Mandatory) Options G80 CU230P-2 HVAC G81 CU230P-2 DP G83 CU240E-2 G84 CU240E-2 DP G85 CU240S G86 CU240S DP G87 CU240S PN G93 CU240E-2 F G94 CU240E-2 DP-F G96 CU240S DP-F G97 CU240S PN-F Mechanical Options M12 NEMA 12 design with air filters Input Options L13 Input contactor L24 Input line reactor 5% nominal impedance L27 Input fuses



Option Code Description L96 Input SPD (surge protective device) Output Options L08 Output reactor Bypass Options L28 2 contactor bypass (FVNR) - Manual Communication Options (CU240S only) G21 Modbus Plus communication G22 Modbus RTU communication G26 Ethernet IP communication G27 Modbus TCP / IP communication Miscellaneous Electrical Options N75 Expanded voltage range (380 - 480 VAC)

2.3.9.2 Mechanical options

M12: NEMA 12 design with air filters Ventilation openings are covered with washable, HVAC style filters and drip-proof covers. Filter elements are front-mounted so that the filter can be replaced without opening the doors.

2.3.9.3 Input options

L13: Input contactor This option is needed if a switching element is required for disconnecting the drive from the supply. The contactor is powered and controlled by the drive cabinet.

L24: Input line reactor 5% nominal impedance This option includes a 5% impedance reactor for G120E. A 5% inductor provides additional harmonic filtering, which may satisfy the recommended practices and requirements of IEEE 519-1992 at the PCC.

Note

This option is only available with PM240 versions.



L27: Input fuses Current-limiting fuses are added for supplementary short-circuit protection for the drive.

L96: Input SPD (surge protective device) This option includes an SPD for three-phase input surge protection.

2.3.9.4 Output options

L08: Output reactor An output reactor may be used to reduce motor current and voltage harmonics and may be required in applications utilizing long motor leads. The rate of voltage rise, dV/dt, to the motor is limited when using an output reactor. For additional information regarding acceptable cable lengths, refer to the section "Permissible cable length from motor connection to drive."

The maximum output frequency is 90 Hz when an output reactor is supplied.

2.3.9.5 Bypass options

L28: 2 contactor manual bypass (FVNR) This option comprises the following components:

● Drive output contactor

● Bypass contactor with motor overload protection

The following control elements are provided:

● Selector switch (VSD - OFF - BYPASS)

● Status indicator lamps (BYPASS READY and BYPASS ON)

The output and bypass contactors are interlocked electrically. In addition, the output and bypass contactors are interlocked mechanically. The bypass contactor is controlled from the customer terminal block. An input contactor may be added to fully isolate the drive while in bypass (refer to option L13).

2.3.9.6 Communication options

G21: Modbus Plus communication A converter is added to convert the Modbus Plus to USS protocol when a CU240S is supplied. For additional information, refer to the converter manual supplied with the drive.



G22: Modbus RTU communication A converter is added to convert the Modbus RTU to USS protocol when a CU240S is supplied. For additional information, refer to the converter manual supplied with the drive.

G26: Ethernet IP communication A converter is added to convert the Ethernet IP to USS protocol when a CU240S is supplied. For additional information, refer to the converter manual supplied with the drive.

G27: Modbus TCP/IP communication A converter is added to convert the Modbus TCP/IP to USS protocol when a CU240S is supplied. For additional information, refer to the converter manual supplied with the drive.

2.3.9.7 Miscellaneous electrical options

N75: Expanded voltage range For this option, the standard control power transformer is replaced with a version that can be configured for 380 to 480 VAC, which allows the drive to be connected to 380V/50Hz, 415V/50Hz, or 480V/60Hz power supplies.

Product Description 2.4 Technical specifications


2.4 Technical specifications

2.4.1 General technical specifications

Table 2- 2 General Technical Specifications

Feature Specification Electrical Data Line voltage 3 AC 460 V to 480 V ± 10% Line frequency 47 Hz to 63 Hz Output frequency 0 Hz to 266Hz (650 Hz with derating) Pulse frequency 2 or 4 kHz (standard); 2 kHz to 16 kHz (in 2 kHz steps) Power factor λ > 0.95 Efficiency

1.1 x Nominal VT output current (110% overload) for 60 s every 300 s Overload capability (VT) 1.5 x Nominal VT output current (150% overload) for 3 s every 300 s 1.5 x Nominal CT output current (150% overload) for 60 s every 300 s Overload capability (CT) 2.0 x Nominal CT output current (200% overload) for 3 s every 300 s

Mechanical Data Degree of protection UL type 1 Cooling method Forced air cooling Paint finish ANSI 61 Gray Compliance with standards Standards NEMA ICS 7, NEMA ICS 7.1, UL508C Ambient conditions Operation Storage Transport

+32 °F to +104 °F (0 °C to +40 °C)

-13 °F to +131 °F (-25 °C to +55 °C)

-13 °F to +158 °F (-25 °C to +70 °C)

Ambient temperature

Up to +122 °F (+50 °C) with derating

-40 °F (-40 °C) for 24 hours

Humidity (non-condensing)

5% to 95% 5% to 95% 5% to 95% at 40C

Up to 3280 ft (1000 m) above sea level without derating Site altitude > 3280 ft (1000 m) above sea level with derating



2.4.2 Derating data

2.4.2.1 Current derating as a function of the site altitude and ambient temperature

Table 2- 3 Output Current (VT) derating as a function of ambient temperature (air temperature at the air inlet of the cabinet) and site altitude

Ambient Temperature Site Altitude Above Sea Level 95 °F (35 °C) 104 °F (40 °C) 113 °F (45 °C) 122 °F (50 °C)

0 to 3280 ft (1000 m) 100% 100% 91.0% 82.0% Up to 4920 ft (1500 m) 100% 96.7% 88.0% 79.3% Up to 6560 ft (2000 m) 100% 93.3% 84.9% 76.5% Up to 8200 ft (2500 m) 98.1% 90.0% 81.9% 73.8% Up to 9840 ft (3000 m) 94.5% 86.7% 78.9% 71.1% Up to 11480 ft (3500 m) 90.8% 83.3% 75.8% 68.3% Up to 13120 ft (4000 m) 87.2% 80.0% 72.8% 65.6%

Table 2- 4 Output Current (CT) derating as a function of ambient temperature (air temperature at the air inlet of the cabinet) and site altitude

Ambient Temperature Site Altitude Above Sea Level 95 °F (35 °C) 104 °F (40 °C) 113 °F (45 °C) 122 °F (50 °C)

0 to 3280 ft (1000 m) 100.0% 87.0% Up to 4920 ft (1500 m) 96.7% 84.1% Up to 6560 ft (2000 m) 93.3% 81.2% Up to 8200 ft (2500 m) 90.0% 78.3% Up to 9840 ft (3000 m) 86.7% 75.4% Up to 11480 ft (3500 m) 83.3% 72.5% Up to 13120 ft (4000 m) 80.0% 69.6%

2.4.2.2 Voltage derating as a function of the site altitude

Table 2- 5 Voltage derating as a function of the site altitude

Site Altitude Above Sea Level Rated Converter Input Voltage 0 to 6560 ft (2000 m) 480V to 7380 ft (2250 m) 460V to 8200 ft (2500 m) 451V



Site Altitude Above Sea Level Rated Converter Input Voltage to 9020 ft (2750 m) 432V to 9840 ft (3000 m) 422V

to 10660 ft (3250 m) 409V to 11480 ft (3500 m) 394V to 12300 ft (3750 m) 381V to 13120 ft (4000 m) 367V

2.4.2.3 Current reduction depending upon pulse frequency

Table 2- 6 Current reduction depending on pulse frequency

Nominal Current Output current at pulse frequency of Nominal Power (VT) 2 kHz 4 kHz 6 kHz 8 kHz 10 kHz 12 kHz 14 kHz 16 kHz

Hp A A A A A A A A 1.0 -- 2.2 1.87 1.54 1.32 1.10 0.99 0.88 1.5 -- 3.1 2.64 2.17 1.86 1.55 1.40 1.24 2.0 -- 4.1 3.49 2.87 2.46 2.05 1.85 1.64 3.0 -- 5.9 5.02 4.13 3.54 2.95 2.66 2.36 4.0 -- 7.7 6.55 5.39 4.62 3.85 3.47 3.08 5.0 -- 10.2 8.67 7.14 6.12 5.10 4.59 4.08 10 -- 16 14.0 11.5 9.88 8.24 7.41 6.59 15 -- 22 19.4 16.0 13.7 11.4 10.3 9.15 20 -- 29 24.9 20.5 17.6 14.6 13.2 11.7 25 -- 34 29.6 24.3 20.9 17.4 15.6 13.9 30 -- 41 35.0 28.8 24.7 20.6 18.5 16.5 40 -- 54 46.7 38.4 32.9 27.5 24.7 22.0 50 -- 68 58.3 48.0 41.2 34.3 30.9 27.5 60 -- 82 70.0 57.6 49.4 41.2 37.1 32.9 75 -- 100 85.6 70.5 -- -- -- --

100 -- 132 113 92.9 -- -- -- -- 125 -- 168 138 114 -- -- -- -- 150 186 168 -- -- -- -- -- -- 200 240 188 -- -- -- -- -- --



2.4.3 G120E specifications

CAUTION High Overload (CT) and Light Overload (VT) input currents

The input current at the rated operating point applies to a power system where the short-circuit voltage of the line supply Vk=1% (referred to the G120E rated power) is at rated voltage.

Table 2- 7 G120E (PM240) Frame Sizes A, 3 AC 460 V … 480 V, ± 10%

Order No. 6SL3710- 1BJ12-2AU0 1BJ13-1AU0 1BJ14-1AU0 Output Rating (VT) Hp 1 1.5 2

kW 0.14 0.15 0.15 Power Loss - Base Cabinet BTU/hr 480 510 510

Rated Input Current A 4.3 5.2 6.3 Output Current (VT) A 2.2 3.1 4.1 Output Current (CT) A 2.2 3.1 4.1 Required cooling air flow Cfm 77 77 77 Sound Pressure dB(A) 45 45 45 Input Cable AWG 14 to 10 14 to 10 14 to 10 Output Cable AWG 14 14 14

kg 104 104 104 Weight - Base Cabinet lb 230 230 230 mm 508x427x1219 508x427x1219 508x427x1219 Dimensions - Base Cabinet

(Width x Depth x Height) in 20.0x16.8x48.0 20.0x16.8x48.0 20.0x16.8x48.0 mm 152 152 152 Installation Clearance

(Left Side Only) in 6.0 6.0 6.0



Table 2- 8 G120E (PM240) Frame Sizes B, 3 AC 460 V … 480 V, ± 10%

Order No. 6SL3710- 1BJ16-0AU0 1BJ17-7AU0 1BJ21-0AU0 Output Rating (VT) Hp 3 4 5


Rated Input Current A 8.1 10.0 12.4 Output Current (VT) A 5.9 7.7 10.2 Output Current (CT) A 5.9 7.7 10.2 Required cooling air flow Cfm 115 115 115 Sound Pressure dB(A) 62 62 62 Input Cable AWG 14 to 10 14 to 10 14 to 10 Output Cable AWG 14 (See Note 1) 14 (See Note 1) 14 to 10




Note 1: This size is applicable for all options. For certain configurations it may be possible to accommodate other wire sizes too.

Table 2- 9 G120E (PM240) Frame Sizes C, 3 AC 460 V … 480 V, ± 10%



Rated Input Current A 18.6 25 30 Output Current (VT) A 16 22 27 Output Current (CT) A 13.2 19 26 Required cooling air flow Cfm 182 182 182 Sound Pressure dB(A) 64 64 64 Input Cable AWG 14 to 10 10 to 1/0 10 to 1/0 Output Cable AWG 14 to 10 14 to 8 14 to 8


(Width x Depth x Height) in 20.0x16.8x48.0 20.0x16.8x48.0 20.0x16.8x48.0



Order No. 6SL3710- 1BJ21-8AU0 1BJ22-5AU0 1BJ23-2AU0 mm 152 152 152 Installation Clearance


Table 2- 10 G120E (PM240) Frame Sizes D, 3 AC 460 V … 480 V, ± 10%



Rated Input Current A 38 45 59 Output Current (VT) A 34 41 54 Output Current (CT) A 32 38 45 Required cooling air flow Cfm 318 318 318 Sound Pressure dB(A) 65 65 65 Input Cable AWG 10 to 1/0 10 to 1/0 10 to 1/0 Output Cable AWG 8 to 6 8 to 4 8 to 4




Table 2- 11 G120E (PM240) Frame Sizes E, 3 AC 460 V … 480 V, ± 10%

Order No. 6SL3710- 1BJ27-5AU0 1BJ29-0AU0 Output Rating (VT) Hp 50 60

kW 1.27 1.49 Power Loss - Base Cabinet BTU/hr 4340 5090

Rated Input Current A 73 86 Output Current (VT) A 68 80 Output Current (CT) A 60 75 Required cooling air flow Cfm 360 360 Sound Pressure dB(A) 67 67 Input Cable AWG 10 to 1/0 2 to 3/0 Output Cable AWG 8 to 4 8 to 2



Order No. 6SL3710- 1BJ27-5AU0 1BJ29-0AU0 kg 150 150 Weight - Base Cabinet lb 330 330 mm 660x527x1524 660x527x1524 Dimensions - Base Cabinet

(Width x Depth x Height) in 26.0x20.8x60.0 26.0x20.8x60.0 mm 305 305 Installation Clearance

(Left Side Only) in 12.0 12.0

Table 2- 12 G120E (PM240) Frame Sizes F, 3 AC 460 V … 480 V, ± 10%



Rated Input Current A 108 138 170 Output Current (VT) A 100 130 160 Output Current (CT) A 90 110 145 Required cooling air flow Cfm 504 504 504 Sound Pressure dB(A) 69 69 69 Input Cable AWG 4 to 350 kcmil 4 to 350 kcmil 4 to 350 kcmil Output Cable AWG 6 to 350 kcmil 6 to 350 kcmil 6 to 350 kcmil



Table 2- 13 G120E (PM240) Frame Sizes F+, 3 AC 460 V … 480 V, ± 10%



Rated Input Current A 194 249 Output Current (VT) A 186 240 Output Current (CT) A 178 205 Required cooling air flow Cfm 525 525 Sound Pressure dB(A) 69 69



Order No. 6SL3710- 1BJ32-0AU0 1BJ32-5AU0 Input Cable AWG 2x3/0 to 250 kcmil 2x3/0 to 250 kcmil Output Cable AWG 2x4 to 350 kcmil 2x4 to 350 kcmil

kg 345 345 Weight - Base Cabinet lb 760 760 mm 762x611x2377 762x611x2377 Dimensions - Base Cabinet

(Width x Depth x Height) in 30.0x24.1x93.6 30.0x24.1x93.6

Table 2- 14 G120E (PM250) Frame Sizes D, 3 AC 460 V … 480 V, ± 10%



Rated Input Current A 34 41 52 Output Current (VT) A 34 41 54 Output Current (CT) A 32 38 45 Required cooling air flow Cfm 318 318 318 Sound Pressure dB(A) 65 65 65 Input Cable AWG 10 to 1/0 10 to 1/0 10 to 1/0 Output Cable AWG 8 to 2 8 to 2 8 to 2




Table 2- 15 G120E (PM250) Frame Sizes E, 3 AC 460 V … 480 V, ± 10%



Rated Input Current A 65 77 Output Current (VT) A 68 80 Output Current (CT) A 60 75



Order No. 6SL3710- 5BJ27-5AU0 5BJ29-0AU0 Required cooling air flow Cfm 360 360 Sound Pressure dB(A) 67 67 Input Cable AWG 10 to 1/0 2 to 3/0 Output Cable AWG 8 to 4 8 to 2

kg 150 150 Weight - Base Cabinet lb 330 330 mm 660x527x1524 660x527x1524 Dimensions - Base Cabinet

(Width x Depth x Height) in 26.0x20.8x60.0 26.0x20.8x60.0 mm 305 305 Installation Clearance

(Left Side Only) in 12.0 12.0

Table 2- 16 G120E (PM250) Frame Sizes F, 3 AC 460 V … 480 V, ± 10%



Rated Input Current A 96 124 152 Output Current (VT) A 100 130 160 Output Current (CT) A 90 110 145 Required cooling air flow Cfm 504 504 504 Sound Pressure dB(A) 69 69 69 Input Cable AWG 4 to 350 kcmil 4 to 350 kcmil 4 to 350 kcmil Output Cable AWG 6 to 350 kcmil 6 to 350 kcmil 6 to 350 kcmil




Drive Installation and Connection 33.1 Connection

3.1.1 Connection to the power supply

Precaution and warning

WARNING

The drive is operated with high voltages. All connection procedures must be carried out when the cabinet is de-energized. All work on the drive must be carried out by trained personnel only. Non-observance of this warning can result in death, severe personal injury or substantial property damage.

Work on the drive must be carried out with extreme caution because external supply voltages may be present. The power and control terminals may be live even when the motor is not running. Dangerously high voltage levels are still present in the drive up to five minutes after it has been disconnected due to the DC link capacitors. For this reason, the cabinet should not be opened until a reasonable period of time has elapsed.

Reforming the DC link capacitors: The storage period should not exceed one year. If the drive is stored for more than one year, its DC link capacitors must be reformed during commissioning.

The operator is responsible for ensuring that the motor, converter, and other devices are installed and connected in accordance with the National Electric Code NFPA 70. Special attention should be paid to cable dimensioning, grounding, and shutdown.

If an input circuit breaker or fuse trips in a branch circuit, a fault current may have been disconnected. To reduce the risk of fire or an electric shock, current-conducting parts and other components in the drive should be inspected and damaged parts replaced.

When a protective device trips, the cause of the trip must be identified and rectified. The drive short circuit current rating (SCCR) is marked on the drive nameplate. To comply with the requirements of NFPA 70, it must not be connected to a network capable of delivering higher fault currents than the drive SCCR.



CAUTION The control cables must be laid separately from the power cables. The connection must be carried out as shown in the installation section in this manual, to prevent inductive and capacitive interference from affecting the correct function of the system.

Note

Enclosed drives are equipped with mechanical door interlocks that require the incoming disconnect to be open before the doors can be opened. Ensure that all doors are closed before energizing the drive.

Internal protective covers may have to be removed during installation and connection procedures. Once work has been completed, the protective covers must be properly refitted.

Grounding

WARNING Power and motor connections

The cabinet must always be grounded. If it is not grounded correctly, extremely dangerous conditions may arise which could prove potentially fatal.

Disconnect and lock-out the main electrical supply before making or changing connections to the unit.

The terminals of the drive can carry dangerous voltages even if the drive is inoperative. Wait at least 5 minutes to allow the unit to discharge after switching off the line supply before carrying out any installation work.

When connecting the line supply to the drive, make sure that the terminal box of the motor is closed.


Ensure that the drive is configured for the correct supply voltage – it must not be connected to a higher voltage supply.



3.1.1.1 Reforming the capacitors

Reforming the capacitors Following a prolonged period of storage, you must reform the capacitors in the G120E Power Module. The figure below shows the reforming periods required depending upon the period in storage.

Figure 3-1 Reforming Capacitors

Instruction 1. Open the cabinet. Remove the covers (if necessary) in front of the connectors on the line side

of the main circuit breaker.

2. Move or remove the plate through which the power cables are fed. Route the cables through the holes punched in the plate or in the cabinet itself.

3. Connect the ground-bonding cable from the building ground grid to the ground bus connection point provided in the cabinet.

4. Connect the power cables to the terminals L1, L2, and L3, located on the main circuit breaker.



3.1.2 Connection to the motor

Precaution and warning

WARNING The drive is operated with high voltages. All connection procedures must be carried out when the cabinet is de-energized. All work on the drive must be carried out by trained personnel only. Non-observance of this warning can result in death, severe personal injury or substantial property damage.

Work on the drive must be carried out with extreme caution because external supply voltages may be present. The power and control terminals may be live even when the motor is not running. Dangerously high voltage levels are still present in the drive up to five minutes after it has been disconnected due to the DC link capacitors. For this reason, the cabinet should not be opened until a reasonable period of time has elapsed.

Reforming the DC link capacitors: The storage period should not exceed one year. If the drive is stored for more than one year, its DC link capacitors must be reformed during commissioning.

The operator is responsible for ensuring that the motor, converter, and other devices are installed and connected in accordance with the National Electric Code NFPA 70. Special attention should be paid to cable dimensioning, grounding, and shutdown.

If an input circuit breaker or fuse trips in a branch circuit, a fault current may have been disconnected. To reduce the risk of fire or an electric shock, current-conducting parts and other components in the drive should be inspected and damaged parts replaced. When a protective device trips, the cause of the trip must be identified and rectified.

Note

Enclosed drives are equipped with mechanical door interlocks that require the incoming disconnect to be open before the doors can be opened. Ensure that all doors are closed before energizing the drive.

Internal protective covers may have to be removed during installation and connection procedures. Once work has been completed, the protective covers must be properly refitted.

Drive Installation and Connection 3.2 Cable accessibility


Instruction

WARNING Swapping the input and output terminals can destroy the drive!

Swapping or short-circuiting the DC link terminals can destroy the drive!

The contactor and relay operating coils that are connected to the same supply network as the drive or are located near the drive must be connected to overvoltage limiters (for example, RC elements).

1. Open the cabinet. Remove the covers (if necessary) in front of the connection panel for motor cables (terminals U2, V2, and W2).

2. Move or remove the plate through which the motor cables are fed. Route the cables through holes punched in the plate or in the cabinet itself.

3. Screw the ground cable from the motor frame into the ground bus connection point provided in the cabinet.

4. Connect the motor cables to the terminals U2, V2, and W2, which may be located at the inverter, output contactor, output reactor, overload relay, or at a motor terminal block, depending on the option provided (refer to schematics).

3.1.3 Customer control terminals Customer control terminals provide a connection for external devices to control, monitor, and extend the functionality of the G120E. For standard control and monitoring, the customer control terminals are provided directly on the control unit, -A10, mounted to the front of the G120 power module. Extended functionality customer control terminals are provided on terminal -X100.

3.2 Cable accessibility In general, the recommended cable access is at the top or bottom of the cabinet. Consult the "as-built" drawings for individual orders to determine exact cable access locations. These outline drawings provide the locations of clear areas for connecting conduit.

CAUTION When cutting holes in the cabinet for conduit, ensure that metal filings and debris do not fall onto the drive components. A paper, plastic or fabric drop cloth should be used to cover the drive panel and its components during such operations

Drive Installation and Connection 3.3 Permissible cable length from motor connection to drive


3.3 Permissible cable length from motor connection to drive

Permissible Cable Length The use of unshielded motor cables is possible. However, to minimize EMI and stray currents, shielded cables with appropriate EMI installation provisions are highly recommended.

The inverters will operate reliably with cable lengths as follows:

Table 3- 1 Cable Lengths for Inverter Operation

Screened 164 ft (50m)

Unscreened 328 ft (100 m)

Using output reactors as specified in the catalog, the following cable lengths are possible:

Table 3- 2 Permissible Cable Lengths Using Output Reactors

Maximum permissible motor cable length for line voltage of: Frame Size

Screened Unscreened 460 V … 480 V ± 10% A 100 m 328 ft. 100 m 328 ft. B ... C 100 m 328 ft. 150 m 492 ft. D ... F 200 m 656 ft. 300 m 984 ft.

3.4 Cooling The SINAMICS G120E cabinets are designed to use ambient air for cooling of internal components. When mounting the cabinets, the specified environmental conditions must not be exceeded, and the installation clearance must be maintained for proper cooling; otherwise, the drive may experience a loss of functionality.

No equipment that could have a negative effect on the flow of cooling air should be installed near the cabinet. Make sure that the cooling vents on the cabinet are unobstructed to allow for the free movement of air. If exhaust air ducts are fitted to the cabinet, an external fan must be added to make up for the pressure drop in the ductwork.

Drive Installation and Connection 3.5 Installation check list and required tools


3.5 Installation check list and required tools

Checklist for electrical installation Use the following checklist to guide you through the electrical installation procedure for the enclosed drive. Read the safety information at the start of these Operating Instructions before you start working on the device.

Before power is applied to the inverter/motor system, the following checks should be performed.

If any recommended checks do not appear normal, refer to Chapter 8: Troubleshooting.

Note

Check the boxes accordingly in the right-hand column if the activity applies to the enclosed drive in your scope of supply. In the same way, check the boxes once you have finished the installation procedure to confirm that the activities are complete.

Table 3- 3 Installation Checklist

Item Activity Fulfilled / Complete 1 The line-side and motor-side power cables must be dimensioned and routed in

accordance with the ambient and routing conditions. The maximum permissible cable lengths between the converter and motor must be observed depending on the type of cable used. The motor ground must be fed back directly to the drive. The ground cables must be properly connected with a torque of 50 Nm to the drive ground terminals. The cables for the motor and low-voltage switchgear must also be connected with the required torques.

2 The cables between the low-voltage switchgear and the drive must be protected with a circuit breaker or line fuses to provide adequate conductor protection.

3 For strain relief, the cables must be fixed to the cabinet structure where possible. 4 When EMC-shielded cables are used, screwed glands that connect the shield to ground

with the greatest possible surface area must be provided on the motor terminal box. On the cabinet, the cable shields must be grounded with the greatest possible surface area directly to the inverter.

5 The cable shields must be properly applied and the cabinet properly grounded at the appropriate points.

6 The nameplate can be used to ascertain the date of manufacture. If the period from the date of manufacture to initial commissioning or the drive downtime is less than one year, the DC link capacitors do not have to be reformed. If the downtime period is longer than one year, they must be reformed in accordance with the description in this manual.

Drive Installation and Connection 3.5 Installation check list and required tools


Item Activity Fulfilled / Complete Signal Connections

7 Drive operation by higher-level controller / control room. The control cables must be connected in accordance with the interface assignment and the shield applied. Taking into account electrical interference and the distance from power cables, the digital and analog signals must be routed with separate cables. When the analog inputs on the customer terminal block are used as current or voltage inputs, DIP switch selectors 1 and 2 on the control unit must be set accordingly.

Required tools To install the connections, you will require:

● Wrench or socket wrench (10 mm)

● Wrench or socket wrench (13 mm)

● Wrench or socket wrench (16/17 mm)

● Wrench or socket wrench (18/19 mm)

● Hexagon-socket wrench (size 8)

● Torque wrench up to 50 Nm

● Screwdriver, size 2

● Screwdriver Torx T20

● Screwdriver Torx T30


Commissioning 44.1 Preliminary check

Check list before powering on the drive:

● Verify that the drive/cabinet is clean and dry. Verify that no parts are broken or hanging loose. Terminal block connections and wire terminations should be verified for good contact and tightness.

● Before applying power to the drive, ensure that the incoming power is 460 - 480 VAC, three phases (or appropriate for the drive input power nameplate rating) and it is connected to the L1, L2 and L3 drive input power terminals. For option N75, expanded voltage range, ensure that all control power transformers (-T10 and -T30) are configured for the appropriate input voltage between 380 and 480 VAC.

● Before connecting the motor to the drive, check the motor for leakage to ground. Readings in excess of 100 M Ohms should be observed.

● Verify that the drive cabinet is connected to ground.

Collect the following data to complete the commissioning:

● Motor nameplate data

● Command/setpoint sources

● Minimum/maximum frequency and ramp-up/ramp-down times

● Control mode

Commissioning 4.2 Commissioning overview


4.2 Commissioning overview The G120E provides two options for commissioning:

● Single commissioning

One inverter is parameterized for commissioning with an individual parameter set. Usually, you use the STARTER or IOP for single commissioning.

● Series commissioning

Several inverters are parameterized for commissioning via download of a complete parameter set. Usually, you use the MMC for series 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 (refer to the control unit operating instructions). This manual describes the parameter-related commissioning through IOP.

When commissioning using STARTER, the part number of the SINAMICS G120 drive chassis must be entered. This information can be found on the power module installed in the G120E cabinet.

4.2.1 Single commissioning

Overview For single commissioning, you set the parameter of the inverter manually. You may use either the IOP (Intelligent Operator Panel) or STARTER (Commissioning software via PC) for commissioning.

Note

We recommend commissioning the drive with the STARTER commissioning tool. It is a tool that gives tremendous insight into the functioning of the drive and the possibilities for its use. STARTER also contains on-line help for understanding the parameters, as well as graphic depictions of control structures, signal flow, and signal status.

This manual describes parameter-related commissioning through IOP.



Settings of commissioning Commissioning the G120E comprises different settings and kinds of single commissioning. The following list provides an overview:

● Basic commissioning

– Quick commissioning

– Motor data identification

● Further settings for commissioning

– Calculating the motor/control data

– Reset parameters to control unit defaults

For detailed information to the settings of single commissioning, refer to the section "Commissioning with the IOP".

4.2.2 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 (for example, series machines or group inverter).

Components for series commissioning Commissioning the G120E can be done in different ways. The following list provides you an overview:

● Series commissioning with MMC

● Series commissioning with STARTER

For detailed information on series commissioning, refer to the chapter "Series Commissioning with STARTER".

Note

We recommend commissioning with STARTER. An MMC is not provided as standard on G120E drives. Refer to the standard G120 control unit documentation when using an MMC.



Order of series commissioning The series commissioning is divided into the following steps:

● Creating a valid parameter set

● Uploading this parameter set

● Downloading of the uploaded parameter set into the next inverter

An appropriate parameter set can be created by parameterizing an inverter through IOP or STARTER.

CAUTION Parameter download between different types of Control Units and of different firmware versions is not recommended.

It is possible to download parameter sets from different Control Unit types, however, as the parameter sets might differ, the user is fully responsible for the consistency of the downloaded parameter set.

Therefore, the customer has to confirm his responsibility in case of an automatic download by acknowledging F0395.

4.2.3 Commissioning with the IOP

4.2.3.1 Quick commissioning with the IOP All G120E drive cabinets are shipped from the factory pre-configured to each customer's specifications. This means that the basic parameter settings for user interface and drive control have already been configured into the CU230P-2 control unit. As a result, only the motor, load, and application specific information are left to configure.

The IOP offers a pre-defined parameter group to assist the user in quick commissioning. Refer to the "CU230P-2 Parameter Manual" for a full description of each parameter.

Commissioning: Menu - Parameters -- Parameter groups -- Quick Commissioning Enter the following parameters:

● Drive commissioning parameter filter (P0010)

● Power unit application (P0205)

● Drive filter type, motor side (P0230)

● Rated motor voltage (P0304)

● Rated motor current (P0305)



● Rated motor power (P0307)

● Rated motor power factor (P0308)

● Rated motor frequency (P0310)

● Rated motor speed (P0311)

● Maximum motor speed (P0322)

● Maximum motor current (P0323)

● Automatic calculation, motor/control parameters (P0340)

● Technology application (P0500)

● Command source selection (P0700)

● Speed setpoint selection (P1000)

● Speed controller encoderless operation P-gain (P1470)

● Speed controller encoderless operation integral time (P1472)

● Motor data identification and rotating measurement (P1900)

● Completion of quick commissioning (P3900)

● RTC time (P8400)

● RTC date (P8401)

4.2.3.2 Identifying motor data Alarm A07791 is output as long as the drive has not identified the motor data. The motor must be switched on so that the drive can identify the motor. An ON command must be issued to the drive either from the control system or through the IOP. From the IOP, place the controller in "Hand", and then depress the green "ON" key to start the drive. After the motor identification is complete, the drive will automatically stop.

4.2.3.3 Reset parameters to control unit default settings With a control unit default, the initial state of the all the control unit parameters can be re-established.

The control unit default values are designated as "Factory setting" in the "Parameter Manual".

Note

When resetting the parameters to the control unit defaults, the communications memory is re-initialized. This means that communications are interrupted for the time it takes to perform the reset.

Commissioning 4.3 Advanced commissioning with STARTER


To reset all parameters to the control unit defaults, follow the steps below:

1. In the "Parameters" menu, select the "Drive factory reset" entry.

2. Confirm the reset by selecting "Yes".

4.3 Advanced commissioning with STARTER

4.3.1 STARTER interfaces A PC with STARTER software can be connected to the G120E through one of many interfaces which are control unit dependent. Refer to the SINAMICS control unit operating instructions manual for further information.

4.3.2 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. To go online the button has to be pressed.

Changing parameters with STARTER Parameters can be changed online or offline (online preferred).

Online parameter changes are stored in the RAM of the inverter. A manual transfer from RAM to

EEPROM can be triggered by pressing the button . When closing STARTER and the contents of the RAM and EEPROM are different, the user is asked whether or not they wish to transfer the RAM data to the EEPROM.

Parameter sets that have been changed offline can be transferred to the inverter using the download button.



4.3.3 Series commissioning with STARTER

Upload of a parameter set with STARTER Prerequisites

● An already-commissioned device with an appropriate 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".

Connect the STARTER PC via the STARTER Port to the upload inverter. Press the online button and perform the upload by activating the button .

Download of a parameter set with STARTER Prerequisites

● Supply voltage is active in the drive for the download inverter.

● The download inverter is in "Ready to Run".

Connect the STARTER PC via the STARTER Port to the download inverter. Press the online button and perform the download by activating the button . The parameter set must then be saved in the EEPROM, by copying RAM to ROM.




Operation 55.1 Running the drive for the first time

WARNING Notify all personnel of the intent to start the unit.

5% speed Apply power to the unit. If everything appears normal, set the speed to approximately 5% and start the drive. After approximately 0.5 second, the inverter and door fans will start. The operator should now be able to verify that the motor has started to turn. If the direction of rotation at this point is incorrect, stop the drive, remove power from the unit, allow 5 minutes for the storage capacitors to discharge, and change any two phases at the motor terminals, or alternatively if no constant speed bypass is provided, change the direction in software and then resume start-up.

25% speed If everything appears normal, change the drive speed to 25%. At this speed, the motor terminal voltage should be 115 volts AC (+5%) (read from the operator panel), for 460 VAC motors.

50% speed Now increase the drive speed to 50%. At 50% speed, variable torque loads such as fans and pumps will begin to provide load on the motor.

100% speed Before proceeding further, stop the drive. The drive should ramp down in a controlled manner and de-energize. Restart the drive and run it to 75% speed. Increase the speed towards 100% watching for proper drive and process operation. The output voltage at 100% speed should be 460 VAC or more appropriately motor rated voltage.

Operation 5.2 Intelligent operator panel


Final steps Stop the drive. It should ramp down to zero speed and shut off.

The drive has now been tested over the operating range and proved to be functional. All that remains to be done is to adjust any application-specific parameters if necessary and verify that meter outputs, the auto control mode, and any auxiliary control logic are functioning correctly.

5.2 Intelligent operator panel

5.2.1 Overview

5.2.1.1 Introduction The Intelligent Operator Panel (IOP) has been designed to enhance the interface and communications capabilities of SINAMICS Inverters.

The IOP connects to the Inverter through an RS232 interface. It is provided as standard on all G120E drives. The IOP is mounted in the door of the drive cabinet.

The IOP provides support, using the USB connection utilizing a PC for the following functions:

● Downloading of wizards

● Downloading additional languages

Note IOP functional support

The actual menu structure and functionality of the IOP will be influenced by the following factors: The software version and type of Control Unit to which the IOP is fitted. The firmware and software version of the IOP. The selected functional group filtering of the parameters.



5.2.1.2 Layout and functions

Layout and functions The physical layout of the IOP is shown below:

Figure 5-1 Layout of IOP

The IOP is operated by using a push-wheel and five additional buttons. The specific functions of the push-wheel and buttons are shown in the table below.



Table 5- 1 Function of the IOP controls

Key Function

The push-wheel has the following functions: In a menu, turning the push-wheel changes the selection. When a selection is highlighted, pressing the push-wheel confirms the selection. When editing a parameter, turning the push-wheel changes the displayed value; clockwise increases the

value and anti-clockwise decreases the displayed value.

The ON key has the following functions: In AUTO mode, the screens displays an information screen, stating that the command sources is AUTO and

can be changed by pressing the HAND/AUTO KEY. In HAND mode the Inverter is started - the Inverter status icon starts turning. Notes: When running in AUTO mode, HAND mode cannot be selected unless the Inverter is stopped. When the Inverter is running in HAND mode, the motor stops when switched to AUTO.

The OFF key has the following functions: If pressed for longer than 3 seconds the Inverter will perform an OFF2; the motor will then coast down to a

standstill. If pressed for less than 3 seconds the following actions will be performed:

– If in AUTO mode the screen will display an information screen stating that the command sources is AUTO and can be changed using the HAND/AUTO key. The Inverter will not be stopped.

– If in HAND mode the Inverter will perform an OFF1; the motor will come to a standstill in the ramp-down time set in parameter P1121.

The ESC key has the following functions: If pressed for less than 3 seconds the IOP returns to the previous screen or if a value has been edited, the

new value is not saved. If pressed longer than 3 seconds the IOP returns to the status screen. When using the ESC key in the parameter editing mode, no data is saved unless the OK key is pressed first.

The INFO key has the following functions: Displays additional information for the currently selected item. Pressing INFO again will display the previous screen.

The HAND/AUTO key switches the command source between HAND and AUTO mode. HAND sets the command source to the IOP. AUTO sets the command source to an external source, for example, fieldbus.

Locking and unlocking the keypad To lock the IOP keypad press ESC and INFO simultaneously for 3 seconds or more. To unlock the keypad press ESC and INFO simultaneously for 3 seconds or more.



5.2.1.3 Screen icons The IOP displays a number of icons at the top right-hand edge of the display to indicate various states or current conditions of the Inverter. These icons are explained in the table below.

Table 5- 2 Screen icons

Function Status Icon Remarks Auto

Command source

Hand

Ready

Inverter status

Running

icon rotates when the motor is running

Fault pending Fault

Alarm pending Alarm

Fully Charged Only for use with the handheld kit. Battery condition

Discharged



5.2.1.4 Menu structure The IOP is a menu-driven device and has the following menu structure:

Figure 5-2 IOP menu structure



5.2.2 Control

5.2.2.1 Overview The Control menu allows the user to change the following settings in real-time:

● Setpoint

● Reverse

● Jog

The control menu is accessed from the menu at the bottom-center of the Status screen, as shown below:

Figure 5-3 Status screen - Control selection

5.2.2.2 Setpoint The setpoint value determines the speed at which the motor runs as a percentage of its full range of motion.

To change the setpoint, the following actions should be performed:

1. Rotate the Wheel to select "Control". 2. Press the Wheel to confirm selection. 3. The "Control" screen is displayed. 4. "Setpoint" is already highlighted. 5. Press the Wheel to select the "Setpoint". 6. The "Setpoint" screen is displayed. 7. Rotate the Wheel to increase or decrease the setpoint. 8. Press the Wheel to confirm new setpoint.



9. The "Control" screen is displayed. 10. Press "Esc" to return to the "Status" screen. The setpoint can only be modified from the IOP when the IOP is in "Hand" mode.

5.2.2.3 Reverse The function of the reverse command is to set the direction of rotation of the motor from its normal forward motion.

To reverse the direction of the motor, the following actions should be performed:

1. Rotate the Wheel to select "Control". 2. Press the Wheel to confirm selection. 3. The "Control" screen is displayed. 4. Rotate the Wheel to select the "Reverse" option. 5. Press the Wheel to confirm selection. 6. The "Reverse" screen is displayed. 7. Rotate the Wheel to select "On" or "Off". 8. Press the Wheel to confirm the selection. 9. The display returns to the "Control" screen. 10. Press "Esc" to return to the "Status" screen.



5.2.2.4 Jog The Jog function, when selected will allow the motor to be manually rotated by a pre-determined

value with each press of . If is pressed continuously, the motor will rotate continuously until

is released.

To enable or disable the Jog function, the following actions should be performed:

1. Rotate the Wheel to select "Control". 2. Press the Wheel to confirm selection. 3. The "Control" screen is displayed. 4. Rotate the Wheel to select the "Jog"

option. 5. Press the Wheel to confirm selection. 6. The "Jog" screen is displayed. 7. Rotate the Wheel to select "On" or "Off". 8. Press the Wheel to confirm selection. 9. The display returns to the "Control" screen10. Press "Esc" to return to the "Status"

screen.

Note Selection of Jog frequencies

It is important that the Jog parameters P1058 and P1059 are set to the required frequencies for the users application.

When the Jog left and Jog right (Jog1 and Jog 2) have been set; it is necessary to press the "INFO" key to select the other jog mode.



5.2.3 Menu

5.2.3.1 Overview The "Menu" is selected from the three menu options at the bottom of the IOP screen. If the menu options are not displayed, then one press of the Wheel will display the menu options.

Menu selection Menu screen

When the "Menu" option is selected the following functions are displayed:

● Diagnostics (see the "Diagnostics with the IOP" chapter)

● Parameters

● Wizards (this is a shortcut to the main Wizards menu)

● Up/Download

● Extras

By rotating the Wheel, the required function can be highlighted. Pushing the Wheel confirms the selection and further sub-menus will be displayed. Pressing "Esc" once, will return the IOP to the previous screen; a longer press will return the display to the "Status" screen.


The actual menu structure and functionality of the IOP will be influenced by the following factors: The software version and type of Control Unit to which the IOP is fitted The firmware and software version of the IOP The selected functional group filtering of the parameters



5.2.3.2 Parameters


The actual menu structure and functionality of the IOP will be influenced by the following factors: The software version and type of Control Unit to which the IOP is fitted The firmware and software version of the IOP The selected functional group filtering of the parameters

The parameter menu allows the user extensive functionality and access to all the Inverter parameters. When this option is selected the user is given the opportunity to perform parameter orientated functions grouped in the following manner: Parameter groups All parameters Search by number My parameters Changed parameters Parameter filter Default dataset Drive factory reset



Parameter groups Quick commissioning

This screen displays a complete listing of all the parameters required for quick commissioning. The parameters are listed in numerical order and can be accessed to either confirm the set values or modified should there be a need to fine tune the application or correct any errors in the parameter values.

Saving & reset This option allows the user access to all the parameters regarding the saving and reset functions of the Inverter. Each parameter displays its currently set value and these can be modified if required.

System Information

This screen displays all the parameters that contain system information regarding the Inverter. The majority of these parameters are read-only and are for information purposes only.



Inputs/Outputs

This option allows access to all the necessary parameters to configure the following signals: Digital inputs Digital outputs Analog inputs Analog outputs The user can navigate through the various inputs and outputs to see the current configuration of the inputs and outputs and, if necessary access the parameters directly to modify their values. In the example screen opposite, the parameters for the digital inputs is shown.

Setpoint channels

This option allows the user to display and modify the following setpoint parameters: Frequency setpoint Fixed setpoints Motor potentiometer Torque setpoint Jog setpoint Frequency limitation Ramp-function generator

Motor control This option allows the user to view, and if required, change themethod by which the Inverter controls the attached motor. It presents the following control functions: V/f control Sensorless Vector control The Inverter will not allow the control mode to be changed while the motor is running. The motor and therefore the system must be stopped to allow the control mode to be changed.



Motor & periphery

This option allows the following motor functions and options to be viewed, configured and modified: Motor data Motor temperature Motor encoder Motor holding brake It is important that if any parameters concerning the above mentioned functions are to be modified, that the Inverter/motor system is in a safe state prior to the parameter changes. This is essential if any changes are being made to the Motor holding brake - all loads that may be affected by the change must be secured to avoid potentially dangerous situations.

Drive functions

This option allows the user direct access to the parameters regarding the following drive functions: Shutdown functions Brake control Vdc controller Automatic restart Flying restart Safety Integrated It is important that if any parameters concerning the above mentioned functions are to be modified, that the Inverter/motor system is in a safe state prior to the parameter changes.

Application functions

This option allows the user direct access to specific application functions parameters as listed below: Technology controller Hibernation Load torque monitoring Digital time switch Positioning deceleration ramp Wobble function Free blocks



Fieldbus

This option allows the user direct access to the parameters that control and configure the fieldbus communications of the Inverter. The parameters can be viewed to confirm their settings and values; they can also be modified if they are not read-only parameters.

Diagnostics

This option allows the user direct access to the parameters that monitor the state of the system. The are divided into the following functional groups: Control/status words Drive enables Interconnections Faults/alarms All the parameters under these groupings are read-only and cannot be modified.

All parameters This option allows the user access to the individual parameters of the Inverter. The default filter is "Standard" which allows the user access to the most frequently used parameters. The default filter settings can be changed by selecting "Parameter filter" from the parameters menu.



Search by number This option allows the user to search for a specific parameter number. Should the parameter number not exist, then the nearest parameter to the entered value is displayed. Use the Wheel to alter the value of each digit and press the Wheel to confirm. The next digit will automatically be highlighted, rotate the Wheel to change the value and press the Wheel to confirm. Once all fields have been entered, the IOP will display the parameter.

My parameters This option allows the user to select the parameters that they wish to list. The user is presented with a list of parameters that can be selected. Once selected - only those parameters are displayed when the "My Parameters" option is selected. There are additional options that allow the user to manage their list of parameters.

Changed parameters When the "Changed parameters" option is selected the IOP will search the Inverter parameter list for all the parameters that have had their values changed from the factory default settings. Once the search is complete, the screen will present a list of all parameters that have changed values. The individual parameters can be accessed so that their current values can be displayed and modified if necessary.



Parameter filter This option allows the user to select the parameter access level. Standard is the default access which give the user access to the most frequently used parameters. Expert level gives access to all available parameters.

Default dataset This option allows the user to determine which is the default command dataset when viewing or selecting a new default dataset from the options provided.

Drive factory reset This option allows the user to restore the Inverter to its factory default settings.



5.2.3.3 Up/Download

Overview The upload and download options allow the user to save parameter sets to the various memory storage that is available to the system. The following options are presented to the user: Download: Panel to drive Upload: Drive to panel

It is important to remember that during the transfer of data to and from the Inverter, that the transfer is not interrupted and must be allowed to complete the process. If the process is interrupted, it is possible that the data could be corrupted and the system may behave in an unexpected manner.

5.2.3.4 Extras

Overview The Extras menu presents a number of options for the configuration of the IOP. These are the following: Status-screen wizard Language Time and date Drive identity Operator panel restart Operator panel factory reset Display backlight Display contrast Lighting duration Panel identity



Status-screen wizard The status-screen wizard allows the user to configure the information displayed on the status screen. By default, it displays the output voltage and output frequency of the Inverter. These can be changed by using the wizard to select other physical values of the Inverter. Displayed units of value can be specifically adapted using known conversion factors and, with the addition of an offset value, allows the units of measure to be displayed as required for the users application.

Language This option allows the user to select the language that is used to display information and text on the IOP. This option has been previously described in the initial set-up section of this manual. Languages can be added or deleted using the USB connection on the IOP and a PC.

Time and date This option allows the user to set the correct time and date for the system. This option has been previously described in the initial set-up section of this manual.



Drive identity The option allows the user to display the technical details of the components that comprise the Inverter system. This includes the details of the Control Unit and Power Module. This is a read-only screen and cannot be modified.

Operator panel restart Should the user wish to restart the operator panel, this option allows the IOP to restart without the loss of any settings.

Operator panel factory reset This option resets the IOP to its default factory settings. All previous settings and data stored on the IOP will be lost.



Display backlight This option allows the user to change intensity of the display lighting.

Display contrast This option allows the user to change the contrast between black and white on the display.

Lighting duration The backlight display, by default, is set to automatically turn off after 10 seconds from the last key press. This time can be adjusted to 30 seconds, 60 seconds, 300 seconds, or permanently on.

Operation 5.3 ON/OFF commands


Panel identity The panel identity screen displays the following technical information regarding the IOP: IOP firmware version Menu description version Parameter description version Menu texts version Parameter name index version

5.3 ON/OFF commands

5.3.1 Overview

5.3.1.1 Overview The G120E provides the following ON/OFF commands:

● ON / OFF (ON/OFF1)

● Coast stop (OFF2)

● Quick stop (OFF3)

5.3.1.2 ON / OFF (ON/OFF1) command 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. 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).

– The monitoring time (P1227), started when the speed setpoint ≤ Switch-off frequency (P2167), has expired.



5.3.1.3 Coast stop (OFF2) command ● Instantaneous pulse suppression, the drive coasts to a standstill.

● If parameterized, the motor holding brake is closed immediately.

● Power-on inhibit is activated.

5.3.1.4 Quick stop (OFF3) command ● 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).

– The monitoring time (P1227), started when the speed setpoint ≤ speed threshold (P2167), has expired.

● Power-on inhibit is activated.

5.3.2 Power ON/OFF

Sources for ON/OFF command For standard Control Units, 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)

● STARTER on RS485 (P0700 = 5)

● A higher-level control system (P0700 = 6)

Refer to Commissioning section for details.

ON/OFF via DI The ON command requires a permanent signal.



ON/OFF via IOP To power the drive ON/OFF, place the IOP in "Hand" mode and press the following keys:

ON Press once

OFF1 Press once

OFF2 Press and hold for 3 seconds.

ON/OFF via a higher-level control system Via a serial interface, you switch ON/OFF the inverter using a higher-level control system (for example, an S7-300 controller).


Parameter Descriptions 66.1 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 (for example, monitoring parameter, write parameter, BICO attribute, and group attribute). Within any one particular inverter system, the parameter number is unique.

Parameters can be accessed using the following operator units:

● IOP

● PC-based commissioning (start-up) tool STARTER

There are two main types of parameters; those that can be altered and those that are read-only.

Figure 6-1 Parameter Types

Parameter Descriptions 6.2 Key parameters for operating the drive


6.2 Key parameters for operating the drive

6.2.1 Parameter attributes

Overview In the Parameter Manual, the header line of each parameter shows all the attributes and groups for that specific parameter. The figure below shows the details for parameter P0700 and r1515.

Figure 6-2 Description of Attributes for Parameter P0700

Figure 6-3 Description of Attributes for Parameter r1515

Index Using the index, a parameter (for example, p0013[20]) is defined with several consecutive elements (in this case, 20). Each individual index is defined using a numerical value.

When transferred to a parameter this means that an indexed parameter can have several values. The values are addressed using the parameter number including the index value (for example, p0013[0], p0013[1], p0013[2], p0013[3], p0013[4], ...).

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".

Table 6- 1 Parameter attributes - BICO

BICO Description BI Binector Input BO Binector Output CI Connector Input CO Connector Output CO/BO Connector Output/Binector Output

Access level The access level is controlled using parameter P0003. In this case, only those parameters are visible at the operator panel, where the access level is less than or equal to the value assigned in parameter P0003. On the other hand, for STARTER, only access levels 0 and 3 are relevant. For example, parameters with access level 3 cannot be changed, if the appropriate access level has not been set.

The following access levels are implemented in the inverters:

Table 6- 2 Parameter attributes - access level

Access level Description 0 User-defined Parameter Manual (refer to P0013) 1 Standard access to the most frequently used parameters 2 Extended access (for example, to inverter I/O functions) 3 Expert access only for experienced users 4 Service access only for authorized service personnel – with password

protection.

Note

In STARTER, all user parameters (access stage 3) are always displayed using the expert list – independent of the setting p0003 = 0, 1, 2 or 3.

When changing parameters using STARTER, or via a higher-level control system, parameter value changes always become immediately effective.



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".

Table 6- 3 Parameter attributes - Can be changed

State Description C Quick commissioning U Operation (Drive running) T Drive ready to run

Data types The data type of a parameter defines the maximum possible value range. Five data types are used for the inverter. They either represent an unsigned integer value (U16, U32) or a floating-point value (float). The value range is frequently restricted by a minimum and maximum value (min, max) or using inverter/motor quantities.

Table 6- 4 Parameter attributes - Data types

Data type Description U16 Unsigned, integer value with a size of 16 bits U32 Unsigned, integer value with a size of 32 bits I16 Signed integer 16-bit value I32 Signed integer 32-bit value Float A simple precise floating point value according to the IEEE standard format

max. value range: -3.39e+38 –+3.39e+38

Unit The values of parameters support the following units:

Table 6- 5 Parameter attributes - Unit

Unit Description Unit Description - No dimension m/s Meters per second % Percentage Nm Newton meter A Ampere W Watt V Volt kW Kilowatt Ohm Ohm Hp Horse power



Unit Description Unit Description us Microseconds kWh Kilowatt hours ms Milliseconds °C Degrees Celsius s Seconds m Meter Hz Hertz kg Kilograms kHz Kilohertz ° Degrees (angular degrees) 1/min Revolutions per minute [RPM]

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.

Table 6- 6 Parameter attributes - Grouping

Grouping Description Main parameter area:

ALWAYS 0 all parameters INVERTER 2 inverter parameters 0200 … 0299 MOTOR 3 motor parameters 0300 … 0399 and

0600 … 0699 ENCODER 4 speed encoder 0400 … 0499 TECH_APL 5 technical applications/units 0500 … 0599 COMMANDS 7 control commands, digital I/O 0700 … 0749 and

0800 … 0899 TERMINAL 8 Analog inputs/outputs 0750 … 0799 SETPOINT 10 Setpoint channel and ramp-function gen. 1000 … 1199 Safety integrated 11 Fail-safe functions 9000 … 9999 FUNC 12 Inverter functions 1200 … 1299 CONTROL 13 Motor open-loop/closed-loop control 1300 … 1799 COMM 20 Communications 2000 … 2099 ALARMS 21 Faults, warnings, monitoring functions 0947 … 2199 TECH 22 Technology controller (PID controller) 2200 … 2399



Quick commissioning This parameter attribute identifies as to whether the parameter is included in the quick commissioning (QC) (P0010 = 1).

Table 6- 7 Parameter attributes - Quick commissioning

QC Description No The parameter is not included in the quick commissioning Yes The parameter is included in the quick commissioning

Value range The value range, which is first specified by the data type, is restricted by minimum and maximum values depending on the quantities of the inverter/motor. The values min and max are permanently saved in the inverter and cannot be changed by the user. To support commissioning each write parameter has a default value called factory setting.

Table 6- 8 Parameter attributes - Value range

Value range Description - No value entered (e.g.: "r parameter") Min Minimum value Max Maximum value Def Default value

Data sets A detailed description for the data sets is given in the respective section

Table 6- 9 Data sets

BICO Description CDS Command data set DDS Drive data set



6.2.2 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: r0002 monitoring parameter 2 r0052.3 monitoring parameter 52, bit 03 r0947[2] monitoring parameter 947 index 2 r0964[0 ... 4] monitoring parameter 964 with 5 indices (indices 0 to 4)

6.2.3 Write parameters

Description Parameters which can be written into and displayed are indicated by the prefix "P".

These parameters directly influence the behavior of a function. The value of this parameter is saved in non-volatile memory (EEPROM) as long as the appropriate option was selected (non-volatile data save). Otherwise, these values are saved in the volatile memory (RAM) of the processor, which are lost after power failure or power-off/power-on operations.

Examples of the standard notation used throughout our manuals are given below.

Notation examples: P0970 parameter 970 P0748.1 parameter 748, bit 01 P0819[1] parameter 819 index 1 P0013[0 ... 19] parameter 13 with 20 indices (indices 0 to 19)

Parameter Descriptions 6.3 BICO technology, data sets, other parameters


6.3 BICO technology, data sets, other parameters

6.3.1 BICO technology overview

Interconnecting signals (BICO) A state-of-the-art inverter must be able to interconnect internal and external signals (setpoint or actual values and control or status signal). This interconnection functionality must have a high degree of flexibility in order to be able to adapt the inverter to new applications. Further, a high degree of usability is required, which also fulfills standard applications. To fulfill these requirements BICO technology and fast parameterization using parameters P0700/P1000 are used.

6.3.2 Using BICO technology

Description Using BICO technology, process data can be freely interconnected using the "standard" inverter parameterization.

For this all values which can be freely interconnected are defined as "Connectors" (for example, frequency setpoint, frequency actual value, and current actual value).

All digital signals which can be freely interconnected are defined as "Binectors" (for example, status of a digital input, ON/OFF, and message function when a limit is violated).

There are many input and output quantities as well as quantities within the closed-loop control which can be interconnected in an inverter. It is possible to adapt the inverter to the various requirements using BICO technology.

Binectors A binector is a digital (binary) signal without any units; it can take the value 0 or 1. Binectors always refer to functions and are sub-divided into binector inputs and binector outputs (see the table below). In this case, the binector input is always designated using a "P" parameter (for example, P0840 BI: ON/OFF1), while the binector output is always represented using an "r" parameter (for example, r1025 BO: FF status).

As can be seen from the examples above, the binector parameters have the following abbreviations in front of the parameter names:

BI: Binector Input, signal sink ("P" parameters)



The BI parameter can be interconnected with a binector output as a source, by entering the parameter number of the binector output (BO parameter) as a value in the BI parameter.

BO: Binector Output, signal source ("r" parameters)

The BO parameter can be used as a source for BI parameters. For a particular interconnection the BO parameter number must be entered into the BI parameter.

Example Combine the ON/OFF1 command with selecting a fixed frequency.

Binector output (BO) ==> Binector input (BI)

When selecting a fixed frequency the fixed frequency status bit (r1025) is internally set from 0 to 1.

The source for the ON/OFF1 command is parameter P0840 (default DI0). If the fixed frequency status bit is connected as source for P0840 (P0840 = 1025) the inverter starts with activating a fixed frequency and stops with OFF1 with deactivating.

Binector symbols

Table 6- 10 Binector symbols

Abbreviation and symbol Name Function

Binector input (signal sink)

Binector output (signal source)

Connectors A connector has a value (16 or 32 bit), which can include a normalized quantity (without dimension) as well as a quantity with associated units. Connectors always refer to functions and are sub-divided into connector inputs and connector outputs. Essentially it is the same as for the binectors, the connector inputs are characterized by a "P" parameter (for example. P0771 CI: AO (analog output)); while the connector outputs are always represented using an "r" parameter (for example, r0021 CO: Act. frequency).



As can be seen from the examples above, connector parameters have the following abbreviations in front of the parameter names:

CI: Connector Input, signal sink ("P" parameters)

The CI parameter can be interconnected with a connector output as a source, by entering the parameter number of the connector output (CO parameter) as a value in the CI parameter.

CO: Connector Output, signal source

The CO parameter can be used as source for CI parameters. For a particular interconnection, the CO parameter number must be entered in the CI parameter.

Example Associate parameter r0755 (Displays analog input, scaled using ASPmin and ASPmax) with an internal value (main frequency setpoint) to calculate internally scaled value. Thus interconnect the CO Parameter r0755 (Scaled analog input) with CI parameter P1070 (Main setpoint).

Connector output (CO) ==> Connector input (CI)

Connector symbols

Table 6- 11 Connector symbols

Abbreviation and symbol Name Function CI Connector input

(signal sink)

CO Connector output

(signal source)

Connector and Binector Outputs Further, there are "r" parameters where several binector outputs are combined in a word (for example, r0052 CO/BO: Status word 1). This feature reduces, on one hand, the number of parameters and simplifies parameterization using the serial interface (data transfer). These parameters are further characterized by the fact that they do not have any units and each bit represents a digital (binary) signal.



As can be seen from the examples of parameters, these combined parameters have the following abbreviation in front of the parameter names:

CO/BO: Connector Output/Binector Output, signal source ("r")

CO/BO parameters can be used as a source for CI parameters and BI parameters:

● In order to interconnect all of the CO/BO parameters, the parameter number must be entered into the appropriate CI parameter (for example, P2016[0] = 52).

● When interconnecting a single digital signal, in addition to the CO/BO parameter number, the bit number must also be entered into the CI parameter (for example, P0731 = 52.3)

Example

Connector output/Binector output (CO/BO)

Connector and Binector Output symbols

Table 6- 12 Connector and binector output symbols

Abbreviation and symbol Name Function

CO BO

Binector/connector output (signal source)

In order to interconnect two signals, a BICO setting parameter (signal sink) must be assigned to the required BICO monitoring parameter (signal source).

Note

BICO parameters of the type CO, BO, or CO/BO can be used for multiple assignments.



6.3.3 Data sets

Description For many applications it is advantageous if several parameters can be simultaneously changed, during operation or in the ready state, using an external signal.

This functionality can be elegantly implemented using indexed parameters. In this case, as far as the functionality is concerned, the parameters are combined to form groups/data sets and are indexed. By using indexing, several different settings can be saved for each parameter which can be activated by changing-over the data set (for example, toggling between indexes).

The following data sets apply:

● Command Data Set CDS

● Drive Data Set DDS

Three independent settings are possible for each data set. These settings can be made using the index of the particular parameter:

● CDS0 … CDS2

● DDS0 … DDS2

Command Data Set Those parameters (connector and binector inputs) which are used to control the inverter and enter a setpoint, are assigned to the command data set (CDS). The signal sources for the control commands and setpoints are interconnected using BICO technology. For that the connector and binector inputs are assigned corresponding to the connector and binector outputs as signal sources. A command data set includes:

Command sources and binector inputs for control commands (digital signals) e.g. Selects the command source P0700 ON/OFF1 P0840 OFF2 P0844 JOG Enable P1057 Enable JOG right P1055 Enable JOG left P1056

Setpoint sources and connector inputs for setpoints (analog signals) e.g. Selection of frequency setpoint P1000 Selection of main setpoint P1070 Selection of additional setpoint P1075



The parameters, combined in a command data set, are designated with [x] in the Parameter Manual in the index field.

Index Pxxxx[0] Command data set 0 (CDS0) Pxxxx[1] Command data set 1 (CDS1) Pxxxx[2] Command data set 2 (CDS2)

Note

A complete list of all of the CDS parameters is contained in the Parameter Manual.

It is possible to parameterize up to three command data sets. This makes it easier to toggle between various pre-configured signal sources by selecting the appropriate command data set. A frequent application involves, for example, the ability to toggle between automatic and manual operation.

Note

The parameters will be altered during data set switchover in the state "Ready" and "Run".

The following parameters will not be changed in the state "run: P0700, P0701, P0702, P0703, P0704, P0705, P0706, P0707, P0708, P0709, P0712, P0713, P0719, P0800, P0801, P0840, P0842, P0844, P0845, P0848, P0849, P0852, P1000, P1020, P1021, P1022, P1023, P1035, P1036, P1055, P1056, P1070, P1071, P1075, P1076, P1110, P1113, P1124, P1140, P1141, P1142, P1330, P1500, P1501, P1503, P1511, P1522, P1523, P2103, P2104, P2106, P2220, P2221, P2222, P2223, P2235, P2236.

The described inverter has an integrated copy function which is used to transfer command data sets.

This can be used to copy CDS parameters corresponding to the particular application. P0809 is used to control the copy operation as follows:

Copy operation controlled with P0809 P0809[0] Number of the command data set which is to be

copied (source) P0809[1] Number of the command data set into which data

is to be copied (target) Copying is started, if P0809[2] = 1 P0809[2] Copying has been completed, if P0809[2] = 0



Figure 6-4 Copying from a CDS

The command data sets are changed-over using the BICO parameters P0810 and P0811, whereby the active command data set is displayed in parameter r0050 (see figure below). Changeover is possible both in the "Ready" as well as in the "Run" states.

Figure 6-5 Changing over a CDS

The currently active command data set (CDS) is displayed using parameter r0050:

Figure 6-6 Active command data set (CDS)



Example

The command source (for example, terminals → BOP) or setpoint (frequency) source (for example, AI → MOP) should be changed-over using a terminal signal (for example, DI3) as a function of an external event (for example, the higher-level control system fails). A typical example in this case is a mixer, which may come to an uncontrolled stop when the control fails.

Figure 6-7 Changing over between the control and setpoint source

CDS0: Command source via terminals and setpoint source via analog input (AI)

CDS1: Command source via BOP and setpoint source via MOP

CDS changeover is realized using digital input 3 (DI3)

Commissioning steps:

1. Carry-out commissioning for CDS0 (P0700[0] = 2 and P1000[0] = 2)

2. Connect P0810 (P0811 if required) to the CDS changeover source (P0704[0] = 99, P0810 = 722.3)

3. Copy from CDS0 to CDS1 (P0809[0] = 0, P0809[1] = 1, P0809[2] = 1)

4. Adapt CDS1 parameters (P0700[1] = 1 and P1000[1] = 1)

Drive data set The drive data set (DDS) contains various setting parameters which are of significance for the open-loop and closed-loop control of a motor:

Drive and encoder data, for example: Select motor type P0300 Rated motor voltage P0304 Main inductance P0360 Select encoder type P0400



Various closed-loop control parameters, for example: Fixed frequency 1 P1001 Min. frequency P1080 Ramp-up time P1120 Control mode P1300

The parameters, combined in a drive data set, are designated with an [x] in the Parameter Manual in the index field:

Index Pxxxx[0] Drive data set 0 (DDS0) Pxxxx[1] Drive data set 1 (DDS1) Pxxxx[2] Drive data set 2 (DDS2)

Note

A complete list of all of the DDS parameters is contained in the Parameter Manual.

It is possible to parameterize several drive data sets. This makes it easier to toggle between various inverter configurations (control mode, control data, motors) by selecting the appropriate drive data set (see figure below).

Note

The parameters will be altered during data set switchover in the state "Ready" and "Run".

The following parameters will not be changed in the state "run": P0300, P0304, P0305, P0307, P0308, P0309, P0310, P0311, P0314, P0320, P0335, P0340, P0400, P0405, P0408, P0410, P0491, P0492, P0500, P1082, P1240, P1256, P1300, P1320, P1322, P1324, P1820, P2000, P2001, P2002, P2003, P2004, P2181.

Just like the command data sets, it is possible to copy drive data sets within the described inverter. P0819 is used to control the copy operation as follows:

Copy operation controlled with P0819 P0819[0] Number of the drive data set which is to be

copied (source) P0819[1] Number of the drive data set into which data is to

be copied (target) Copying is started, if P0819[2] = 1 P0819[2] Copying has been completed, if P0819[2] = 0



Figure 6-8 Copying from a DDS

Drive data sets are changed-over using the BICO parameter P0820 and P0821 whereby the active drive data set is displayed in parameter r0051 (see figure below). Drive data sets can only be changed-over in the "Ready" state and this takes approximately 50 ms.

Figure 6-9 Changing over a DDS



The currently active drive data set (DDS) is displayed using parameter r0051[1]:

Figure 6-10 Active drive data set (DDS)

Example

The inverter should be switched-over from motor 1 to motor 2.

Figure 6-11 Changeover from motor 1 to motor 2

Commissioning steps with 2 motors (motor 1, motor 2):

1. Carry-out commissioning at DDS0 with motor 1; adapt the remaining DDS0 parameters.

2. Connect P0820 (P0821 if required) to the DDS changeover source (for example, via DI4: P0705[0] = 99, P0820 = 722.4).

3. Changeover to DDS1 (check using r0051).

4. Carry-out commissioning at DDS1 with motor 2; adapt the remaining DDS1 parameters.


Drive Functions 77.1 Overview of functions

This chapter provides a overview of the many functions that can be used by the various control units available for G120E to handle various application and interface situations that may present themselves in both routine and special applications. Functions in the context of the drive control are areas of complex control behavior and control monitoring, the characteristics and assignments of which are controlled by a group of parameters.

Since the different control units available for G120E have different functionality for their intended application, the details of the functions are not described in the manual. Refer to the SINAMICS control unit operating instructions for the detailed functionality.

Drive Functions 7.2 Overview of the CU230P-2 functions


7.2 Overview of the CU230P-2 functions

Figure 7-1 Overview of CU230P-2 Functions

Drive Functions 7.2 Overview of the CU230P-2 functions


Functions relevant to all applications Functions required in special applications only The functions that you require in each application are located at the center of the function overview above. The parameters of these functions are provided with a matching basic setting during quick commissioning so that in many cases, the motor can be operated without requiring additional parameterization.

The functions whose parameters you only need to adapt when actually required are located at the outer edge of the upper function overview.

Inverter control is responsible for all of the other inverter functions. Among other things, it defines how the inverter responds to external control signals.

The production functions avoid overloads and operating states that could cause damage to the motor, inverter and driven load. The motor temperature monitoring, for example, is set here.

The command source defines where the control signals are received from to switch on the motor (for example, through digital inputs or a fieldbus).

The status messages provide digital and analog signals at the Control Unit outputs or via the fieldbus. Examples include the current speed of the motor or fault message issued by the inverter.

The setpoint source defines how the speed setpoint for the motor is specified (for example, through an analog input or a fieldbus)

The technological functions allow you to activate a motor holding brake or implement a higher-level pressure or temperature control using the technology controller, for example.

The setpoint calculation uses a ramp-function generator to prevent speed steps occurring and to limit the speed to a permissible maximum value.

The HVAC functions provide solutions especially for applications containing pumps, fans and heating/air-conditioning systems.

The motor closed-loop control ensures that the motor follows the speed setpoint.

Drive Functions 7.3 Overview of the CU240E-2 functions


7.3 Overview of the CU240E-2 functions

Figure 7-2 Overview of CU240E-2 Functions

Drive Functions 7.3 Overview of the CU240E-2 functions


Functions relevant to all applications Functions required in special applications only The functions that you require in your application are provided in the center of the function overview above. In the quick commissioning, the parameters of these functions are assigned an appropriate basic setting, so that in many cases the motor can be operated without having to assign any other parameters.

The functions whose parameters you only need to adapt when actually required are located at the outer edge of the upper function overview.


The production functions avoid overloads and operating states that could cause damage to the motor, inverter, and driven load. The motor temperature monitoring, for example, is set here.

The command source defines where the control signals are received from to switch on the motor (for example, through digital inputs or a fieldbus).

The status messages provide digital and analog signals at the Control Unit outputs or through the fieldbus. Examples include the actual speed of the motor or fault message issued by the inverter.

The setpoint source defines how the speed setpoint for the motor is specified, (for example, through an analog input or a fieldbus).


The setpoint processing uses a ramp-function generator to prevent speed steps occurring and to limit the speed to a permissible maximum value.

The safety functions are used in applications that must fulfill special requirements placed on the functional safety.

The motor closed-loop control ensures that the motor speed or torque follows its setpoint.

Drive Functions 7.4 Overview of CU240S functions


7.4 Overview of CU240S functions

Figure 7-3 Overview of CU240S functions



Functions relevant to all applications The functions that you require in each application are located at the center of the function overview above. The parameters of these functions are provided with a matching basic setting during quick commissioning so that in many cases, the motor can be operated without requiring additional parameterization.


The command source defines from where the control signals are received to switch-on the motor (for example, through digital inputs or a fieldbus.

The setpoint source defines how the speed setpoint is for the motor is entered (for example, through an analog input or a fieldbus.

The setpoint calculation uses a ramp-function generator to prevent speed steps occurring and to limit the speed to a permissible maximum value.

The motor closed-loop control ensures that the motor follows the speed setpoint.



Functions required in special applications only The functions, whose parameters you only have to adapt when actually required, are located at the outer edge of the function overview above.

The production functions avoid overloads and operating states that could cause damage to the motor, inverter, and driven load. The motor temperature monitoring is, for example, set here.

The status messages provide digital and analog signals at the digital outputs or via the fieldbus. Examples include the actual speed of the motor or fault message output by the inverter.


The safety functions are used for applications that must fulfill special requirements placed on the functional safety. These are only available for fail-safe drives, which are not offered as standard options for the W120 drive.

Connection to a fieldbus If you wish to operate the inverter on a fieldbus, then you must connect the following inverter functions with the fieldbus:

● Command sources

● Setpoint sources

● Status messages

A connection with a fieldbus can be established through software tools in the control systems. This manual includes descriptions of how you proceed for PROFIBUS and PROFINET with a SIMATIC control.


Troubleshooting 88.1 Faults and alarms

Description The inverter indicates unfavorable states as faults and alarms:

● Alarms: Alarms are indicated through an "!" icon on the IOP. Alarms require no acknowledgement and cause no systems reaction. The alarm description is displayed on the IOP, STARTER, or a higher-level control system.

● Faults: Faults indicate a severe unfavorable state. Faults are indicated through an "X" icon on the IOP. If a fault occurs, the inverter powers off, and the LED "SF" on the Control Unit is active.

The fault description is displayed on the IOP, STARTER, or a higher-level control system. You cannot restart the inverter not until the fault is remedied. After remedy the fault requires an acknowledgement.

Note

For detailed descriptions of the faults and alarms, refer to the Parameter Manual

Parameterizing faults and alarms

Faults

For fault handling, regard the following parameters:

● Stored in parameter r0947 under their code number (for example, F0003 = 3)

● Associated error value stored in parameter r0949 (0 = no error value)

● Time stamp of the fault stored in r0948 and can be read out

● Number of fault messages (P0952) is stored in r0947 and can be read out

Alarms

For alarm handling, regard the following parameter:

● Stored in parameter r2110 under their code number and can be read out (for example, A0503 = 503). The value 0 indicates, that no warning is applied. Through the index, you have access to the actual alarms and a list of the last historical alarms.

Troubleshooting 8.1 Faults and alarms


Display Faults and alarms are displayed on the following components:

● IOP: The status display of the IOP indicates the occurring faults and alarms. If several messages arise, the display scrolls constantly through all active faults.

● STARTER: The detail view in the alarms tab displays information, faults and alarms in the table. In the field "messages," the fault or information / alarm text is displayed in plain text.

● A higher-level control system. For detailed information, refer the respective manual of the control system.

General acknowledgement of faults To reset the fault code, one of the following methods can be used:

● Power cycle the inverter.

(Switch OFF / ON the main supply voltage and the external 24 V supply for the Control Unit.)

● Select "Acknowledge all" on the IOP when in the Faults/Alarms menu.

● Activate the default setting of DI 2.

● Set bit 7 in control word 1 (r0054).

Special acknowledgement of faults Some faults can only be acknowledged by a power cycle of the drive and control unit. Refer to the Parameter Manual for a list of the relevant faults.

Note

The drive cannot resume operation until all active faults have been acknowledged.

8.1.1 Overview of alarms and faults If a fault occurs, the drive indicates the fault and/or alarm. Faults and alarms are listed in a fault/alarm list, together with the following information:

● Fault/alarm number

● Standard drive response

● Description of the possible cause of the fault/alarm

Troubleshooting 8.2 Diagnostics display


● Description of the procedure for rectifying the problem

● Standard fault acknowledgement after it has been rectified

Note

The list of faults and alarms is contained in the Parameter manual.

It also contains descriptions of the responses (for example, OFF1 and OFF2).

8.2 Diagnostics display

8.2.1 Introduction This section describes procedures for identifying the causes of problems and the measures you need to take to rectify them.

Note

If errors or malfunctions occur in the device, you must carefully check the possible causes and take the necessary steps to rectify them. If you cannot identify the cause of the problem or you discover that components are defective, your regional office or sales office should contact Siemens Service and describe the problem in more detail.

8.2.2 Diagnostics with the IOP There are a wide range of functions that protect the drive against damage if a fault occurs (faults and alarms).

What is a fault? A fault is a message from the drive indicating an error or other exceptional (unwanted) status. This could be caused by a fault within the converter or an external fault triggered, for example, from the winding temperature monitor for the induction motor. The faults are displayed and can be reported to a higher-level control system via PROFIdrive. In the factory default setting, the message "drive fault" is also sent to a relay output. Once you have rectified the cause of the fault, you have to acknowledge the fault message.



What is an alarm? An alarm is the response to a fault condition identified by the drive. It does not result in the drive being switched off and does not have to be acknowledged. Alarms are "self acknowledging", that is, they are reset automatically when the cause of the alarm has been eliminated.

Diagnostics menu When the diagnostic function is selected the following options are presented:

Active faults/alarms History Identification/Maintenance I/O status Communications status I/O simulation Drive enables

Active faults/alarms When this option is selected the screen will display any active faults and alarms that have not yet been acknowledged. Each fault and alarm can be selected and by pressing the "INFO" key, an explanation of the fault or alarm will be displayed. Pressing the "INFO" key again will return the display to the previous list of faults and alarms.

History When this option is selected the screen will display a list of all previous faults and alarms with the time that they occurred. Pressing the "INFO" key on any highlighted fault and alarm will displayed more detailed information regarding that specific fault or alarm. Pressing the "INFO" key again will return the display to the previous list.



Identification/Maintenance Displays specific technical information regarding the Control Unit and Power Module to which the IOP is attached will be displayed. The actual information displayed depends on the type of Control Unit and Power Module to which the IOP is connected.

I/O status This option displays a list of the digital and analog inputs and outputs of the Inverter and their current status. This is an information screen and cannot be changed. Pressing "Esc" will return the display to the previous menu. In the example shown opposite, the status of the digital inputs are displayed.



Communications status The option displays the status of the fieldbus interface and the details of the settings for the data exchange, for example status words and control word lengths. In the example shown opposite, the status of the fieldbus communications is shown.

I/O simulation

WARNING Loss of control of the Inverter

If the Inverter is started using the I/O simulation and the IOP is removed from the Inverter it will not be possible to stop the Inverter running the motor. If the I/O simulation is activated, then only the I/O simulation can be used to stop the Inverter.



The IOP simulation screen allows digital and analog IOs to be simulated without the requirement for external signals. These features are of great benefit during commissioning and fault finding, as the user can quickly simulate a situation without using wires, tools, and external equipment.

Here are some examples: A digital input can be made high without any wires in the terminals. An analog input or output can be driven to any value without any wires in the terminals. A digital output can be overridden and made high. The screen presents the following options: I/O - Three I/Os can be simulated - two digital and one analog. Status - this indicates the real-time status of the input or output. If the square is shaded

then the input or output signal is present. This is a read-only section of the screen. Control - this column of the screen displays the present status of the input or output and

can be altered. To use the I/O simulation the following actions should be performed: 1. Using the wheel, rotate the wheel until the required digital input or output is displayed in

the first field. 2. Press OK. 3. The relevant control field is highlighted. 4. Using the wheel, rotate the wheel until the required control signal is displayed. 5. Press OK. 6. Repeat this process until all the fields have been completed as required. 7. When all fields have been completed the "activate the simulation" will be highlighted. 8. Press OK. The simulation will start running. 9. Press "Esc" to stop the simulation and return to the previous menu screen.



Drive enables The drive enables screen displays a list of all the current enabling signals for the Inverter. If the enable signal is present and active it will be selected ☑. If the enable signal is not present and is not active it will be unselected ⃞. This screen is read-only and is for information purposes only.


Maintenance, Service, and Support 99.1 Maintenance

9.1.1 Overview This chapter provides information on the following:

● Maintenance and servicing procedures that must be carried out on a regular basis to ensure the availability of the drive.

● Exchanging device components when the unit is serviced

● Storage requirements

DANGER

Before carrying out any maintenance or repair work on the de-energized drive, wait for 5 minutes after switching off the supply voltage. This allows the capacitors to discharge to a harmless level (< 50 V) after the supply voltage has been switched off.

Before starting work, you should also measure the voltage after the 5 minutes have elapsed. The voltage can be measured on DC link terminals DCP and DCN.

DANGER

When the external power supply for 120 V AC controls or the external 120 V AC auxiliary supply is connected, dangerous voltages are still present in the drive, even when the main circuit breaker is open.

9.1.2 Maintenance procedure

9.1.2.1 Overview The drive mainly comprises electronic components. Apart from the fan(s), the unit contains very few components that are subject to wear or require maintenance or servicing. Maintenance aims to preserve the specified condition of the drive. Dirt and contamination must be removed regularly and parts subject to wear replaced.



The following points must generally be observed.

WARNING The following must be taken into account when the devices are transported: Some of the devices are heavy or top heavy. Due to their weight, the devices must be handled with care by trained personnel. Serious injury or even death and substantial material damage can occur if the devices

are not lifted or transported properly.

WARNING

The drive is operated with high voltages.

All connection work must be carried out when the cabinet is de-energized!

All work on the drive must be carried out by trained personnel only. Non-observance of these warnings can result in death, serious personal injury, or substantial property damage.

Work on the drive must be carried out with extreme caution because external supply voltages may be present. The power and control terminals may be live even when the motor is not running.

Dangerously high voltage levels are still present in the drive up to five minutes after it has been disconnected due to the DC link capacitors. For this reason, the cabinet should not be opened until after a reasonable period of time has elapsed.

9.1.2.2 Cleaning

Dust deposits Dust deposits inside the drive cabinet must be removed at regular intervals (or at least once a year) by qualified personnel in line with the relevant safety regulations. The drive must be cleaned using a brush and vacuum cleaner, and dry compressed air (max. 1 bar) for areas that cannot be easily reached.

Ventilation The ventilation openings in the cabinet must never be obstructed. The fan(s) must be checked to make sure that it is functioning correctly.



9.1.2.3 Inspecting

Cable and screw terminals Cable and screw terminals must be checked regularly (or at least once a year) to ensure that they are secure in position, and if necessary, retightened. Cabling must be checked for defects. Defective parts must be replaced immediately.

Note

The actual intervals at which maintenance procedures are to be performed depend on the installation conditions (cabinet environment) and the operating conditions.

Siemens offers its customers support in the form of a service contract. For further details, contact your regional office or sales office.

Tightening torque for current-carrying parts When securing connections for current-carrying parts (DC link, motor connections, input connections, and busbars), you must observe the following tightening torques:

Table 9- 1 Tightening Torques for Connecting Current-carrying Parts

Screws Torque M6 6 Nm M8 13 Nm

M10 25 Nm M12 50 Nm

9.1.2.4 Replacing components

Fuses Fuses must be replaced with the same class, type, and current rating. Refer to the fuse labels installed inside the cabinet.



Air filter replacement The air filters must be checked at regular intervals. If the filters are too dirty to allow the air supply to flow normally, they must be replaced or cleaned. Air filters can be changed without opening the doors; however, it is recommended to exchange the filters with the drive off.

Note

Failure to replace or clean contaminated air filters can cause premature drive shutdown.

Replacing the cabinet operator panel 1. Switch the drive into a no-voltage condition.

2. Open the cabinet.

3. Disconnect the power supply and communications line on the operator panel.

4. Release the fastenings on the operator panel.

5. Remove the operator panel.

6. Install the new operator panel.

7. Carry out any other work by reversing the sequence.

Door fan replacement 1. Switch the drive into a no-voltage condition.

2. Open the cabinet door(s).

3. Disconnect the wires from the fan terminals.

4. Remove the fan from the door.

5. Install the new fan.

6. Carry out any other work by reversing the sequence.

Power module fan replacement Frame sizes A, B and C have been designed to allow the cooling fans to be replaced. Although the various frame sizes differ in physical size and the number of fans, the replacement procedure is similar. Frame size A contains one fan and frame size B and C contain two fans. The Control Unit must be removed from the Power Module. Power-down the Power Module and disconnect all cables. The Power Module must be placed face-down on a clean and safe surface and the cooling fan removed by releasing the power connection and the retaining screws. The new cooling fan is fitted in reverse order.



To replace the cooling fan on the G120E Power Modules for FSA, FSB and FSC, the following procedure should be performed.

1. Power-down the drive.

2. Remove the Control Unit from the inverter.

3. Disconnect all the cables from the Power Module.

4. Release the fan cable connector(s).

5. Using a posi-drive screwdriver, remove the fan retaining screws.

6. Slide the cooling fan out from the inverter.

7. Fit the new cooling fan into the fan housing area.

8. Secure the replacement cooling fan in place by tightening the retaining screws.

9. Reattach the fan cable connector(s).

10. Mount the Power Module.

11. Reconnect all the necessary cables to the Power Module.

12. Reattach the Control Unit.

13. Check that the installation is correct and safely installed.

14. Apply power to the system.

15. Check that the cooling fan(s) are running correctly.

9.1.3 Storage requirements The drives must be stored in clean, dry rooms. Temperatures between -13 °F and +131 °F (-25 °C and +55 °C) are permissible. Temperature variations greater than 20 K per hour are not permitted.

If the drive is stored for a prolonged period once it has been unpacked, cover it or take other appropriate measures to ensure that it does not become dirty and that it is protected against environmental influences. Failure to take such measures will invalidate any claims for damages under the terms of the warranty.

WARNING The drive should not be stored longer than one year. If the drive is stored for more than one year, its DC link capacitors must be reformed during commissioning.

Maintenance, Service, and Support 9.2 Service and support


9.2 Service and support

Service and support helpline If you need help and do not know who to contact, we make sure that you receive all the help you need as quickly as possible.

The helpline ensures that a specialist in your area can provide you with professional support. The helpline is available 24 hours a day, 365 days a year. German and English are spoken.

Table 9- 2 America (Johnson City, TN):

Internet Support-Request: http://www.siemens.com/automation/support-request Tel: +1 (800) 333-7421 Tel: +1 (423) 262-2522 Fax: +1 (423) 262-2200

Online support Our round-the-clock, worldwide online support service provides quick and efficient support in five languages. The comprehensive Internet-based information system, which is available round the clock, provides product support, services, and support tools in the shop.

Online support provides a wide range of technical information:

● FAQs, tips and tricks, downloads, current news

● Manual

● Helpful programs and software products

● http://support.automation.siemens.com

Field service If your plant is down and you need fast, on-site help, we can provide the specialists with the required expertise wherever you are.

With our comprehensive service network, we offer professional and reliable expertise to get your plant up and running again as quickly as possible.

Experts are available 24 hours a day, 365 days a year.

Of course, we can also arrange special service contracts tailored to your specific requirements. For details, please contact your Siemens office.



Spare parts and repairs During the operational phase of your machinery, we provide a comprehensive repairs and spare parts service to ensure maximum operational reliability. Our service includes expert advice with technical problems, and a wide range of product and system support services tailored to your needs.




List of Abbreviations AA.1 List of abbreviations

Table A- 1 Abbreviations

Abbreviation Description A AC Alternating Current ACT Actual value A/D Analog digital converter AG Automation unit AI Analog input ANSI American National Standards Institute AO Analog output ASD Adjustable speed drive AWG American Wire Gauge B BI Binector input BICO Binector/connector BO Binector output BOP Basic operator panel BTU British Thermal Unit C CCW Counterclockwise CDS Command data set CFM Cubic feet per minute CI Connector input CMD Command CO Connector output CO/BO Connector output/Binector output COM Common (terminal is connected to NO or NC) CT Constant torque CU Control unit CW Clockwise D D/A Digital analog converter

List of Abbreviations A.1 List of abbreviations


Abbreviation Description dB(A) Decibel A-weighted DC Direct current DDS Drive data set DEC Decimal DI Digital input DIP DIP switch DO Digital output DP Distributed I/Os DP-V1 Acyclic data transfer (extended PROFIBUS function) E EEPROM Electrical erasable programmable read-only memory EM Electro-Magnetic EMC Electromagnetic compatibility EMF Electromagnetic force EMI Electromagnetic interference ESD Elecrostatic Sensitive Device F FAQ Frequently asked question Fast FFB Fast freely programmable function blocks FB Function block FCL Fast current limiting FF Fixed frequency FFB Freely programmable function blocks FREQ Frequency FSA Frame size A FSB Frame size B FSC Frame size C FSD Frame size D FSE Frame size E FSF Frame size F FVNR Forward voltage non-reversing G GND Ground GSD Device Data File (Geräte Stamm Datei) GSG Getting Started Guide H HEX Hexidecimal HIW Main actual value



Abbreviation Description HMI Human machine interface HSW Main setpoint HVAC Heating, ventilation, air-conditioning I I/O Input/output IEEE Institute of Electrical and Electronics Engineers IGBT Insulated gate bipolar transistor IND Sub-index IOP Intelligent operator panel IP Internet Protocol J JOG JOG K KIB Kinetic buffering L LED Light emitting diode M MHB Motor holding brake MOP Motor operated potentiometer MMC Micro Memory Card N NC Normally closed NEC National Electric Code NEMA National Electrical Manufacturers Association NFPA National Fire Protection Association NO Normally open O OSHA Occupational Safety and Health Administration P PC Personal computer PCC Point of common coupling PID Proportional, integral, derivative controller PLC Programmable logic control PM Power module PM-IF Power module interface PN PROFINET PPE Personal protective equipment PWM Pulse-width modulation



Abbreviation Description Pxxxx Write parameter Q QC Quick commissioning R RAM Random-access memory RFG Ramp-function generator RFI Radio frequency interference RMS Root mean square ROM Read-only memory RPM Revolutions per minute RTD Resistance temperature detector RTU Remote terminal unit rxxxx read-only parameters of analog signals S SBC Safe brake control SCCR Short-circuit current rating SLS Safely limited speed SLVC Sensorless vector control SPD Surge protective device SS1 Safe stop 1 STO Safe torque off STW Control word T TCP Transmission Control Protocol THID Total harmonic current distortion U UL Underwriters Laboratories USB Universal serial bus USS Universal serial interface V V/Hz Volts per Hertz (also V/f - Voltage/frequency) VC Vector control VSD Variable speed drive VT Variable torque W WEA Automatic restart Z



Abbreviation Description ZSW Status word ZUSW Additional setpoint




Index

A

Alarms, 112

B

BICO technology, 92 Binector Connector Technology, 92 Bypass options

Manual, 34

C

Cleaning, 120 Command source, 109 Control menu

IOP settings, 67 Cooling, 50 Current reduction, 38

D

Data sets, 96 Derating data, 37

Current derating as a function of the site altitude and ambient temperature, 37 Voltage derating as a function of the site altitude, 37

Diagnostics, 113 DIP switch, 29 Drive control, 109 Drive features, 19 Drive functions, 19

Commissioning functions, 19 Control functions, 20 Maintenance functions, 20 Operating functions, 20 Protective functions, 20

E

Electrical installation, 14

F

Faults, 112 functions

Technological, 110

G

G120E Standard options, 32

General Specifications, 39

General technical specifications, 36

I Interfaces, 29 IOP, 31

Control menu settings, 67 Diagnostics with, 113 Menu, 70 Menu structure, 66

L

LEDs, 29

M

Maintenance and servicing, 119 Maintenance procedure

safety, 120 Mechanical installation, 13 Menu

IOP, 70 IOP diagnostics, 114

Index


Structure, 66 Monitoring parameters, 91 Motor control, 109

P

Parameter Attributes, 86 Index, 86

Parameter attribute Access level, 87 BICO, 87 Can be changed, 88 Data type, 88 Grouping, 89 Quick commissioning, 90 Unit, 88 Value range, 90

Parameters Data sets, 90

Power Modules Overview, 31

Protection functions, 110 Pulse frequency, 38

R

Replacement Air filters, 122 Operator panel, 122

Replacing the cabinet operator panel, 122

S

Safety functions, 110 Safety notes

Commissioning, 13 Electrical installation, 14 Mechanical installation, 13 Operation, 15 Repair, 16 Safety Instructions, 9 Transport and storage, 12

Setpoint calculation, 109 Setpoint source, 109 STARTER

Download, 59 Upload, 59

Status messages, 110

T

Typical free-standing enclosure, 23 Typical wall-mount enclosure, 21

U

User interfaces, 29

Documents

Sinamics g120e Oper Manual 032012