siemens CPU 230 User Manual

Converter with Control Units CU230P-2;

CU240B-2; CU240E-2

___________________

SINAMICS G120

Converter with Control Units CU230P-2; CU240B-2; CU240E-2

Getting Started

Edition 04/2014, Firmware V4.7

04/2014

A5E32885834B AB

Fundamental safety instructions

Design of the frequency converter

Installing

Commissioning

Manuals and technical support

Siemens AG Industry Sector Postfach 48 48 90026 NÜRNBERG GERMANY

A5E32885834B AB

Ⓟ

Legal information

Warning notice system

DANGER

indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING

indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION

indicates that minor personal injury can result if proper precautions are not taken.

NOTICE

indicates that property damage can result if proper precautions are not taken.

Qualified Personnel

personnel qualified

Proper use of Siemens products

WARNING

Siemens products may only be used for the applications described in the catalog and in the relevant technical

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

Disclaimer of Liability

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.

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.

The product/system described in this documentation may be operated only by 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.

for the specific

Note the following:

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

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.

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.

05/2014 Subject to change

1 Fundamental safety instructions .............................................................................................................. 7

2 Design of the frequency converter ......................................................................................................... 15

3 Installing ............................................................................................................................................... 17

4 Commissioning ..................................................................................................................................... 35

5 Manuals and technical support .............................................................................................................. 47

1.1 General safety instructions ............................................................................................................ 7

1.2 Safety instructions for electromagnetic fields (EMF) ................................................................... 11

1.3 Handling electrostatic sensitive devices (ESD) ........................................................................... 11

1.4 Industrial security ......................................................................................................................... 12

1.5 Residual risks of power drive systems ......................................................................................... 13

3.1 Installing the Power Module ......................................................................................................... 17

3.2 Snapping the Control Unit onto the Power Module...................................................................... 19

3.3 Installing Control Unit ................................................................................................................... 20

3.3.1 CU230P-2 control unit .................................................................................................................. 20

3.3.1.1 Interfaces at the front of the CU230P-2 ....................................................................................... 20

3.3.1.2 Terminal strips of the CU230P-2 .................................................................................................. 21

3.3.2 CU240B / CU240E Control Unit ................................................................................................... 23

3.3.2.1 Interfaces at the front of the CU240B-2 and CU240E-2 .............................................................. 23

3.3.2.2 Terminal strips on CU240B-2 Control Units ................................................................................. 24

3.3.2.3 Terminal strips on CU240E-2 Control Units ................................................................................. 26

3.3.3 Default settings of the terminal strip............................................................................................. 28

3.3.4 Wiring the terminal strip ............................................................................................................... 32

3.4 Connecting up the fieldbus .......................................................................................................... 33

4.1 Tools to commission the converter .............................................................................................. 35

4.2 IOP Intelligent Operator Panel ..................................................................................................... 36

4.3 Commissioning............................................................................................................................. 38

4.3.1 Settings in the basic commissioning menu .................................................................................. 39

4.3.2 Enable "Safe Torque Off" safety function .................................................................................... 41

4.3.3 The most important parameters at a glance ................................................................................ 42

5.1 Manuals for your inverter ............................................................................................................. 47

5.2 Product support ............................................................................................................................ 48

Converter with Control Units CU230P-2; CU240B-2; CU240E-2 Getting Started, 04/2014, A5E32885834B AB

Table of contents

Objective of these instructions

Additional information on SINAMICS G120

What is the meaning of the symbols in the manual?

An operating instruction starts here. This concludes the operating instruction.

Firmware upgrade and downgrade

Transferring license terms of the OSS code to a PC

Procedure

This Getting Started describes how you install an inverter and commission and operate it using the IOP operator panel.

The functions and properties of the IOP are described in detail in the "SINAMICS IOP" operating instructions and are only explained here to an extent that is necessary to understand the described functions.

All manuals for the inverter can be downloaded from the Internet and are additionally available on DVD. See also Section: Manuals and technical support (Page 47).

Options for upgrading and downgrading the firmware can be found on the Internet at http://support.automation.siemens.com/WW/view/de/67364620 (http://support.automation.siemens.com/WW/news/en/67364620).

To transfer the OSS license terms from the inverter to a PC, proceed as follows:

1. Switch off the inverter power supply.

2. Insert an empty memory card into the card slot of the inverter. Also see Section:Installing Control Unit (Page 20)

3. Switch on the inverter power supply.

4. When you have switched on the power supply, wait 30 seconds.

During this time, the inverter writes the "Read_OSS.ZIP" file onto the memory card.

5. Switch off the inverter power supply.

6. Remove the card from the inverter.

7. Use a card reader and load the file to a PC.

You have then transferred the OSS license terms from the inverter to a PC.

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1.1

General safety instructions

DANGER

Danger to life due to live parts and other energy sources

WARNING

Danger to life through a hazardous voltage when connecting an unsuitable power supply

Death or serious injury can result when live parts are touched.

• Only work on electrical devices when you are qualified for this job.

• Always observe the country-specific safety rules.

Generally, six steps apply when establishing safety:

1. Prepare for shutdown and notify all those who will be affected by the procedure.

2. Disconnect the machine from the supply. – Switch off the machine. – Wait until the discharge time specified on the warning labels has elapsed. – Check that it really is in a no-voltage condition, from phase conductor to phase

conductor and phase conductor to protective conductor. – Check whether the existing auxiliary supply circuits are de-energized. – Ensure that the motors cannot move.

3. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or water.

4. Isolate or neutralize all hazardous energy sources by closing switches, grounding or short-circuiting or closing valves, for example.

5. Secure the energy sources against switching on again.

6. Ensure that the correct machine is completely interlocked.

After you have completed the work, restore the operational readiness in the inverse

Converter with Control Units CU230P-2; CU240B-2; CU240E-2 Getting Started, 04/2014, A5E32885834B AB

sequence.

Touching live components can result in death or severe injury.

• Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV- (Protective Extra Low Voltage) output voltages for all connections and terminals of the electronics modules.

Fundamental safety instructions

WARNING

Danger to life when live parts are touched on damaged devices

WARNING

Danger to life through electric shock due to unconnected cable shields

WARNING

Danger to life due to electric shock when not grounded

WARNING

Danger to life due to electric shock when opening plug connections in operation

WARNING

Danger to life due to fire spreading if housing is inadequate

1.1 General safety instructions

Improper handling of devices can cause damage.

For damaged devices, hazardous voltages can be present at the enclosure or at exposed components; if touched, this can result in death or severe injury.

• Ensure compliance with the limit values specified in the technical data during transport, storage and operation.

• Do not use any damaged devices.

Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected cable shields.

• As a minimum, connect cable shields and the conductors of power cables that are not used (e.g. brake cores) at one end at the grounded housing potential.

For missing or incorrectly implemented protective conductor connection for devices with protection class I, high voltages can be present at open, exposed parts, which when touched, can result in death or severe injury.

• Ground the device in compliance with the applicable regulations.

When opening plug connections in operation, arcs can result in severe injury or death.

• Only open plug connections when the equipment is in a no-voltage state, unless it has been explicitly stated that they can be opened in operation.

Fire and smoke development can cause severe personal injury or material damage.

• Install devices without a protective housing in a metal control cabinet (or protect the device by another equivalent measure) in such a way that contact with fire is prevented.

• Ensure that smoke can only escape via controlled and monitored paths.

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Fundamental safety instructions

WARNING

Danger to life through unexpected movement of machines when using mobile wireless devices or mobile phones

WARNING

Danger to life due to the motor catching fire in the event of insulation overload

WARNING

Danger to life due to fire if overheating occurs because of insufficient ventilation clearances

WARNING

Danger of an accident occurring due to missing or illegible warning labels

1.1 General safety instructions

Using mobile wireless devices or mobile phones with a transmit power > 1 W closer than approx. 2 m to the components may cause the devices to malfunction, influence the functional safety of machines therefore putting people at risk or causing material damage.

• Switch the wireless devices or mobile phones off in the immediate vicinity of the

components.

There is higher stress on the motor insulation through a ground fault in an IT system. If the insulation fails, it is possible that death or severe injury can occur as a result of smoke and fire.

• Use a monitoring device that signals an insulation fault.

• Correct the fault as quickly as possible so the motor insulation is not overloaded.

Inadequate ventilation clearances can cause overheating of components with subsequent fire and smoke. This can cause severe injury or even death. This can also result in increased downtime and reduced service lives for devices/systems.

• Ensure compliance with the specified minimum clearance as ventilation clearance for

the respective component.

Missing or illegible warning labels can result in accidents involving death or serious injury.

• Check that the warning labels are complete based on the documentation.

• Attach any missing warning labels to the components, in the national language if

necessary.

• Replace illegible warning labels.

Converter with Control Units CU230P-2; CU240B-2; CU240E-2 Getting Started, 04/2014, A5E32885834B AB

Fundamental safety instructions

NOTICE

Device damage caused by incorrect voltage/insulation tests

WARNING

Danger to life when safety functions are inactive

Note Important safety notices for Safety Integrated functions

If you want to use Safety Integrated functions, you must observe the safety notices in the Safety Integrated manuals.

WARNING

Danger to life or malfunctions of the machine as a result of incorrect or changed parameterization

1.1 General safety instructions

Incorrect voltage/insulation tests can damage the device.

• Before carrying out a voltage/insulation check of the system/machine, disconnect the devices as all converters and motors have been subject to a high voltage test by the manufacturer, and therefore it is not necessary to perform an additional test within the system/machine.

Safety functions that are inactive or that have not been adjusted accordingly can cause operational faults on machines that could lead to serious injury or death.

• Observe the information in the appropriate product documentation before commissioning.

• Carry out a safety inspection for functions relevant to safety on the entire system, including all safety-related components.

• Ensure that the safety functions used in your drives and automation tasks are adjusted and activated through appropriate parameterizing.

• Perform a function test.

• Only put your plant into live operation once you have guaranteed that the functions

relevant to safety are running correctly.

As a result of incorrect or changed parameterization, machines can malfunction, which in turn can lead to injuries or death.

• Protect the parameterization (parameter assignments) against unauthorized access.

• Respond to possible malfunctions by applying suitable measures (e.g. EMERGENCY

STOP or EMERGENCY OFF).

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Fundamental safety instructions

1.2

Safety instructions for electromagnetic fields (EMF)

WARNING

Danger to life from electromagnetic fields

1.3

Handling electrostatic sensitive devices (ESD)

NOTICE

Damage through electric fields or electrostatic discharge

1.2 Safety instructions for electromagnetic fields (EMF)

Electromagnetic fields (EMF) are generated by the operation of electrical power equipment such as transformers, converters or motors.

People with pacemakers or implants are at a special risk in the immediate vicinity of these devices/systems.

• Ensure that the persons involved are the necessary distance away (minimum 2 m).

Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules or devices that may be damaged by either electric fields or electrostatic discharge.

Electric fields or electrostatic discharge can cause malfunctions through damaged individual components, integrated circuits, modules or devices.

• Only pack, store, transport and send electronic components, modules or devices in their

original packaging or in other suitable materials, e.g conductive foam rubber of aluminum foil.

• Only touch components, modules and devices when you are grounded by one of the

following methods: – Wearing an ESD wrist strap – Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring

• Only place electronic components, modules or devices on conductive surfaces (table

with ESD surface, conductive ESD foam, ESD packaging, ESD transport container).

Converter with Control Units CU230P-2; CU240B-2; CU240E-2 Getting Started, 04/2014, A5E32885834B AB

Fundamental safety instructions

1.4

Industrial security

Note Industrial security

Siemens provides products and solutions with industrial security functions that support the secure o important components in a holistic industrial security concept. With this in mind, Siemens’ products and solutions undergo continuous development. Siemens recommends strongly that

For the secure operation of Siemens products and solutions, it is necessary to take suitable preventive action (e.g. cell protection concept) and integrate each component into a holistic, state also be considered. For more information about industrial security, visit Hotspot (

To stay informed about product updates as they occur, sign up for a product newsletter. For more information, visit Hotspot (

WARNING

Danger as a result of unsafe operating states resulting from software manipulation

1.4 Industrial security

peration of plants, solutions, machines, equipment and/or networks. They are

you regularly check for product updates.

-of-the-art industrial security concept. Third-party products that may be in use should

-Text

http://www.siemens.com/industrialsecurity).

-specific

-Text

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

Software manipulation (e.g. by viruses, Trojan horses, malware, worms) can cause unsafe operating states to develop in your installation which can result in death, severe injuries and/or material damage.

• Keep the software up to date. You will find relevant information and newsletters at this address

(http://support.automation.siemens.com).

• Incorporate the automation and drive components into a holistic, state-of-the-art industrial security concept for the installation or machine.

You will find further information at this address (http://www.siemens.com/industrialsecurity).

• Make sure that you include all installed products into the holistic industrial security concept.

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Fundamental safety instructions

1.5

Residual risks of power drive systems

1.5 Residual risks of power drive systems

The control and drive components of a drive system are approved for industrial and commercial use in industrial line supplies. Their use in public line supplies requires a different configuration and/or additional measures.

These components may only be operated in closed housings or in higher-level control cabinets with protective covers that are closed, and when all of the protective devices are used.

These components may only be handled by qualified and trained technical personnel who are knowledgeable and observe all of the safety instructions on the components and in the associated technical user documentation.

When assessing the machine's risk in accordance with the respective local regulations (e.g., EC Machinery Directive), the machine manufacturer must take into account the following residual risks emanating from the control and drive components of a drive system:

1. Unintentional movements of driven machine components during commissioning, operation, maintenance, and repairs caused by, for example,

– Hardware and/or software errors in the sensors, control system, actuators, and cables

and connections

– Response times of the control system and of the drive

– Operation and/or environmental conditions outside the specification

– Condensation/conductive contamination

– Parameterization, programming, cabling, and installation errors

– Use of wireless devices/mobile phones in the immediate vicinity of the control system

– External influences/damage

2. In the event of a fault, exceptionally high temperatures, including an open fire, as well as emissions of light, noise, particles, gases, etc. can occur inside and outside the inverter, e.g.:

– Component failure

– Software errors

– Operation and/or environmental conditions outside the specification

– External influences/damage

Inverters of the Open Type/IP20 degree of protection must be installed in a metal control cabinet (or protected by another equivalent measure) such that contact with fire inside and outside the inverter is not possible.

Converter with Control Units CU230P-2; CU240B-2; CU240E-2 Getting Started, 04/2014, A5E32885834B AB

Fundamental safety instructions

Note

The components must be protected against conductive contamination (e.g. by installing them in a control cabinet with degree of protection IP54 according to IEC 60529 or NEMA 12).

Assuming that conductiv lower degree of cabinet protection may be permitted.

1.5 Residual risks of power drive systems

3. Hazardous shock voltages caused by, for example,

– Component failure

– Influence during electrostatic charging

– Induction of voltages in moving motors

– Operation and/or environmental conditions outside the specification

– Condensation/conductive contamination

– External influences/damage

4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a risk to people with a pacemaker, implants or metal replacement joints, etc., if they are too close

5. Release of environmental pollutants or emissions as a result of improper operation of the system and/or failure to dispose of components safely and correctly

e contamination at the installation site can definitely be excluded, a

For more information about residual risks of the components in a drive system, see the relevant sections in the technical user documentation.

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Main components of the inverter

Each SINAMICS G120 inverter comprises a Control Unit and a Power Module.

•

The following data is provided on the Power Module type plate (①

●

Designation:

e.g. Power Module 240

●

Technical data:

Voltage and current

●

Order number:

e.g. 6SL3224-0BE13-7UA0

●

Version:

e.g. A02

The following data can be found on the Control Unit type plate (②):

●

Designation:

e.g. Control Unit CU240E-2 DP-F

●

Order number:

e.g. 6SL3244-0BB13-1PA0

●

Version:

e.g. A02 (hardware)

With which Power Modules is it permissible to operate the Control Unit?

Power Module

✓ = operation with Power Module permissible, --- = not permissible

CU230P-2

CU240B-2

CU240E-2

PM340 1AC

---

✓

PM230 IP20 and push-through

✓ ✓ ✓

PM230 IP55

✓

---

PM240

✓ ✓ ✓

PM240-2

✓ ✓ ✓

PM250, IP20

✓ ✓ ✓

PM260, IP20

✓ ✓ ✓

PM330, IP20

✓

---

The Control Unit controls and monitors the

Power Module and the connected motor.

The Power Modules are available for motors

with a power range of between 0.37 kW and 250 kW.

Converter with Control Units CU230P-2; CU240B-2; CU240E-2 Getting Started, 04/2014, A5E32885834B AB

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