Operating Instructions (Compact) · Edition 04/2006 Control Unit CU240S CU240S DP CU240S DP-F Software version 2.
Installing/Mounting 1 Commissioning (software) 2 SINAMICS Operation 3 SINAMICS G120 Control Units CU240S Service and maintenance 4 Troubleshooting/FAQs 5 Operating Instructions (Compact) Note This Compact Operating Instructions contains the most important information for commissioning and operation of the inverter. The Compact Operating Instructions can be used for Quick Commissioning of standard applications.
Safety Guidelines This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger. Danger indicates that death or severe personal injury will result if proper precautions are not taken.
Table of contents 1 2 Installing/Mounting.................................................................................................................................. 1-1 1.1 Fitting the CU to the PM............................................................................................................. 1-2 1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 Connecting the Control Unit via terminals .................................................................................
Table of contents 3 4 5 2.7.8.10 2.7.8.11 2.7.8.12 2.7.8.13 2.7.9 2.7.9.1 2.7.9.2 2.7.9.3 2.7.9.4 2.7.9.5 2.7.10 2.7.11 Flow chart - Additional Setpoints ............................................................................................. 2-38 Flow chart - Skip Frequency .................................................................................................... 2-39 Flow chart - Ramp times, rounding ......................................................................................
Table of contents Tables Table 1-1 Encoder interface terminals ..................................................................................................... 1-10 Table 1-2 Typical Encoder connections ................................................................................................... 1-11 Table 1-3 Encoder voltage settings.......................................................................................................... 1-11 Table 2-1 Parameter attributes - BICO ........
1 Installing/Mounting Installing the Control Unit The Control Unit allows the user to access the full functionality of the inverter. Warning An inverter can be switched on unintentionally if the installation is not performed correctly. The inverter must be started-up by personnel who are qualified and trained in installing systems of this type.
Installing/Mounting 1.1 Fitting the CU to the PM 1.1 Fitting the CU to the PM Fitting the Control Unit to the Power Module The Control Unit is fitted to the Power Module as shown in the figure below. To disconnect the CU push the release button on top of the PM. The process of fitting the Control Unit to the Power Module is the same technique no matter which Control Unit or Power Module combination is required.
Installing/Mounting 1.1 Fitting the CU to the PM 1.2 Connecting the Control Unit via terminals 1.2.1 Common information to the control terminals Common information to the control terminals To have access to the control terminals, the terminal cover must be removed, as shown in the figure below. The control terminals have a maximum tighting torque of 0.25 Nm (2.2 lbf.in) and a nominal cable cross section of 1.5 mm2.
Installing/Mounting 1.1 Fitting the CU to the PM Figure 1-4 Removing the two-part connectors with a CU240S DP as example After all the wiring of the control unit is completed - ensure that the terminal cover is replaced. 1.2.2 Setting-up the Control Unit via terminals Terminal wiring examples for the Control Unit CU240S, not for CU240S DP and CU240S DP-F In this section examples of controlling a SINAMICS G120 inverter with a CU240S via terminals are shown.
Installing/Mounting 1.1 Fitting the CU to the PM 1.2.3 Control wiring for a CU240S Control Unit with default setting Basic control with the default settings When shipped from the factory and fitted to the power module, a factory reset must be performed to read the power stack data into the control unit, before operating the inverter with the basic settings.
Installing/Mounting 1.
Installing/Mounting 1.1 Fitting the CU to the PM 1.2.4 Voltage input control wiring Frequency setpoint and an additional setpoint via terminals AI0 and AI1 used as voltage inputs This type of control wiring allows a main frequency setpoint and an additional setpoint to be established, using potentiometers on analog inputs AI0 and AI1. The figure below shows the wiring that is necessary to accomplish this functionality.
Installing/Mounting 1.1 Fitting the CU to the PM 1.2.5 Current input control wiring Frequency setpoint and an additional setpoint via terminals AI0 and AI1 used as current inputs This type of control wiring allows a main frequency setpoint and an additional setpoint to be established, for example from a PLC. The figure below shows the wiring that is necessary to accomplish this functionality. DIP switch Settings The general I/O DIP switch is used to configure the analog inputs (AI).
Installing/Mounting 1.
Installing/Mounting 1.1 Fitting the CU to the PM 1.3 Installing the Encoder Interface Preparation • The Encoder unit has been fitted to the motor as described by the Installation Instructions supplied with the Encoder unit. • The SINAMICS G120 inverter has been powered-down. Screening To ensure the correct functioning of the encoder the guidelines listed below should be followed: • Only twisted-pair screened cable should be used to connect the encoder to the Encoder Interface.
Installing/Mounting 1.1 Fitting the CU to the PM Table 1-2 Typical Encoder connections Encoder pin assignment 1xP8001 Encoder designations Enocder terminals Rotary Pulse Encoder 1XP8001-1/Up = 10 V … 30 V (HTL) 1XP8001-2/Up = 5 V ± 5 % (TTL) A Ua2 BN B Up + 24 V or + 5 V C Ua0 Z D Ua0 ZN E Ua1 A 6KLHOG B F Ua1 AN G Uas - H Ua2 B K 0V 0V L 0V - M Up - C L A K D E M J H G F (QFRGHU FRQQHFWRU The encoder voltage is using the general I/O DIP switches 3 and 4.
Commissioning (software) 2.1 2 General commissioning information General commissioning information The inverter can be adapted to various applications by changing the parameter values.
Commissioning (software) 2.2 Parameters 2.2 Parameters 2.2.1 Overview of Parameters Overview of parameters The inverter is adapted to a particular application using the appropriate parameters. This means that each parameter is identified by a parameter number and specific attributes (e.g. readable, can be written into, BICO attribute, group attribute etc.). Within any one particular inverter system, the parameter number is unique.
Commissioning (software) 2.2 Parameters 2.2.2 Write parameters Description Parameters which can be written into and displayed are indicated by the prefix "P". These parameters directly influence the behaviour 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).
Commissioning (software) 2.
Commissioning (software) 2.2 Parameters Access level The access level is controlled using parameter P0003. In this case, only those parameters are visible at the OP, 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.
Commissioning (software) 2.2 Parameters Table 2-4 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 For SINAMICS G120, the units of a particular parameter involve the physical quantity (e.g. m, s, A).
Commissioning (software) 2.2 Parameters Table 2-6 Parameter attributes - Grouping Grouping Description 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.
Commissioning (software) 2.2 Parameters Quick commissioning This parameter attribute identifies as to whether the parameter is included in the quick commissioning (QC) (P0010 = 1).
Commissioning (software) 2.3 Factory settings 2.3 Factory settings Factory default settings The inverter system is shipped from the factory as a Control Unit and a Power Module. The Control Unit has three or seven LEDs (depending on the type of Control Unit) on the front panel which display the operating state of the inverter. For commissioning and operation the control unit has to be fitted to the power module as shown in section 4.
Commissioning (software) 2.
Commissioning (software) 2.4 Parameterization with Operator Panel 2.4 Parameterization with Operator Panel 2.4.1 Handling of the Operator Panel The Operator Panel (OP) The OP is available as an option to enhance the effectiveness of parameterizing and control of the inverter. The control signals and speed reference can easily be set by pressing the appropriate buttons. The OP has the ability to upload and download parameter sets from an inverter to another inverter.
Commissioning (software) 2.4 Parameterization with Operator Panel 2.4.2 Function Keys of the OP Operator Panel - function keys Table 2-12 OP keys and their functions Operator Panel Key Function Effects Status display The LCD indicates the settings which the drive inverter is presently using. Start motor The inverter is started by pressing the key. This key is deactivated in the default setting. Parameter P0700 or P0719 should be changed as follows to activate the key: OP: P0700 = 1 or P0719 = 0 .
Commissioning (software) 2.4 Parameterization with Operator Panel 2.4.3 Changing parameters via OP Changing parameter with the OP The description below serves as an example that shows how to change any parameter using the OP.
Commissioning (software) 2.5 Parameterization with MMC 2.5 Parameterization with MMC Overview A G120 inverter can be parameterized by downloading a parameter set from the MMC to the inverter. The download can be performed as • manual download • automatic download • start-up download A detailed download description can be found in the operation section. 2.6 Parameterization with STARTER 2.6.
Commissioning (software) 2.6 Parameterization 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.
Commissioning (software) 2.7 Commissioning modes 2.7 Commissioning modes 2.7.1 Commissioning overview Commissioning overview A differentiation is made between the following scenarios when commissioning the inverter via OP: • Quick commissioning • Motor data identification • Calculating the motor/control data • Commissioning the application • Series commissioning. When commissioning, initially, a quick or series commissioning should be carried-out.
Commissioning (software) 2.7 Commissioning modes In addition, to carrying-out all of the installation work, an important prerequisite for successful commissioning is that the Inverter is not disconnected from the line supply while being parameterized. If a line supply failure interrupts commissioning, then inconsistencies can occur regarding the parameterization. In this case, it is important that the commissioning is re-started, possibly with a factory reset to establish the original factory settings.
Commissioning (software) 2.7 Commissioning modes 2.7.2 Quick commissioning Description If there is still no appropriate parameter set for the drive, then a quick commissioning must be carried-out for the closed-loop vector control and for the V/f control including a motor data identification routine. The following operator units can be used to carry-out quick commissioning: • OP (option) • PC Tools (with commissioning program STARTER).
Commissioning (software) 2.7 Commissioning modes 3 3 3 3 3 3 Figure 2-6 2.7.
Commissioning (software) 2.7 Commissioning modes Table 2-16 Quick commissioning - flow chart Parameter Action/Description (Factory setting: bold) Parameters with an "*" have more settings than listed below. Please refer to the parameter list P0003 = 3 User access level* 1: Standard: Allows access into most frequently used parameters 2: Extended: Allows extended access e.g.
Commissioning (software) 2.7 Commissioning modes Parameter Action/Description (Factory setting: bold) Your own Parameters with an "*" have more settings than listed below. Please refer to the parameter list setting 2: 4-pole motor Recalculated automatically when P0310 (rated motor frequency) or P0311 (rated motor speed) is changed. P0320 = ? Motor magnetizing current Setting P0320 = 0 causes calculation according the setting of P0340 = 1 (data entered from rating plate) or by P3900 = 1, 2 or 3.
Commissioning (software) 2.7 Commissioning modes Parameter Action/Description (Factory setting: bold) Parameters with an "*" have more settings than listed below.
Commissioning (software) 2.7 Commissioning modes Parameter Action/Description (Factory setting: bold) Your own Parameters with an "*" have more settings than listed below. Please refer to the parameter list setting 2: Motor calculation and reset of all I/O settings to factory settings. 3: Only motor calculation - other parameters are not reset. Note: If P3900 = 1, 2, or 3 P0340 is set to 1 and the value from P1082 is written into P2000. The appropriate motor data will be calculated.
Commissioning (software) 2.7 Commissioning modes 2.7.4 Calculating the motor and control data Overview Internal motor/control data is calculated using parameter P0340 or, indirectly using parameter P3900 or P1910. The functionality of parameter P0340 can, for example, be used if the equivalent circuit diagram data or the moment of inertia values are known.
Commissioning (software) 2.7 Commissioning modes 2.7.5 Calculating the motor and control data - flow chart Performing the calculation of motor and control data via OP Parameter Description P0340 = 1 Calculation of motor parameters This parameter is required during commissioning in order to optimize the operating behavior of the inverter. For the complete parameterization (P0340 = 1), in addition to the motor/control parameters, parameters are pre-assigned which refer to the rated motor data (e.g.
Commissioning (software) 2.7 Commissioning modes 2.7.6 Motor data identification Motor identification data The Inverter has a measuring technique which is used to determine the motor parameters: Equivalent circuit diagram (ECD) ➙ P1910 = 1 Magnetizing characteristic (saturation curve) ➙ P1910 = 3 For control-related reasons, it is essential that the motor data identification is performed.
Commissioning (software) 2.7 Commissioning modes ˓ > @ 3 3 3 3 3 3 3 3 L w > @ L >$@ Lw > @ w U Figure 2-8 Magnetizing characteristic After selecting the motor data identification using parameter P1910, alarm A0541 is immediately generated. The motor identification routine is started by the ON command and different excitation signals are impressed in the motor (DC and AC voltages).
Commissioning (software) 2.7 Commissioning modes Note The equivalent circuit data (P0350, P0354, P0356, P0358, P0360), with the exception of parameter P0350, should be entered as phase values. In this case, parameter P0350 (lineto-line value) corresponds to twice the phase value. The motor cable resistance P0352 is defined as a phase value. During the motor identification routine, the stator resistance and the motor cable resistance are determined and entered into parameter P0350.
Commissioning (software) 2.7 Commissioning modes 2.7.7 Motor data identification - flowchart Motor data identification - flow chart Parameter or Action Description (Factory setting: Bold) P0625 = ? Ambient motor temperature (entered in °C) The motor ambient temperature is entered at the instant that motor data is being determined (factory setting: 20 °C). The difference between the motor temperature and the motor ambient temperature P0625 must lie in the tolerance range of approx. ± 5 °C.
Commissioning (software) 2.7 Commissioning modes 2.7.8 Commissioning the application 2.7.8.1 Commissioning the application Commissioning the application After the motor - Inverter combination has been commissioned using quick commissioning, the following parameters should be adapted and set according to the requirements of your specific application.
Commissioning (software) 2.7 Commissioning modes 2.7.8.2 Flow chart - General settings Commissioning the application - flow charts The parameters designated with an "*" offer more setting possibilities than are listed here. Refer to the parameter list for additional setting possibilities. General settings Parameter Description (Factory setting: bold) P0003 = 3 User access level* 1: Standard: Allows access into most frequently used parameters. 2: Extended: Allows extended access e.g.
Commissioning (software) 2.7 Commissioning modes 2.7.8.4 Flow chart - Temperature Sensor Temperature Sensor Parameter Description (Factory setting: bold) Setting P0601 = 0 or P0601 = ? Motor temperature sensor 0: No sensor (→ P0610) 1: PTC thermistor (→ P0604) 2: KTY84 (→ P0604) P0604 = ? Threshold motor temperature Enter the warning threshold for motor overtemperature protection.
Commissioning (software) 2.
Commissioning (software) 2.7 Commissioning modes 2.7.8.
Commissioning (software) 2.7 Commissioning modes Frequency setpoint via MOP (P1000 = 1) Parameter Description (Factory setting: bold) Setting P1031 = 0 Setpoint memory of the MOP The last motorized potentiomenter setpoint, which was active before the OFF command or switching-off, can be saved.
Commissioning (software) 2.7 Commissioning modes Frequency setpoint via fixed frequency (P1000 = 3) Parameter Description (Factory setting: bold) P1016 = 1 Fixed frequency mode, defines the selection method for fixed frequencies. The fixed frequency can be selected via four digital inputs (default DI3 … DI6). 1: direct selection 2: binary coded With the default settings additional combinations as follows are possible: P1001 = 0 Fixed frequency 1, (FF1) Value given in Hz.
Commissioning (software) 2.7 Commissioning modes 2.7.8.
Commissioning (software) 2.7 Commissioning modes 2.7.8.9 Flow chart - JOG frequency JOG frequency Parameter Description (Factory setting: bold) P1057 = 1 JOG Enable P1057 = 0 JOG-function diabled P1057 = 1 JOG-function enabled P1058 = 5 JOG frequency right Frequency in Hz when the motor is being jogged in the clockwise direction of roatation. P1059 = 5 JOG frequency left Frequency in Hz when the motor is being jogged in the counter-clockwise direction of rotation.
Commissioning (software) 2.7 Commissioning modes 2.7.8.11 Flow chart - Skip Frequency Skip Frequency Parameter Description (Factory setting: bold) P1091 = 7.5 Skip frequency 1 (entered in Hz) Avoids mechanical resonance effects and suppresses (skips) frequencies in the range around the skip frequency ± P1101 (skip frequency bandwidth). P1092 = 0.0 Skip frequency 2 P1093 = 0.0 Skip frequency 3 P1094 = 0.0 Skip frequency 4 P1101 = 1.
Commissioning (software) 2.7 Commissioning modes 2.7.8.13 Flow chart - Finishing the application setting Parameters to set before finishing the application setting The following parameters should be configured for each application Parameter Description (Factory setting: bold) P1800 = 4 Pulse frequency (kHz) The pulse frequency can be changed in 2 kHz steps. The range extends from 2 kHz up to 16 kHz. The complete inverter output current at 50 °C is reached with 4 kHz.
Commissioning (software) 2.7 Commissioning modes Finishing the application setting Parameter Description (Factory setting: bold) P0971 = 1 Transfer data from RAM to EEPROM 0: Disabled 1: Start data transfer, RAM → EEPROM All of the parameter changes are transferred from the RAM into the EEPROM which means that they are saved in a non-volatile state within the Inverter (data is not lost when the power fails). Setting While the transfer is active, "bUSY" will be displayed on the OP.
Commissioning (software) 2.7 Commissioning modes 67$57(5 YLD 68% ' FDEOH 67$57(5 YLD 3& FRQQHFWLRQ NLW %23 GLUHFWO\ ILWWHG 00& 0XOWL 0HGLD &DUG 3& FRQQHFWLRQ NLW 2SWLRQ 3RUW 866 RQ 56 56 ! 56 FRQYHUWHU Figure 2-9 ' W\SH FRQQHFWRU ထ 866 RQ 56 ထ 352),%86 Series commissioning interfaces Warning For series commissioning, all of the communication interfaces as well as also the digital and analog interfaces are re-initialized.
Commissioning (software) 2.7 Commissioning modes Note Manual and automatic download With a manual download all necessary parameters excluding the safety parameters (only with fail-safe CUs) are downloaded into the inverter. A manual download can be triggered by the customer as described in the following. With an automatic download even the safety parameters are downloaded into the inverter.
Commissioning (software) 2.7 Commissioning modes To copy a parameter set from one inverter to another, the following procedure should be performed. Upload a parameter set with an OP Prerequisites • An inverter with an apropriate parameter set is available (upload inverter) • Supply voltage is active for the upload inverter • The upload inverter is in "Ready State".
Commissioning (software) 2.
Commissioning (software) 2.7 Commissioning modes Download a parameter set with STARTER Prerequisites • Supply voltage is active for the download inverter • The download inverter is in "Ready State". Connect the STARTER PC via the Option Port (USS on RS232, peer to peer) to the download inverter (PC connection Kit requiered), press the online button and perform the download by activating the button . The data set must be saved in the EEPROM.
Commissioning (software) 2.7 Commissioning modes Removing the MMC To remove the MMC from the Control Unit, the following procedure should be performed: 6. Using a thin-bladed screwdriver, push down the release-catch on the MMC housing. 7. Grasp the MMC gently and pull upwards. This procedure is shown in the figure below. 6,1$0,&6 6,1$0,&6 Figure 2-11 2.7.9.
Commissioning (software) 2.7 Commissioning modes Parameter Action/Description (Factory setting: bold) Setting Insert the MMC to the inverter - for the parameter set to be uploaded, perform the following steps: P0010 = 30 Commissioning parameter* 0: Ready 1: Quick commissioning 2: Inverter 30: Factory setting 95: Commissioning the fail-safe functions (CUs with Safety-Integrated functions only) P0804 = ? Select Clone file 0: clone00.bin … 99: clone99.
Commissioning (software) 2.7 Commissioning modes Prerequisites • Supply voltage is active for the download inverter • The download inverter is in "Ready State". Parameter Action/Description (Factory setting: bold) Setting Insert the MMC to the download inverter and perform the manual download according the flow chart.
Commissioning (software) 2.7 Commissioning modes Power ON QR QR yes swap? yes MMC plugged? QR P8458 > 0? (Clone Control) yes QR P7844 = 1? (acceptance test/ confirmation) go to Swap behavior P8458 = 1? (Clone Control) yes yes valid Par.
Commissioning (software) 2.7 Commissioning modes Successful automatic download After a successful automatic download, F0395 will be displayed. • In case of a standard CU a confirmation is necessary. • In the case of CUs with safety integrated functions, an acceptance test must be performed. Confirmation On standard CUs the current parameter set needs to be checked and confirmed by clearing F0395. It can be cleared via: • Digital input or PLC signal (depends on the settings of P0700) • setting P7844 = 0.
Commissioning (software) 2.7 Commissioning modes 2.7.10 Reset parameters to factory settings Overview With a factory setting a defined initial state of all of the inverter parameters can be realized. You can re-establish the initial state by carrying-out a factory via p0970. The factory setting values are designated as "Def" in the parameter list.
Commissioning (software) 2.7 Commissioning modes Warning Safety-Integrated parameters When using CUs without safety-integrated functions, only the factory reset with P0970 = 1 must be taken into account. When using CUs with safety integrated functions two reset methods are available: • P0970 = 1 resets only non fail-safe function relating parameters (application parameters).
Commissioning (software) 2.8 Encoder Commissioning 2.8 Encoder Commissioning 2.8.1 Commissioning the Encoder Interface Commissioning the Encoder Interface Warning Before installing and commissioning, please read these safety instructions and warning carefully and all the warning labels attached to the equipment. Make sure that the warning labels are kept in a legible condition and replace missing or damaged labels.
Commissioning (software) 2.8 Encoder Commissioning Encoder commissioning To commission the Encoder, the following procedure should be performed: Table 2-18 Commissioning the Encoder Step Description TTL HTL 1. Ensure the Inverter is switched off. X X 2. Connect the Channel A wire from the encoder to terminal 70 (ENC AP) on the Control Unit. X X 3. Connect the Channel A inverted wire from the encoder to terminal 71 (ENC AN) on the Control Unit. X X 4.
Commissioning (software) 2.8 Encoder Commissioning Table 2-19 Encoder voltage settings 9 (QFRGHU VXSSO\ 9 (QFRGHU VXSSO\ 9 (QFRGHU VXSSO\ 9 (QFRGHU VXSSO\ 9 (QFRGHU VXSSO\ 9 (QFRGHU VXSSO\ 9 (QFRGHU VXSSO\ OFF 9 (QFRGHU VXSSO\ On 3 4 3 4 3 4 3 4 Encoder supply voltage 0V 24 V 5V 24 V Encoder type No encoder HTL encoder TTL encoder HTL encoder Warning DIP switches 3 and 4 in ON position provide a supply voltage of 24 V to the encoder.
Commissioning (software) 2.8 Encoder Commissioning Parameter Name Values Bit 03 - Encoder low speed loss Bit 05 - Single edge measurement 1 Yes 0 No 1 Yes 0 No 1 Yes P0405 Encoder pulse Enables selection of various pulse types. Only bits 04 and 05 are used types for the SINAMICS G120. See parameter list. P0408[3] Pulses per revolution Specifies the number of encoder pulses per revolution P0491[3] Reaction on speed signal loss Selects reaction on loss of speed signal.
Commissioning (software) 2.8 Encoder Commissioning Caution Once the correct parameters values have been entered, it is recommended to operate the inverter in V/f mode (P1300 = 0) before speed/torque control with the encoder feedback is used and check that it functions correctly. The user must observe the motor shaft to check the direction of rotation. The direction of rotation must be checked against the value displayed in r0061.
Commissioning (software) 2.8 Encoder Commissioning 2.8.3 Encoder fault codes Encoder fault codes The Encoder Interface has only one fault code, – F0090. This condition occurs when the allowed frequency rate of change, set in P0492[3] is exceeded or when low speed encoder loss is detected.
3 Operation 3.1 General Operation behaviour Overview The operation and start-up behavior depends on the settings during commissioning of the inverter. As specific operation features the "Normal start-up behavior" and "Swap behavior" as well as "up and download of parameter sets" are described in this section. 3.2 Start-up Behavior Overview When starting-up the inverter checks, wether an MMC is plugged in or not.
Operation 3.2 Start-up Behavior 3.2.1 Normal Start-up behavior of the Inverter Normal start-up behavior of the inverter A normal start-up is a start-up after a power-cycle or a black-out. It can be performed with or without MMC. Power ON QR QR MMC plugged? QR yes swap? yes P8458 > 0? (Clone Control) yes QR P7844 = 1? (acceptance test/ confirmation) go to Swap behavior P8458 = 1? (Clone Control) yes yes valid Par.
Operation 3.2 Start-up Behavior Normal start-up behavior without MMC After a power-cycle or a black-out the inverter reads the parameters from EEPROM to RAM. Normal start-up behavior with MMC The CUs have been designed to detect automatically whether an MMC is present in the CU. The interaction between the CU and the MMC is controlled using parameter P8458. The possible settings for P8458 and their functions are given below. P8458 = 0: No automatic parameter download from the MMC.
Operation 3.2 Start-up Behavior Successful automatic download After a successful automatic download, F0395 will be displayed. • In case of a standard CU a confirmation is necessary. • In the case of CUs with safety integrated functions, an acceptance test must be performed. Confirmation On standard CUs the current parameter set needs to be checked and confirmed by clearing F0395. It can be cleared via: • Digital input or PLC signal (depends on the settings of P0700) • setting P7844 = 0.
Operation 3.2 Start-up Behavior 3.2.2 Swap Behavior of the Inverter Swap behavior of the inverter The SINAMICS G120 inverter comprises of Power Modules (PM) and Control Units (CU) Both, PM and CU, can be replaced e.g. to change a defective component. The exchange of either a PM or a CU is called a "swap".
Operation 3.2 Start-up Behavior Power ON go to Normal start-up behavior no yes swap? yes no MMC plugged? no valid Par.
Operation 3.2 Start-up Behavior PM hotswap with powered CU Caution Before performing a hotswap, make sure that all parameters are stored in the EEPROM of the Control Unit (see P0014 or P0971). In this case the power module can be hot swapped without power cycling the CU. A parameter set either from MMC or from CU EEPROM is loaded into the CU RAM to prevent faults. A successful swap is indicated by F0395, a swap fault by F0061 or F0063. See description below.
Operation 3.2 Start-up Behavior PM swap, including a power cycle Same behavior as CU swap Successful swap After a successful swap, F0395 will be displayed. • In case of a standard CU a confirmation is necessary. • In the case of CUs with safety integrated functions, an acceptance test must be performed. Confirmation On standard CUs the current parameter set needs to be checked and confirmed by clearing F0395.
Operation 3.3 Upload and download of parameter sets 3.3 Upload and download of parameter sets Upload of parameter sets With an upload, a parameter set can be saved in one of the following devices: • PC (via STARTER) • MMC • OP An upload can be triggered via • PROFIBUS, • OP • STARTER A detailed description is given in "Series Commissioning" in the commissioning section.
Operation 3.3 Upload and download of parameter sets Manual download A manual download can be performed similar to an upload via • PC (STARTER) • MMC • OP It can be triggered - like upload - via • PROFIBUS, • OP • STARTER With a manual download a parameter set without the safety related parameters is downloaded from one of the above mentioned devices into the inverter. A detailed description is given in "Series Commissioning" in the commissioning section.
Service and maintenance 4.1 4 Service and support information A&D Technical support 24-hour technical support is provided by three main centres worldwide. A&D Global service and support Europe/Africa (Erlangen) Tel: +49 (180) 5050 222 Fax: +49 (180) 5050 223 Email: adsupport@siemens.com America (Johnson City) Tel: +1 (423) 262 2552 Fax: +1 (423) 262 2589 Email: simatic.hotline@sea.siemens.
Service and maintenance 4.1 Service and support information Asia/Pacific (Beijing) Tel: +86 (1064) 757 575 Fax: +86 (1064) 747 474 Email: adsupport.asia@siemens.com China (Beijing) Tel: +86 (1064) 71 9990 Fax: +86 (1064) 71 9991 Email: adscs.china@siemens.com Online Service and support Comprehensive information and support tools are available from the Service and Support internet site at: http://support.automation.siemens.
Service and maintenance 4.2 Faults and Alarms 4.2 Faults and Alarms Faults In the event of a failure, the inverter switches off and the red LED "SF" will be on. The fault code will be displayed via OP, STARTER or Communication interface (if fitted, resp. connected). Note To reset the fault code, one of three methods listed below can be used: 1. Cycle the power to the inverter. 2. Press the Fn button on the OP 3. Use digital input 2 (default setting).
Service and maintenance 4.3 LED Overview 4.3 LED Overview Status display via LED The SINAMICS G120 inverters provide multiple functions and operating states which are indicated via LED. 6WDWXV /(' RQ &X 6 &8 6 '3 6WDWXV /(' RQ &8 6 '3 ) 5HDG\ 5HDG\ *HQHUDO )DXOW *HQHUDO %XV )DXOW )DLOXUH Figure 4-1 (QG 6WDWH %XV )DLOXUH 6DIH 6WRS 6DIH 7RUTXH 2II 6DIHO\ /LPLWHG 6SHHG State LED on the CU240S, CU240S DP, CU240S DP-F Colours The colours of the LEDs are self explanatory.
Service and maintenance 4.3 LED Overview LED description • System-Fault LED (SF) The system-fault LED indicates a general system error either software or hardware related. • Ready LED (RDY) The ready LED indicates whether the inverter is ready to operate by transmitting a control-word. This LED does not indicate whether the drive is running or not. For that purpose an OP would be more convenient.
Service and maintenance 4.4 Normal Status LEDs 4.
Service and maintenance 4.5 Fail -Safe Function Status LEDs 4.
Service and maintenance 4.6 Further indication for LEDs SLS Fail-safe function states via LED Description LED SF RDY BF red green red ES STO SS1 SLS yellow not relevant not relevant not relevant SLS parameterized not relevant not relevant not relevant not relevant not relevant not relevant not relevant not relevant not relevant not relevant 4.
Service and maintenance 4.7 Troubleshooting with the OP 4.7 Troubleshooting with the OP Troubleshooting with the OP If the motor fails to start when the ON command has been given: • Check that P0010 = 0. • Check the inverter state via r0052 • Check command and setpoint source (P0700 and P1000) Warnings and faults are displayed on the OP with Axxx and Fxxx respectively. The individual messages are shown in the Parameter List. Note Motor data must relate to the inverter data power range and voltage.
5 Troubleshooting/FAQs Status display via LED The SINAMICS G120 inverters provide multiple functions and operating states which are indicated via LED. 6WDWXV /(' RQ &X 6 &8 6 '3 6WDWXV /(' RQ &8 6 '3 ) 5HDG\ 5HDG\ *HQHUDO )DXOW *HQHUDO %XV )DXOW )DLOXUH Figure 5-1 (QG 6WDWH %XV )DLOXUH 6DIH 6WRS 6DIH 7RUTXH 2II 6DIHO\ /LPLWHG 6SHHG State LED on the CU240S, CU240S DP, CU240S DP-F Colours The colours of the LEDs are self explanatory.
Troubleshooting/FAQs LED description • System-Fault LED (SF) The system-fault LED indicates a general system error either software or hardware related. • Ready LED (RDY) The ready LED indicates whether the inverter is ready to operate by transmitting a control-word. This LED does not indicate whether the drive is running or not. For that purpose an OP would be more convenient.
Troubleshooting/FAQs Diagnostics using alarm numbers If a Basic Operator Panel (BOP) is fitted to the Control Unit and a alarm or fault condition occurs, the BOP will display the appropriate alarm or fault number. If an alarm occurs, the alarm number will be displayed and the inverter will continue to run, although it is possible that it may run in an unexpected manner depending upon the alarm condition. If a fault occurs, the fault number will be displayed and normally the inverter will be stopped.
Troubleshooting/FAQs Identification of the communications components The read-only parameter r2053 shows the information by which the various firmware components of the PROFIBUS-DP interface can be identified. Table 5-2 Identification of communications firmware Parameter Meaning r2053.00 0: Inverter cannot identify the communications interface 1: PROFIBUS DP detected 2: No assigned 56: Undefined communications error r2053.01 Firmware version r2053.02 Constant "0" r2053.
Troubleshooting/FAQs Table 5-4 Parameter accessing error numbers Number Cause Remedy 0 … 199: Parameter access has been converted to a PKW request. Error detected in the inverter. Additional information is in r2054.05 and r2054.
Troubleshooting/FAQs Troubleshooting with the OP If the motor fails to start when the ON command has been given: • Check that P0010 = 0. • Check the inverter state via r0052 • Check command and setpoint source (P0700 and P1000) Warnings and faults are displayed on the OP with Axxx and Fxxx respectively. The individual messages are shown in the Parameter List. Note Motor data must relate to the inverter data power range and voltage.
Index A O Alarm messages, 4-3 OP, 2-43 C P Calculating the motor/control data, 2-24 Changing parameters with the Operator Panel, 2-13 Commissioning, 2-54 Commissioning the application, 2-30 Control Wiring, 1-4 Encoder Interface Connections, 1-10 Preparation, 1-10 Parameter upload, 3-9 Parameters Access level, 2-5 Active, 2-7 Atrributes, 2-3 BICO, 2-4 Change state, 2-5 Data sets, 2-8 Data types, 2-5 Grouping, 2-6 Quick commissioning, 2-8 Unit, 2-6 Value range, 2-8 Power Modules Fitting the Control Un
Index U Upload parameter, 3-9 Upload parameters, 2-43 Index-2 Control Units CU240S Operating Instructions (Compact), 04/2006, A5E00766042B AA
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