Page 1
SINAMICS
G120 Control Units
CU240E
Getting Started
FW 3.1
10/2007
A5E01301680B AA
Warnings and Cautions
1
Installation
2
Check List
3
Commissioning
4
Diagnostics
A
Page 2
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. 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 device/system may only be set up and used in conjunction with this
documentation. Commissioning and operation of a device/system may only be
performed by qualified personnel. Within the context of the safety notes in this
documentation qualified persons are defined as persons who are authorized to
commission, ground and label devices, systems and circuits in accordance with
established safety practices and standards.
Prescribed Usage:, Note the following:
WARNING
This device may only be used for the applications described in the catalog or the technical
description and only in connection with devices or components from other manufacturers which
have been approved or recommended by Siemens. Correct, reliable operation of the product
requires proper transport, storage, positioning and assembly as well as careful operation and
maintenance.
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 AG
Automation and Drives
Postfach 48 48
90327 NÜRNBERG
GERMANY
Ⓟ 09/2007 Copyright © Siemens
AG 2007.
Technical data
subject to change
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Warnings and Cautions
CU240E
Getting Started, 10/2007, A5E01301680B AA 3
Table of contents
1 Warnings and Cautions............................................................................................. 4
2 Installation ................................................................................................................ 6
2.1 Installing the Control Unit ...................................................................................... 6
2.2 Terminals ............................................................................................................ 10
2.3 Connecting a CU240E via USS........................................................................... 10
3 Check List................................................................................................................11
4 Commissioning........................................................................................................12
4.1 Create a STARTER Project................................................................................. 13
4.2 Going Online with the Inverter............................................................................. 17
4.3 Start Commissioning ........................................................................................... 19
4.4 Factory reset ....................................................................................................... 27
A Diagnostics..............................................................................................................28
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Warnings and Cautions
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1 Warnings and Cautions
General
WARNING
This equipment contains dangerous voltages and controls potentially dangerous
rotating mechanical parts. Non-compliance with the Warnings or failure to follow the
instructions contained in this manual can result in loss of life, severe personal injury
or serious damage to property.
Only suitable qualified personnel should work on this equipment, and only after
becoming familiar with all safety notices, installation, operation and maintenance
procedures contained in this instruction. The successful and safe operation of this
equipment is dependent upon its proper handling, installation, operation and
maintenance.
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. It is strictly prohibited for any mains disconnection to be
performed on the motor-side of the system; any disconnection of the mains must be
performed on the mains-side of the Inverter.
When connecting the line supply to the Inverter, make sure that the terminal case of
the motor is closed. 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 inverter must always be grounded. Isolate the line supply before making or
changing connections to the unit. Ensure that the inverter is configured for the
correct supply voltage. The inverter must not be connected to a higher voltage
supply.
Take particular notice of the general and regional installation and safety regulations
regarding work on dangerous voltage installation (e.g. EN 50178) as well as the
relevant regulations regarding the correct use of tools and personal protective
equipment (PPE).
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Warnings and Cautions
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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 these instructions within easy reach of the equipment and make them available
to all users.
Whenever measuring or testing has to be performed on live equipment, the
regulations of Safety Code BGV A2 must be observed, in particular § 8 "Permissible
Deviations when Working on Live Parts". Suitable electronic tools should be used.
Before installing and commissioning, please read the 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.
Ensure that the appropriate circuit-breakers/fuses with the specified current rating
are connected between the power supply and the inverter.
These instructions assume that the user is fully conversant with the use of the
following technologies:
- PLCs
- The commissioning software STARTER
- PROFIdrive profiles and protocols.
The commissioning procedure outlined in this manual is for Standard Inverters only -
Fail-safe commissioning is covered in the Operating Instructions.
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2 Installation
Command and setpoint sources ot the CU240E
The inverter is controlled and monitored per default via terminals.
Note
The command and setpoint sources can be changed in the commissioning procedure
or via Parameters P0700 and P1000.
2.1 Installing the Control Unit
The CU controls the functions of the PM. The CU cannot be used without a PM, also
the PM cannot be used without a CU.
WARNING
An inverter can be switched on unintentionally if the installation is not performed
correctly. The inverter must be started-up by personnel who are qualified and trained
in installing systems of this type.
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Installation
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Installation
CU240E
8 Getting Started, 10/2007, A5E01301680B AA
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Installation
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Fitting the Control Unit to the Power Module
The Control Unit is snapped onto 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
independent from the type of G120 control unit or G120 power module.
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Installation
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2.2 Terminals
Overview of CU240E Terminals
The terminals are designed as cage clamps for cable cross sections from 0.2 mm2 up
to 1,5 mm
2
(24 … 14 AWG). The different types are listed below:
• Digital Inputs (DI)
6
• Digital Outputs (DO)
3
• Analog Inputs (AI)
2
• Analog Outputs (AO)
2
• PTC interface
1
Cable length for I/O cables
The maximum cable length connected to the CU must not exceed 10 m (32.8 ft).
Use of unscreened cables is possible, however we recommend the use of screened
cables, in order to fulfill the EMC requirements for the CE marking.
2.3 Connecting a CU240E via USS
Description
The CU240E can be connected via terminals 29 and 30 to an RS485-USS bus system
with a maximum transfer rate of 115200 baud.
The bus termination switch is located directly beneath terminals 29 and 30.
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3 Check List
Before power is applied to the inverter/motor system, the following checks should be
performed:
Check that: ✓
1 The environmental conditions conform to the inverter/motor specifications
2 The inverter and the motor are securely mounted
3 The inverter and motor are correctly installed with adequate cooling provision
4 The motor and the application/equipment are ready to start, i.e. safe state - motor can
rotate
5 The inverter is correctly earthed/grounded
6 The input power (supply) voltage matches the inverter's nominal input voltage
7 The input power (mains) fuses are the correct type and installed correctly
8 The motor connections are connected to ensure the correct direction of rotation of the
motor at start-up
9 The motor and mains connections are connected and tightened to the required
specification
10 The motor connections are not reversed - the motor will start but serious damage may
occur to the connected equipment
11 The motor cable is routed away from other cables
12 The control connections are connected and tightened to the required specification
13 No tools or other objects that can cause damage to the system are present
14 The inverter is the only power source to the motor
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12 Getting Started, 10/2007
4 Commissioning
Description
When shipped from the factory the G120 inverter (control unit and power module) must
not be operated before a commissioning of the inverter has been performed.
This can be done via:
● downloading a valid parameter set from BOP or STARTER
● performing a commissioning via BOP or STARTER
For a successful operation of the inverter-motor combination, the following
prerequisites must be fulfilled:
● The rated inverter current is at least as great as the rated current of the motor.
● The power range of the inverter matches the power range of the motor.
Commissioning with the Getting Started Guide
Commissioning in the Getting Started Guide is described using STARTER via PC
Connection Kit. For other commissioning modes please refer to the Operating
Instructions of the Control Module.
The STARTER software uses a series of wizards and masks to guide the user through
the commissioning procedures for the inverter.
What do you need?
The following items are required to
commission the Inverter with STARTER:
● STARTER software is installed on
your PC
● The inverter is connected to the PC
via the PC connection cable - order
number: 6SL3255-0AA00-2AA0
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Commissioning
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Note
For commissioning the inverter you can use the STARTER software, delivered with
the PC Connection Kit or download the latest STARTER software version from the
internet under the following link:
http://support.automation.siemens.com/WW/view/de/10804985/133100
4.1 Create a STARTER Project
Commissioning procedure
● Switch the supply voltage to the inverter
● Start Commissioning Software STARTER and use the project wizard as described
in the following steps
● In the next screen (not shown here), enter a significant project name (in the
example "Basic Commissioning)" and if you want a comment then press the
"Continue" button. The following dialog box will appear.
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Press "Change and test
..." button to set the
PG/PC interface.
– If "PC COM-Port
(USS)" is available as
shown in the dialog
box "PG/PC interface",
press the "properties"
button.
– If not press the "Select
..." button to install the
"PC COM-Port (USS)"
interface as shown in
the dialog box
"Install/Remove
Interfaces". If it is
installed close the dialog box and
press now the "properties"
button.
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● Setting properties of the COM port
Via this dialog box, you set the com
interface (COM1, COM2, COM3) and
the Baud rate (default 38400). To find
out the right values, select e.g. COM1
and press the "Read" button. If "???"
is displayed in the Baud rate test area
select another com interface. In case
of the right interface a value will be
displayed, that must be chosen via the
"Baud rate" select box. In addition,
select "Automatic mode" under the tab
"RS485". Quit with "OK" brings you
back to the dialog box "Set PG/PC
interface". Quitting again with "OK"
brings you to the step "Insert drives" of
the Project Wizard.
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● In this dialog you can enter a name for your inverter - in this case
"SINAMICS_G120_CU240E" (no blanks or special characters), then press
"Continue" and close the following summary dialog via the "Complete" button.
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4.2 Going Online with the Inverter
Description
With the above described procedure the project is created and the following STARTER
dialog appears, but there is still no online connection established so far.
To go online with this inverter press
. The following dialog box shows in the left
column the online and in the right column the offline saved data. To load the online
data to your PC, press "Load HW configuration to PG" and end the dialog with close.
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4.3 Start Commissioning
Description
With closing the last dialog from the "Going Online Section" the "Offline mode" at the
very down in the dialog box changes to "Online mode" and in case of first
commissioning the message F00395 appears.
It states that no commissioning has been performed so far with the inverter. To
confirm, select the message and press the "Acknowledge" button.
WARNING
Message F0395
With acknowledging F00395 you overtake the responsibility to perform a
commissioning.
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Commissioning
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Note
Information about the symbols used in STARTER can be found in the online help.
Press <shift><F1> and then click at the requested symbol. E.g.
If you have confirmed F0395, open the drive unit ( ), double-click the drive object
(
) and start the wizard for basic commissioning from the following STARTER dialog.
Perform Commissioning
Start dialog:
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Now you can select the basic commissioning settings for your application via pull-down
menus. With pressing "Continue" button you jump to the next item.
In case of "Drive functions" we recommend to select "Identification of all parameters
inclusive the saturation curve" as shown in the figure below:
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For calculation of the motor data we recommend to select "Restore factory setting and
calculate motor data only" as shown in the dialog box.
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The basic commissioning wizard ends with the following dialog:
To complete basic commissioning, the motor data identification, selected during basic
commissioning must be performed via switching on the inverter. This can be done via
the chosen command source (e.g. terminals, BOP or communication) or via STARTER
as shown in the dialog box below.
Motor Data identification via STARTER
First click "Control panel" to open the dialog, then press "Assume control priority"
(when connected via PC connection Kit, select BOP link (RS232) (the "assume-button"
changes to "Return") and select "Enables". Now the ON and OFF buttons get active.
Press the ON button start the Motor data identification. While Motor data identification
is active, the
-button is disabled and in the alarm 541 "Motor Identification active"
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will be displayed. Once Motor data identification has finished, the alarm disappears
and the inverter switches OFF (
becomes colored again).
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To set the command source back press "Give up control priority!" in the following
dialog box. Take care of the warnings displayed.
Now the basic commissioning is finished. To save the settings in the EEPROM of your
inverter, select the SINAMICS project and press the "Copy RAM to ROM" button
.
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Commissioning
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Commissioning the application
Now you can commission your application via the dialog boxes of the drive navigator
or via the functions in the navigation area.
If you have performed the application commissioning, disconnect your PC from the
inverter via
. In the following dialog select "save changes to drive unit (EEPROM), to
current offline project and to PG/PC hard disk".
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This selection performs in addition to disconnecting the PC form the inverter the
following steps:
: saves project on your PC
: saves drive settings on your PC (Upload)
: Saves data from inverter RAM to EEPROM
4.4 Factory reset
Description
With a factory reset a defined initial state of all of the inverter parameters can be reestablished.
To perform a factory reset with STARTER, the inverter must be in the online mode. If it
is offline, perform "connect to target system" (
)
The factory reset is performed in the following steps:
Select the drive unit in the navigation tree (
)
● Click the factory reset icon (
).
Note
When resetting the parameters to the factory setting, the communications memory
is re-initialized. This means that communications are interrupted for the time it takes
to perform the reset.
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A Diagnostics
Fault s and alarms
A fault indicates a severe unfavorable state of the inverter. If a fault occurs, the inverter
is powered down with an OFF2 command and the LED "SF" on the Control Unit is
active. Faults must be acknowledged before the inverter can be switched on again.
An alarm states that the inverter is
● in a critical state that can lead to a fault (e.g. A0501 current limit)
● in an extraordinary temporarily state e.g. motor data identification
An alarm requires no reaction'
Fault Cause Remedy
F00001 Overcurrent - Motor power does not
correspond to the inverter power
Check that the motor and inverter power
ratings are the same.
F00002 Overvoltage - mains supply voltage too high
or motor is in regenerative mode.
Check the mains supply voltage
F00003 Undervoltage - mains supply has failed Check mains supply
F00004 Inverter over temperature - the inverter has
exceeded the temperature limits
Check motor loading, pulse frequency
setting, ambient temperature or if fitted the
fan is working correctly.
F00005 Inverter overload Check motor power and load cycle
F00041 Motor data identification failure check that the motor is connected to the
inverter correctly and that the motor data
entered is correct.
F00052 Power stack failure Check the connections between the CU and
PM.
F00062 MMC contents invalid Recopy data to MMC and ensure that the
process is completed.
F00070 PLC setpoint fault Check the value of P2040 and ensure it is
correct
F00071 USS setpoint fault Check and improve monitoring timing using
STARTER
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Diagnostics
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Fault Cause Remedy
F00072 USS setpoint fault Check USS master
F00090 Encoder feedback loss Check that the encoder is installed and
commissioned correctly.
F0395 The fault occurs after a CU/PM swap or
startup clone. It can also be cause by a
faulty read from the EEPROM.
Alarm Meaning
A0700 Correct the PROFIBUS configuration The parameter or configuring settings by the
PROFIBUS master are invalid.
A0702 Check connector, cable and PROFIBUS
master.
The link to the PROFIBUS is interrupted.
A0703 Check setpoints from the PROFIBUS
master. Switch SIMATIC CPU to "RUN".
No setpoints or invalid setpoints (control
word = 0) are being received from the
PROFIBUS master.
A0704 Activate internode transmitter. At least one configured internode transmitter
is not yet active, or has failed.
A0705 None (fault is with the inverter). No actual values received from inverter.
A0706 None diagnostic parameter r2041. PROFIBUS DP software error.
A0710 Communication interface on Control Unit
may be broken.
Inverter has detected failure of PROFIBUS
communications link.
A0711 Check P0918 address and P2041. Invalid value of PROFIBUS parameter.
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Diagnostics
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Status display via LEDs
The SINAMICS G120 inverters provide multiple functions and operating states which
are indicated via LEDs.
Colors
The colors of the LEDs are self explanatory. The Status of the inverter is displayed by
the following different LED colors and states:
State Meaning Color
on off Temporary state
(flashing 0.5 Hz)
sample fault (SF) Red
Ready (RDY) Green
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 run.
This LED does not indicate whether the drive is running or not.
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