Siemens SINAMICS G120D, CU240D-2, CU250D-2 Getting Started

SINAMICS G120D converter with control

units CU240D-2 and CU250D-2

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SINAMICS

SINAMICS G120D
SINAMICS G120D converter with
control units CU240D-2 and
CU250D-2

Getting Started

Edition 04/2014, firmware V4.7

04/2014, FW V4.7

A5E34262374B AA

Fundamental safety
instructions

1

Introduction

2

Installation

3

Commissioning

4

Troubleshooting

5

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBER

G

GERMANY

A5E34262374B AA

Ⓟ

05/2014 Subject to change

Copyright © Siemens AG 2012 - 2014.
All rights reserved

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

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.

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.

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
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5

Table of contents

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

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

2 Introduction ........................................................................................................................................... 15

2.1 SINAMICS G120D converter ....................................................................................................... 15

2.2 Commissioning tools .................................................................................................................... 17

3 Installation ............................................................................................................................................ 19

3.1 Fitting the CU to the PM ............................................................................................................... 19

3.2 Drill pattern SINAMICS G120D .................................................................................................... 20

3.3 Overview of the interfaces ........................................................................................................... 22

3.4 Electrical data ............................................................................................................................... 23

3.5 Basic EMC Rules ......................................................................................................................... 24

3.6 Connections and cables ............................................................................................................... 25

3.7 Default settings of inputs and outputs .......................................................................................... 39

3.8 Settings PROFIBUS DP address with DIP switches ................................................................... 41

3.9 Connecting the PROFINET interface ........................................................................................... 42

3.10 Grounding converter and motor ................................................................................................... 42

3.11 Connections and interference suppression ................................................................................. 44

3.12 Equipotential bonding .................................................................................................................. 44

4 Commissioning ..................................................................................................................................... 47

4.1 Default settings for the SINAMICS G120D .................................................................................. 47

4.2 Commissioning with the IOP ........................................................................................................ 48

4.3 Commissioning the application .................................................................................................... 53

4.4 Reset Parameters to Factory Settings ......................................................................................... 54

5 Troubleshooting .................................................................................................................................... 55

5.1 List of alarms and faults ............................................................................................................... 55

5.2 Status LED overview .................................................................................................................... 61

5.3 Further information ....................................................................................................................... 63

Table of contents

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

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Objective of these instructions

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.

Additional information on SINAMICS G120

All manuals for the inverter can be downloaded from the Internet and are additionally
available on DVD. See also Section: Further information (Page 63).

What is the meaning of the symbols in the manual?

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

Firmware upgrade and downgrade

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).

Transferring license terms of the OSS code to a PC

Procedure

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:Overview
of the interfaces (Page 22)

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.

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
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1

1.1

General safety instructions

DANGER

Danger to life due to live parts and other energy sources

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
sequence.

WARNING

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

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

1.1 General safety instructions

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WARNING

Danger to life when live parts are touched on damaged devices

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.

WARNING

Danger to life through electric shock due to unconnected cable shields

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.

WARNING

Danger to life due to electric shock when not grounded

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.

WARNING

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

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.

WARNING

Danger to life due to fire spreading if housing is inadequate

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.

Fundamental safety instructions

1.1 General safety instructions

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
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WARNING

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

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.

WARNING

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

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.

WARNING

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

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.

WARNING

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

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.

Fundamental safety instructions

1.1 General safety instructions

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NOTICE

Device damage caused by incorrect voltage/insulation tests

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.

WARNING

Danger to life when safety functions are inactive

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.

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

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).

Fundamental safety instructions

1.2 Safety instructions for electromagnetic fields (EMF)

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1.2

Safety instructions for electromagnetic fields (EMF)

WARNING

Danger to life from electromagnetic fields

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).

1.3

Handling electrostatic sensitive devices (ESD)

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

NOTICE

Damage through 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).

Fundamental safety instructions

1.4 Industrial security

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1.4

Industrial security

Note
Industrial security

Siemens provides pro

ducts and solutions with industrial security functions that support the

secure operation of plants, solutions, machines, equipment and/or networks. They are
important components in a holistic industrial security concept. With this in mind, Siemens’
product

s and solutions undergo continuous development. Siemens recommends strongly

that you regularly check for product updates.

For the secure operation of Siemens products and solutions, it is necessary to take suitable
preventive action (e.g. cell protection c

oncept) and integrate each component into a holistic,

state

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

also be considered. For more information about industrial security, visit Hotspot

-Text

(

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

To stay informed about product updates as they occur, sign up for a product

-specific

newsletter. For more information, visit Hotspot

-Text

(

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

WARNING

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

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.

Fundamental safety instructions

1.5 Residual risks of power drive systems

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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.

Fundamental safety instructions

1.5 Residual risks of power drive systems

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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

Note

The components must be protected against conductive contamination (e.g. by installing them
in a control cabinet with degre

e of protection IP54 according to IEC 60529 or NEMA 12).

Assuming that conductive contamination at the installation site can definitely be excluded, a
lower degree of cabinet protection may be permitted.

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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2

2.1

SINAMICS G120D converter

Overview

The SINAMICS G120D is a range of converters for controlling the speed of three-phase
motors. The converter consists of two parts, the Control Unit and the Power Module.

Table 2- 1 Control Units of the SINAMICS G120D converter

Designation

Order number

Encoder type

Field bus

CU240D-2 DP

6SL3544-0FB20-1PA0

HTL Encoder PROFIBUS

CU240D-2 DP-F

6SL3544-0FB21-1PA0

CU250D-2 DP-F 6SL3546-0FB21-1PA0 HTL Encoder

SSI Absolute Encoder

CU240D-2 PN

6SL3544-0FB20-1FA0

HTL Encoder PROFINET,

EtherNet/IP

CU240D-2 PN-F

6SL3544-0FB21-1FA0

CU250D-2 PN-F 6SL3546-0FB21-1FA0 HTL Encoder

SSI Absolute Encoder

CU240D-2 PN-F PP

Push-Pull connections

6SL3544-0FB21-1FB0 HTL Encoder

CU240D-2 PN-F FO

Fibre optic connections

6SL3544-0FB21-1FC0

CU250D-2 PN-F PP

Push-Pull connections

6SL3546-0FB21-1FB0 HTL Encoder

SSI Absolute Encoder

CU250D-2 PN-F FO

Fibre optic connections

6SL3546-0FB21-1FC0

Introduction

2.1 SINAMICS G120D converter

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

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Table 2- 2 PM250D Power Modules for the SINAMICS G120D converter

Frame
size

Rated output
power

Rated output
current

Order number
based on High Overload (HO)

FSA

0.75 kW

2.2 A

6SL3525-0PE17-5AA1

1.5 kW 4.1 A 6SL3525-0PE21-5AA1

FSB 3.0 kW 7.7 A 6SL3525-0PE23-0AA1

FSC

4.0 kW

10.2 A

6SL3525-0PE24-0AA1

5.5 kW

13.2 A

6SL3525-0PE25-5AA1

7.5 kW 19.0 A 6SL3525-0PE27-5AA1

Introduction

2.2 Commissioning tools

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2.2

Commissioning tools

Figure 2-1 Commissioning tools - PC or IOP Handheld Kit

Introduction

2.2 Commissioning tools

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Table 2- 3 Components and tools for commissioning

Component or tool

Order number

Operator Panel

IOP Handheld

6SL3255-0AA00-4HA0

STARTER Commissioning tool (PC

software)

You obtain STARTER on a DVD
(Order number: 6SL3072­0AA00-0AG0)
and it can be downloaded:
STARTER Download
(http://support.automation.sieme

ns.com/WW/view/en/26233208)

PC Connection Kit

Comprising USB cable (3 m).

6SL3255-0AA00-2CA0

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3

3.1

Fitting the CU to the PM

Fitting the Control Unit to the Power Module

The inverter is delivered as two separate components - the Power Module (PM) and the
Control Unit (CU). The CU must be fitted to the PM prior to any further commissioning taking
place.

CAUTION

Seals fitted correctly

It is important that when assembling the Power Module and the Control Unit that all the
seals are fitted correctly to ensure IP65 rating.

TN and TT mains supplies

The SINAMICS PM250D Power Module with the Class A integrated mains filter is only
suitable for operation on TN and TT mains supplies.

The CU is fitted to the PM as shown in the diagram below.

Figure 3-1 Fitting the Control Unit to the Power Module

Installation

3.2 Drill pattern SINAMICS G120D

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3.2

Drill pattern SINAMICS G120D

Drill pattern and dimensions

The inverter has an identical drill pattern for all frame sizes. The drill pattern, depth and
tightening torques are shown in the diagram below.

Figure 3-2 SINAMICS G120D drill pattern

Installation

3.2 Drill pattern SINAMICS G120D

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21

Mounting orientation

Mount the converter on a table or on a wall. The minimum clearance distances are as
follows:

● Side-by-side - no clearance distance is required

● Above and below the inverter 150 mm (5.9 inches).

Figure 3-3 Mounting orientation: correct (✓), impermissible (X), permissible with restrictions (!)

Restrictions due to vertical mounting

If the converter is mounted in the vertical position, the maximum ambient temperature is
40°C.

Additionally you have to reduce the converter output current to 80 % of rated converter
current.

If the output current derating adversely affects the application, you have to use an converter
of the next highest power rating.

Installation

3.3 Overview of the interfaces

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3.3

Overview of the interfaces

Interfaces of the converter

①

Digital inputs 0 … 5 with status LED

⑧

HTL Encoder connection

②

Fieldbus IN and OUT (PROFINET or

PROFIBUS)

⑨

CU250D-2: SSI encoder connector

CU240D-2: Analog inputs 0 and 1

③

24 V DC supply IN and OUT

⑩

Slot for a memory card at rear of the Control

Unit

④

Optical interface for operator panel IOP

handheld

⑪

PROFINET status LED

⑤

Converter status LED

⑫

PE grounding terminal

⑥

USB PC connection, address and bus

termination switch for PROFIBUS

⑬

Mains supply connection

⑦

Digital outputs 0 and 1 with status LED

⑭

Motor, brake and temperature sensor

connections

Figure 3-4 Interfaces on the converter variants

Installation

3.4 Electrical data

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3.4

Electrical data

Power Module specifications - 3AC 380 V ... 500 V ± 10 %

Table 3- 1 Rated Output, Input and Fuses

Product

Frame size

Rated output

HO

Fuse

Rated output
current

Rated input
current

3NA3…
6SL3525-…

kW A A A Type

0PE17-5AA1

A

0.75

2.2

2.1

10

803

0PE21-5AA1

A

1.5

4.1

3.8

10

803

0PE23-0AA1

B 3 7.7

7.2

16

805

0PE24-0AA1

C 4 10.2

9.5

20

807

0PE25-5AA1

C

5.5

13.2

12.2

20

807

0PE27-5AA1

C

7.5

19

17.7

32

812

Standby current

If the converter is powered-up, but the motor is still switched off, the converter requires a
standby current.

You have to consider the standby current when calculating the size of the conductors and
selecting the correct protective devices on the line supply.

Table 3- 2 Standby currents of the converter

Converter

Standby current (A)

50 Hz

60 Hz

380 V

400 V

415 V

380 V

440 V

480 V

0.75 - 1.5 kW

0.6

0.63

0.66

0.7

0.8

0.91

3.0 - 4.0 kW

2.2

2.32

2.40

2.7

3.2

3.33

5.5 - 7.5 kW

2.9

3.05

3.15

3.5

4.0

4.40

For more comprehensive information on the standby current, please read the following FAQ:

PM250D Standby Current Information
(http://support.automation.siemens.com/WW/view/en/34189181)

Brake voltage

The brake voltage of 180 V DC is suitable for brakes which require 400 V AC with rectifier.

Remove the rectifier module and connect the brake output of the converter directly to the
brake coil.

The UL approved current rating for the brake output is 600 mA.

Installation

3.5 Basic EMC Rules

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

24 Getting Started, 04/12014, FW V4.7, A5E34262374B AA

3.5

Basic EMC Rules

Measures to limit Electromagnetic Interference (EMI)

Listed below are the necessary measures that must be taken to ensure the correct
installation of the Inverter within a system, which will minimize the effect of EMI.

Cables

● Keep all cable lengths to the minimum possible length; avoid excessive cable lengths.

● Route always signal and data cables, as well as their associated equipotential bonding

cables, in parallel and with as short a distance as possible.

● Don't route signal and data cables and line supply cables in parallel to motor cables.

● Signal and data cables and line supply cables should not cross motor cables; if crossing

is necessary, they should cross at an angle of 90 °.

● Shield signal and data cables.

● Route particularly sensitive signal cables, such as setpoint and actual value cables, with

optimum shield bonding at both ends and without any interruptions of the shield.

● Ground spare wires for signal and data cables at both ends.

● Route all power cables (line supply cables, as well as motor cables) separately from

signal and data cables. The minimum distance should be approximately 25 cm.
Exception: hybrid motor cables with integrated shielded temperature sensor and brake
control wires are allowed.

● Shield the power cable between inverter and motor. We recommend shielded cables with
symmetrical three-phase conductors (L1, L2, and L3) and an integrated, 3-wire, and
symmetrically arranged PE conductor.

Cable shields

● Use shielded cables with finely stranded braided shields. Foil shields are not suitable
since they are much less effective.

● Connect shields to the grounded housings at both ends with excellent electrical
conductivity and a large contact area.

● Bond the cable shields to the plug connectors of the inverter.

● Don't interrupt cable shields by intermediate terminals.

● In the case of both, the power cables and the signal and data cables, the cable shields

should be connected by means of suitable EMC shield clips or via electrically conductive
PG glands. These must connect the shields to the shield bonding options for cables and
the unit housing respectively with excellent electrical conductivity and a large contact
area.

● Use only metallic or metallized connector housings for shielded data cables (e. g.
PROFIBUS cables).

Installation

3.6 Connections and cables

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
Getting Started, 04/12014, FW V4.7, A5E34262374B AA

25

NOTICE

Material damage from inappropriate supply system Vt > 1%

Operating the converter on an inappropriate supply system can cause damage to the
converter and other loads.

• Only operate the converter on supply systems with V

t

≤ 1%.

3.6

Connections and cables

DANGER

Electrical shock by touching the pins in the motor terminal box

The temperature sensor and motor holding brake connections are at DC link negative
potential. Touching the pins in the motor terminal box can lead to death due electrical
shock.

• Keep the motor terminal box closed whenever the mains is applied to the converter.

• Insulate the cables that are not used.

• Use appropriate insulation on the cables.

NOTICE

Damage of the converter by disconnecting the motor during operation

The disconnection of the motor cable by a switch or contactor during operation may
damage the converter.

• Disconnect converter and motor during operation only if it is necessary in terms of
personal security or machine protection.

Connectors

"Switched" and" unswitched" 24 V power supply

The unswitched 24 V power supply (1L+) is required for the device to function.

The switched 24 V (2L+) supplies the two digital outputs. Switching brings all of the actuators
connected to the digital outputs into the no-voltage state.

If you don't need the switching of 2L+ power supply, then both the switched as well as the
non-switched 24 V may come from the same supply.

Installation

3.6 Connections and cables

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

26 Getting Started, 04/12014, FW V4.7, A5E34262374B AA

Figure 3-5 CU240D-2 PROFIBUS connectors

Installation

3.6 Connections and cables

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
Getting Started, 04/12014, FW V4.7, A5E34262374B AA

27

Figure 3-6 CU240D-2 PROFINET connectors

Installation

3.6 Connections and cables

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

28 Getting Started, 04/12014, FW V4.7, A5E34262374B AA

Figure 3-7 CU240D-2 PROFINET Push-Pull connectors

Installation

3.6 Connections and cables

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
Getting Started, 04/12014, FW V4.7, A5E34262374B AA

29

Figure 3-8 CU240D-2 PROFINET FO connectors

Installation

3.6 Connections and cables

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

30 Getting Started, 04/12014, FW V4.7, A5E34262374B AA

Figure 3-9 CU250D-2 PROFIBUS connectors

Installation

3.6 Connections and cables

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
Getting Started, 04/12014, FW V4.7, A5E34262374B AA

31

Figure 3-10 CU250D-2 PROFINET connectors

Installation

3.6 Connections and cables

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

32 Getting Started, 04/12014, FW V4.7, A5E34262374B AA

Figure 3-11 CU250D-2 PROFINET Push-Pull connectors

Installation

3.6 Connections and cables

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
Getting Started, 04/12014, FW V4.7, A5E34262374B AA

33

Figure 3-12 G120D CU250D-2 PROFINET FO connectors

Installation

3.6 Connections and cables

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

34 Getting Started, 04/12014, FW V4.7, A5E34262374B AA

Figure 3-13 PM250D connectors

Cable, connectors and tools specifications

The detailed specifications for the cables, connectors and tools required to manufacture the
necessary cables for the SINAMICS G120D are listed in the following tables. The
connections that are detailed in this section relate to the physical connections that exist on
the Inverter. Information for the preparation and construction of the individual connectors
have separate detailed instructions delivered with the ordered parts, direct from the
manufacturers. Use 75° C copper wire only.

Note
NFPA compatibility

These devices are intended only for installation on industrial machines in accordance with
the "Electrical Standard for Industrial Machinery" (NFPA79). Due to the nature of these
devices

they may not be suitable for installation accordance with the "National Electrical

Code" (NFPA70).

Table 3- 3 Tools

Order number

Crimp tool (Q8/0 and Q4/2)

3RK1902-0AH00

Removal tool (Q8/0) 3RK1902-0AJ00

Removal tool (Q4/2)

Harting part number 0999-000-0305

No special tools are required for the Control Unit connectors

Installation

3.6 Connections and cables

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
Getting Started, 04/12014, FW V4.7, A5E34262374B AA

35

Table 3- 4 Control unit connectors

Connector

Order number

Straight connector

Right-angle connector

24 V DC power supply In (7/8" )

6GK1905-0FB00

3RK1902-3DA00

24 V DC power supply Out (7/8" )

6GK1905-0FA00

3RK1902-3BA00

PROFIBUS In (M12 )

6GK1905-0EB00

3RK1902-1DA00

PROFIBUS Out (M12 )

6GK1905-0EA00

3RK1902-1BA00

PROFINET Port 1 and Port 2 (M12)

6GK1901-0DB20-6AA0

3RK1902-2DA00

Encoder (M12 ) Via KnorrTec: Knorrtec

(http://www.knorrtec.de/index.php/en/company-

profile/siemens-solution-partner)

Digital input and output, analog input (M12 )

3RK1902-4BA00-5AA0

3RK1902-4DA00-5AA0

Table 3- 5 Push-Pull variant PROFINET and 24 V DC connectors

Connector

Order number

24 V DC power supply

6GK1907-0AB10-6AA0

RJ45 PROFINET

6GK1901-1BB10-6AA0

Table 3- 6 Fibre optic connectors

Connector

Order number

IE SC RJ POF PLUG PRO

6GK1900-0MB00-6AA0

IE SC RJ PCF PLUG PRO

6GK1900-0NB00-6AA0

Table 3- 7 Mains connector

Power rating

cable size

Order number

0.75 kW … 1.50 kW

2.5 mm2 (14 AWG)

3RK1911-2BE50

3.00 kW … 4.00 kW

4 mm2 (12 or 10 AWG)

3RK1911-2BE10

5.50 kW … 7.50 kW

6 mm2 (10 AWG)

3RK1911-2BE30

Order motor connector including temperature sensor and motor holding brake via solution
partner: Solution partner
(https://www.automation.siemens.com/solutionpartner/partnerfinder/Partner-

Finder.aspx?lang=en)

Installation

3.6 Connections and cables

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

36 Getting Started, 04/12014, FW V4.7, A5E34262374B AA

Cable lengths

Table 3- 8 Maximum cable lengths

Cable

Screening

Max. length

Motor 1)

Screened

15 m (49 ft)

Unscreened

30 m (98 ft)

Temperature sensor 1)

Screened

15 m (49 ft)

Unscreened

30 m (98 ft)

Motor holding brake 1)

Screened

15 m (49 ft)

Unscreened

30 m (98 ft)

Digital inputs

Screened

30 m (98 ft)

Digital outputs

Screened

30 m (98 ft)

Analog input

Screened

30 m (98 ft)

Encoder

Screened

30 m (98 ft)

1)

The motor, temperature sensor and motor holding brake are connected through a hybrid cable to

the inverter using a Harting connector.

Installation

3.6 Connections and cables

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
Getting Started, 04/12014, FW V4.7, A5E34262374B AA

37

Factory settings of the inputs and outputs of the control unit CU240D-2

In the factory settings, the fieldbus interface of the inverter is not active.

Figure 3-14 Factory settings of the control units CU240D-2

Installation

3.6 Connections and cables

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

38 Getting Started, 04/12014, FW V4.7, A5E34262374B AA

Factory settings of the inputs and outputs of the CU250D-2 control unit

In the factory settings, the fieldbus interface of the inverter is not active.

Figure 3-15 Factory settings of the CU250D-2 control units

Changing the function of terminals

The function of every color-coded terminal can be set.

In order that you do not have to successively change terminal for terminal, several terminals
can be jointly set using default settings.

The factory setting of the terminals described above corresponds to the default setting 7
(switchover between fieldbus and a jog using DI 3).

See also: Default settings of inputs and outputs (Page 39).

Installation

3.7 Default settings of inputs and outputs

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
Getting Started, 04/12014, FW V4.7, A5E34262374B AA

39

3.7

Default settings of inputs and outputs

Default settings of inputs and outputs (CU240D-2)

Default setting 1: Two fixed speeds

Default setting 2: Two fixed speeds

with safety function

Default setting 3: Four fixed speeds

Fieldbus interface is not active.

DI 4 and DI 5 = high: The inverter adds
both fixed speeds.

Fieldbus interface is not active.

Fieldbus interface is not active.

Multiple DIs = high: The inverter adds

the corresponding fixed speeds.

Default setting 4: PROFIBUS or

PROFINET

Default setting 5: PROFIBUS or

PROFINET with safety function

Default setting 6: PROFIBUS or

PROFINET with two safety functions

PROFIdrive telegram 352

PROFIdrive telegram 352

PROFIdrive telegram 1
Only with Control Units

CU240D-2 DP-F and CU240D-2 PN-F.

Default setting 7: Switch over between fieldbus and jogging using DI 3

Factory setting

Default setting 8: Motorized

potentiometer (MOP) with safety

function

PROFIdrive telegram 1

Fieldbus interface is not active.

Fieldbus interface is not active.

Installation

3.7 Default settings of inputs and outputs

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

40 Getting Started, 04/12014, FW V4.7, A5E34262374B AA

Default setting 9: Motorized

potentiometer (MOP)

Default setting 12: Two-wire control

with method 1

Default setting 13: Setpoint via analog

input with safety function

Fieldbus interface is not active.

Fieldbus interface is not active.

Fieldbus interface is not active.

Default setting 14: Switch over between fieldbus and motorized potentiometer

(MOP) using DI 3

Default setting 24: Communication via
fieldbus; transfer of all DIs and DOs to

fieldbus

PROFIdrive telegram 20

Fieldbus interface is not active.

PROFIdrive telegram 352 + PZD7

Default setting 25: Communication via fieldbus with safety

function; transfer of the DI 0 to DI 3 and all DOs to fieldbus

PROFIdrive telegram 352 + PZD7

Default settings of inputs and outputs (CU250D-2)

Default setting 26: Basic positioner via inputs and outputs;

factory settings

Default setting 27: Basic positioner via fieldbus

The fieldbus interface is not active.

PROFIdrive telegram 111

Installation

3.8 Settings PROFIBUS DP address with DIP switches

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
Getting Started, 04/12014, FW V4.7, A5E34262374B AA

41

3.8

Settings PROFIBUS DP address with DIP switches

Setting the PROFIBUS DP address

Prior to using the PROFIBUS DP interface, the address of the node (Inverter) must be set
using the seven PROFIBUS DP address DIP switches on the Control Unit.

The PROFIBUS DP address can be set between 1 and 126.

Note

The address is taken from P0918 if all PROFIBUS

DP address DIP switches are in the OFF

position, otherwise the DIP switch setting is valid.

NOTICE

External 24 V power supply must be disconnected

The external 24 V power supply must be switched off before the DIP switch settings are
changed. DIP switch setting changes do not take effect until the Control Unit has been
powered-up again.

Setting the PROFIBUS DP address via DIP switches

The PROFIBUS DP address can be set via DIP switch, as shown in the table below.

Table 3- 9 Example address for the PROFIBUS DP interface

DIP switch

1 2 3 4 5 6 7

Add to address 1 2 4 8 16 32 64
Example 1: Address = 3 = 1 + 2

Example 2: Address = 88 = 8 + 16 + 64

Installation

3.9 Connecting the PROFINET interface

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

42 Getting Started, 04/12014, FW V4.7, A5E34262374B AA

3.9

Connecting the PROFINET interface

Industrial Ethernet Cables and cable length

Listed in the table below are the recommended Ethernet cables.

Table 3- 10 Recommended PROFINET cables

Max. Cable Length

Order Number

Industrial Ethernet FC TP Standard Cable GP 2 x 2

100 m (328 ft)

6XV1840-2AH10

Industrial Ethernet FC TP Flexible Cable GP 2 x 2

85 m (278 ft)

6XV1870–2B

Industrial Ethernet FC Trailing Cable GP 2 x 2

85 m (278 ft)

6XV1870–2D

Industrial Ethernet FC Trailing Cable 2 x 2

85 m (278 ft)

6XV1840–3AH10

Industrial Ethernet FC Marine Cable 2 x 2

85 m (278 ft)

6XV1840–4AH10

Cable screening

The screen of the PROFINET cable must be connected with the protective earth. The solid
copper core must not be scored when the insulation is removed from the core ends.

3.10

Grounding converter and motor

Grounding the converter

● Ground the converter via the PE connection in the mains supply connector.

● Ground the connectors as shown in the diagram below.

Figure 3-16 Grounding the line supply and motor connectors

Installation

3.10 Grounding converter and motor

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
Getting Started, 04/12014, FW V4.7, A5E34262374B AA

43

•

Connect the PE terminal on the left-hand side

of the converter to the metal frame it is
mounted on.

•

Recommended cable cross section: 10 mm²

•

Use a short wire connection preferably.

•

Clean the connection to the steel construction

from paint or dirt.

•

Use a ring clamp to ensure a good physical

connection which is resistant to accidental
disconnection.

Grounding the motor

● Ground the motor via the PE connection in the motor connector.

● Ground the connector as shown in the diagram above (grounding the converter).

Although the line and motor connectors are of a different type, the principle of grounding
them is the same.

● If possible, ground the motor housing.

EMC cable glands

Where cable glands are used within the installation of the system, it is recommended that
EMC glands are used.

The cable gland provides protection to the IP68 standard when fitted correctly.

Figure 3-17 Example of a Blueglobe EMC cable gland

Table 3- 11 Brass-nickel plated EMC cable gland with metric thread as per EN50262.

Connection thread/length

Clamping range
without inlet
max/min [mm]

Clamping
range max/min
[mm]

Spanner
width SW *
E

Order No.

A

D [mm]

C [mm]

M16 x 1.5 6.0 29 11 … 7 9 … 7 20 x 22.2 bg216mstri

M20 x 1.5

6.5

29

14 … 9

12 … 7

24 x 26.5

bg220mstri

M25 x 1.5 7.5 29 20 … 13 16… 10 30 x 33 bg255mstri

M32 x 1.5

8.0

32

25 … 20

20 … 13

36 x 39.5

bg232mstri

Installation

3.11 Connections and interference suppression

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

44 Getting Started, 04/12014, FW V4.7, A5E34262374B AA

3.11

Connections and interference suppression

All connections should be made so that they are permanent. Screwed connections on
painted or anodized metal components must be made either by means of special contact
washers, which penetrate the isolating surface and establish a metallically conductive
contact, or by removing the isolating surface on the contact points.

Contactor coils, relays, solenoid valves, and motor holding brakes must have interference
suppressors to reduce high-frequency radiation when the contacts are opened (RC elements
or varistors for AC currentoperated coils, and freewheeling diodes for DC current-operated
coils). The interference suppressors must be connected directly on each coil.

3.12

Equipotential bonding

Grounding and high-frequency equipotential bonding measures

Equipotential bonding within the drive system has to be established by connecting all
electrical and mechanical drive components (transformer, motor and driven machine) to the
grounding system. These connections are established by means of standard heavy-power
PE cables, which do not need to have any special high-frequency properties.

In addition to these connections, the inverter (as the source of the high-frequency
interference) and the motor must be interconnected with respect to the high-frequency point
of view:

1. Use a shielded motor cable.

2. Connect the cable shield both to the motor connector on the inverter and to the motor
terminal box.

3. Use a short grounding connection from the PE terminal on the inverter to the metal frame.

The following figure illustrates all grounding and high-frequency equipotential bonding
measures using an example.

Installation

3.12 Equipotential bonding

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
Getting Started, 04/12014, FW V4.7, A5E34262374B AA

45

①

Transformer

②

Second level distribution with PE equipotential bonding

③

Metal frame

④

Short connection from the PE terminal to the metal frame.

⑤

Electrical connection of motor cable shield and connector body.

⑥

Electrical connection of motor cable

shield and motor terminal box via electrically conductive PG

gland.

⑦

Driven machine

⑧

Conventional grounding system.

• Standard, heavy-power PE conductors without special high-frequency properties.

• Ensures low frequency equipotential bonding as well as protection against injury.

⑨

Foundation ground

Figure 3-18 Grounding and high-frequency equipotential bonding measures in the drive system and

in the plant

For general rules for EMC compliant installation see also:
http://support.automation.siemens.com/WW/view/de/60612658
(http://support.automation.siemens.com/WW/view/en/60612658)

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
Getting Started, 04/12014, FW V4.7, A5E34262374B AA

47

4

4.1

Default settings for the SINAMICS G120D

Factory default settings

The inverter system is shipped from the factory as a Control Unit and a Power Module.
Without any parameterization or after a factory reset, the inverter can be operated without
additional parameterization if the inverter default settings (which depend on the inverter type
and size) match the following data of a 4-pole motor:

Default line supply frequency

50 Hz

Rated motor voltage

P0304

Rated motor current

P0305

Rated motor power

P0307

Rated motor frequency

P0310

Rated motor speed

P0311

(A Siemens standard motor is recommended.)

Further, the following conditions must be fulfilled:

Control (ON/OFF command) using digital inputs

See pre-assigned inputs below.

Asyncronous motor

P0300 = 1

Self-cooled motor

P0335 = 0

Motor overload factor

P0640 = 150 %

Min. frequency

P1080 = 0 Hz

Max. frequency

P1082 = 50 Hz

Ramp-up time

P1120 = 10 s

Ramp-down time

P1121 = 10 s

Linear V/f characteristic P1300 = 0

The Control Unit is intended to be control and operate the inverter utilizing the PROFIBUS or
PROFINET interface. The PROFIBUS or PROFINET interface may be used to further
configure and control the inverter as required.

Commissioning

4.2 Commissioning with the IOP

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

48 Getting Started, 04/12014, FW V4.7, A5E34262374B AA

4.2

Commissioning with the IOP

Commission the Inverter

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

The IOP is connected to the Inverter using an Optical RS232 cable. It will automatically
recognise the specific Control Unit to which it is connected, and displays only the parameters
and funtionality of the connected Control Unit.

What do you need?

The IOP Handheld Kit is a completed package that contains the necessary items to
commission and configure the Inverter utilizing the Optical Interface. The cable that is
delivered with the IOP Handheld kit is not compatible with the Optical Interface on the
G120D Inverters; the order details of the necessary cable is given below.

● The IOP Handheld Kit - order number: 6SL3255-0AA00-4HA0.

● Optical Cable - order number: 3RK1922-2BP00

Figure 4-1 CU240D-2 and CU250D-2 Optical Interfaces

Commissioning

4.2 Commissioning with the IOP

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
Getting Started, 04/12014, FW V4.7, A5E34262374B AA

49

Basic commissioning wizard

The Basic Commissioning wizard detailed below is for Control Units with version 4.4
software or higher.

Procedure

For performing the basic commissioning of the converter with the IOP operator panel,
proceed the following steps:

1. Select "Basic Commissioning..." from the Wizards
menu.

2. Select "Yes" or "No" to a factory reset.

The factory reset is performed prior to saving all t

he

parameter changes that have been made during the
basic commissioning process.

3. Select the Control Mode for the attached motor.

4. Select the correct Motor Data for your Inverter and
attached motor.

This data is used to calulate the correct speed and
displayed values for the application.

5. Select the correct frequency for your Inverter and
attached motor.

The use of the 87 Hz characteristic allows the motor to
operate at 1.73 times of its normal speed.

Commissioning

4.2 Commissioning with the IOP

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

50 Getting Started, 04/12014, FW V4.7, A5E34262374B AA

6. At this stage the wizard will begin to ask for the data
relating specifically to the attached motor. The data is
obtained from the motor rating plate.

7. The Motor Data screen indicates the frequency
characteristic of the attached motor.

8. Inpu

t the correct Motor Voltage from the motor rating

plate.

9. Input the correct Motor Current from the motor rating
plate.

10. Input the correct Power Rating from the motor rating
plate.

11. Input the correct Motor Speed from the

motor rating

plate.
This value is given in RPM.

Commissioning

4.2 Commissioning with the IOP

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
Getting Started, 04/12014, FW V4.7, A5E34262374B AA

51

12. Select to run or disable Motor Data Identification
function.

This function, if active, will not start until

the first run

command is given to the Inverter.

13. Select either zero pulse on no zero pulse for the
attached encoder.

If no encoder is fitted to the motor, the

option will not be

displayed.

14. Enter the correct pulses per revolution for the encoder.
This information is normally printed on the casing of the

encoder.

15. Select the macro that is suitable for your application.
Once selected all inputs, outputs, command sources
and setpoints will be automatically configured by th

e

software.
For further information see the section that details the

precise settings for each macro. Please see installation
section of this manual.

16. Set the

Minimum Speed at which the attached motor

should run.

17. Set the Ramp Up time in seconds.
This is the time the Inverter/motor system will take from

being given

the run command, to reaching the selected

motor speed.

Commissioning

4.2 Commissioning with the IOP

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

52 Getting Started, 04/12014, FW V4.7, A5E34262374B AA

18. Set the Ramp Down time in seconds.
This is the time the Inverter/motor system will take from

being gi

ven the OFF1 command, for the motor to reach

a standstill.

19. A summary of all the settings is display.
If the settings are correct, select Continue.

20. The final screen gives two options:

•

Save settings

•

Cancel Wizard

If save is selected, a factory reset will be performed then
the settings are saved to the Inverter memo

ry. The

location of safe data is assigned using the "Parameter
saving mode" function in "Parameter settings" in
"Menu".

The basic commissioning of your converter is finished.

Commissioning

4.3 Commissioning the application

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
Getting Started, 04/12014, FW V4.7, A5E34262374B AA

53

4.3

Commissioning the application

Commissioning the applications

The Intelligent Operator Panel (IOP) allows the commissioning of a variety of applications
utilizing a step-by-step wizard that presents the user with the questions relevant to the
application being commissioned. When used in conjunction with the various wiring diagrams
contained within the IOP Operating Instructions, the application can be quickly and easily
commissioned.

Figure 4-2 Example of IOP Wizards and Inverter wiring diagrams

Commissioning

4.4 Reset Parameters to Factory Settings

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

54 Getting Started, 04/12014, FW V4.7, A5E34262374B AA

4.4

Reset Parameters to Factory Settings

Overview

With a factory reset via P0970 the initial state of the all the inverter parameters can be re­established.

The factory setting values are designated as "Factory setting" in the Parameter Manual.

For further information, refer to the section "Factory Settings of the Control Unit" in this
manual.

Note

When resetting the paramete

rs 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.

WARNING

Parameter reset in case of CUs with fail-safe functions

Parameters that don't relate to fail-safe functions are reset with P0970 = 1.

To reset parameters that relate to fail-safe functions an additional parameter reset with
P0970 = 5 must be performed. This parameter reset is password protected.

In case of a parameter reset with P0970 = 5 an acceptance test necessary.

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
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55

5

5.1

List of alarms and faults

Axxxxx Alarm

Fyyyyy: Fault

Table 5- 1 The most important alarms and faults of the safety functions

Number

Cause

Remedy

F01600

STOP A Triggered

STO Select and then deselect again.

F01650 Acceptance test required Carry out acceptance test and create test certificate.

Switch the Control Unit off and then on again.

F01659 Write task for parameter rejected Cause: The converter should be reset to the factory setting. The resetting of

the safety functions is, however, not allowed, because the safety functions
are currently enabled.

Remedy with operator panel:

p0010 = 30

Parameter reset

p9761 = …

Enter password for the safety functions.

p0970 = 5 Reset Start Safety Parameter.

The converter sets p0970 = 5 if it has reset the parameters.

Then reset the converter to the factory setting again.

A01666 Static 1 signal atF-DI for safe

acknowledgment

F-DI to a logical 0 signal.

A01698 Commissioning mode active for

safety functions

This message is withdrawn after the Safety commissioning has ended.

A01699 Shutdown path test required After the next time that the "STO" function is deselected, the message is

withdrawn and the monitoring time is reset.

F30600

STOP A Triggered

STO Select and then deselect again.

Table 5- 2 The most important alarms and faults

Number

Cause

Remedy

F01018 Power-up aborted more than

once

1. Switch off the converter power supply and switch it on again.

2. After this fault, the converter powers up with the factory settings.

3. Recommission the converter.

A01028 Configuration error Explanation: Parameterization on the memory card has been created with a

different type of module (order number, MLFB)

Check the module parameters and recommission if necessary.

F01033 Unit switchover: Reference

parameter value invalid

Set the value of the reference parameter to a value other than 0.0 (p0304,

p0305, p0310, p0596, p2000, p2001, p2002, p2003, r2004).

Troubleshooting

5.1 List of alarms and faults

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

56 Getting Started, 04/12014, FW V4.7, A5E34262374B AA

Number

Cause

Remedy

F01034 Unit switchover: Calculation of

the parameter values after
reference value change

unsuccessful

Select the value of the reference parameter so that the parameters involved
can be calculated in the per unit notation (p0304, p0305, p0310, p0596,
p2000, p2001, p2002, p2003, r2004).

F01122 Frequency at the probe input too

high

Reduce the frequency of the pulses at the probe input.

A01590 Motor maintenance interval

lapsed

Carry out the maintenance.

A01900 PROFIBUS: Configuration

telegram faulty

Explanation: A PROFIBUS master is attempting to establish a connection
with a faulty configuration telegram.

Check the bus configuration on the master and slave side.

A01910
F01910

Fieldbus SS setpoint timeout The alarm is generated when p2040 ≠ 0 ms and one of the following causes

is present:

• The bus connection is interrupted

• The MODBUS master is switched off

• Communications error (CRC, parity bit, logical error)

An excessively low value for the fieldbus monitoring time (p2040)

A01920 PROFIBUS: Cyclic connection

interrupt

Explanation: The cyclic connection to PROFIBUS master is interrupted.
Establish the PROFIBUS connection and activate the PROFIBUS master

with cyclic operation.

F03505 Analog input, wire break Check the connection to the signal source for interrupts.

Check the level of the signal supplied.

The input current measured by the analog input can be read out in r0752.

A03520

Temperature sensor fault

Check that the sensor is connected correctly.

A05000
A05001
A05002
A05004

A05006

Power Module overtemperature Check the following:

- Is the ambient temperature within the defined limit values?

- Are the load conditions and duty cycle configured accordingly?

- Has the cooling failed?

F06310 Supply voltage (p0210)

incorrectly parameterized

Check the parameterized supply voltage and if required change (p0210).

Check the line voltage.

F07011 Motor overtemperature Reduce the motor load.

Check ambient temperature.

Check sensor's wiring and connection.

A07012 I2t Motor Module

overtemperature

Check and if necessary reduce the motor load.
Check the motor's ambient temperature.
Check thermal time constant p0611.

Check overtemperature fault threshold p0605.

A07015 Motor temperature sensor alarm Check that the sensor is connected correctly.

Check the parameter assignment (p0601).

F07016 Motor temperature sensor fault Make sure that the sensor is connected correctly.

Check the parameterization (p0601).

F07086

F07088

Unit switchover: Parameter limit

violation

Check the adapted parameter values and if required correct.

Troubleshooting

5.1 List of alarms and faults

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
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57

Number

Cause

Remedy

F07320 Automatic restart aborted Increase the number of restart attempts (p1211). The current number of

start attempts is shown in r1214.
Increase the wait time in p1212 and/or monitoring time in p1213.
Create ON command (p0840).
Increase the monitoring time of the power unit or switch off (p0857).
Reduce the wait time for resetting the fault counter p1213[1] so that fewer

faults are registered in the time interval.

A07321 Automatic restart active Explanation: The automatic restart (AR) is active. During voltage recovery

and/or when remedying the causes of pending faults, the drive is

automatically switched back on.

F07330 Search current measured too

low

Increase search current (P1202), check motor connection.

A07400 V

DC_max

controller active If the controller is not to intervene:

• Increase the ramp-down times.

• Deactivate the V

DC_max

controller (p1240 = 0 for vector control, p1280 = 0

for V/f control).

A07409 V/f control current limiting

controller active

The alarm automatically disappears after one of the following measures:

• Increase the current limit (p0640).

• Reduce load.

• Increase the ramp-up time to the speed setpoint.

F07426 Technology controller actual

value limited

• Adapt the limits to the signal level (p2267, p2268).

• Check the actual value scaling (p2264).

F07801 Motor overcurrent Check current limits (p0640).

U/f control: Check the current limiting controller (p1340 … p1346).
Increase acceleration ramp (p1120) or reduce load.
Check motor and motor cables for short circuit and ground fault.
Check motor for star-delta connection and rating plate parameterization.
Check power unit / motor combination.

Select flying restart function (p1200) if switched to rotating motor.

A07805 Drive: Power unit overload I2t

• Reduce the continuous load.

• Adapt the load cycle.

• Check the assignment of rated currents of the motor and power unit.

F07807 Short circuit detected

• Check the converter connection on the motor side for any phase-phase
short-circuit.

• Rule out that line and motor cables have been interchanged.

A07850 External alarm 1 The signal for "external alarm 1" has been triggered.

Parameter p2112 defines the signal source of the external alarm.

Remedy: Rectify the cause of this alarm.

F07860

External fault 1

Remove the external causes for this fault.

F07900 Motor blocked

• Make sure that the motor can rotate freely.

• Check the torque limit: r1538 for a positive direction of rotation; r1539 for

a negative direction of rotation.

Troubleshooting

5.1 List of alarms and faults

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

58 Getting Started, 04/12014, FW V4.7, A5E34262374B AA

Number

Cause

Remedy

F07901

Motor overspeed

Activate precontrol of the speed limiting controller (p1401 bit 7 = 1).

F07902 Motor stalled Check whether the motor data has been parameterized correctly and

perform motor identification.
Check the current limits (p0640, r0067, r0289). If the current limits are too

low, the drive cannot be magnetized.

Check whether motor cables are disconnected during operation.

A07903 Motor speed deviation Increase p2163 and/or p2166.

Increase the torque, current and power limits.

A07910 Motor overtemperature Check the motor load.

Check the motor's ambient temperature.

Check the KTY84 sensor.

A07920

Torque/speed too low

The torque deviates from the torque/speed envelope curve.

• Check the connection between the motor and the load.

• Adapt the parameterization corresponding to the load.

A07921

Torque/speed too high

A07922 Torque/speed out of tolerance

F07923

Torque/speed too low

• Check the connection between the motor and the load.

• Adapt the parameterization corresponding to the load.

F07924 Torque/speed too high

A07927

DC braking active

Not required

A07980

Rotary measurement activated

Not required

A07981 No enabling for rotary

measurement

Acknowledge pending faults.
Establish missing enables (see r00002, r0046).

A07991 Motor data identification

activated

Switch on the motor and identify the motor data.

F08501 Setpoint timeout

• Check the PROFINET connection.

• Set the controller to RUN mode.

• If the error occurs repeatedly, check the monitoring time set (p2044).

F08502 Monitoring time, sign-of-life

expired

• Check the PROFINET connection.

F08510

Send configuration data not valid

• Check the PROFINET configuration

A08511 Receive configuration data not

valid

A08526 No cyclic connection

• Activate the controller with cyclic operation.

• Check the parameters "Name of Station" and "IP of Station" (r61000,

r61001).

A08565 Consistency error affecting

adjustable parameters

Check the following:

• IP address, subnet mask or default gateway is not correct.

• IP address or station name used twice in the network.

• Station name contains invalid characters.

Troubleshooting

5.1 List of alarms and faults

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
Getting Started, 04/12014, FW V4.7, A5E34262374B AA

59

Number

Cause

Remedy

F08700 Communications error A CAN communications error has occurred. Check the following:

• Bus cable

• Baud rate (p8622)

• Bit timing (p8623)

• Master

Start the CAN controller manually with p8608 = 1 after the cause of the fault

has been resolved!

F13100 Know-how protection: Copy

protection error

The know-how protection and the copy protection for the memory card are
active. An error occurred during checking of the memory card.

• Insert a suitable memory card and switch the converter supply voltage
temporarily off and then on again (POWER ON).

• Deactivate the copy protection (p7765).

F13101 Know-how protection: Copy

protection cannot be activated

Insert a valid memory card.

F30001 Overcurrent Check the following:

• Motor data, if required, carry out commissioning

• Motor's connection method (Υ / Δ)

• U/f operation: Assignment of rated currents of motor and Power Module

• Line quality

• Make sure that the line commutating reactor is connected properly

• Power cable connections

• Power cables for short-circuit or ground fault

• Power cable length

• Line phases

If this doesn't help:

• U/f operation: Increase the acceleration ramp

• Reduce the load

• Replace the power unit

F30002 DC-link voltage overvoltage Increase the ramp-down time (p1121).

Set the rounding times (p1130, p1136).
Activate the DC link voltage controller (p1240, p1280).
Check the line voltage (p0210).

Check the line phases.

F30003

DC-link voltage undervoltage

Check the line voltage (p0210).

F30004 Converter overtemperature Check whether the converter fan is running.

Check whether the ambient temperature is in the permissible range.
Check whether the motor is overloaded.
Reduce the pulse frequency.

F30005 I2t converter overload Check the rated currents of the motor and Power Module.

Reduce current limit p0640.

When operating with U/f characteristic: Reduce p1341.

Troubleshooting

5.1 List of alarms and faults

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

60 Getting Started, 04/12014, FW V4.7, A5E34262374B AA

Number

Cause

Remedy

F30011 Line phase failure Check the converter's input fuses.

Check the motor cables.

F30015 Motor cable phase failure Check the motor cables.

Increase the ramp-up or ramp-down time (p1120).

F30021 Ground fault

• Check the power cable connections.

• Check the motor.

• Check the current transformer.

• Check the cables and contacts of the brake connection (a wire might be

broken).

F30027 Time monitoring for DC link pre-

charging

Check the line voltage.

Check the line voltage setting (p0210).

F30035

Overtemperature, intake air

• Check whether the fan is running.

• Check the fan filter elements.

• Check whether the ambient temperature is in the permissible range.

F30036 Overtemperature, inside area

F30037 Rectifier overtemperature See F30035 and, in addition:

• Check the motor load.

• Check the line phases

A30049

Internal fan defective

Check the internal fan and if required replace.

F30059

Internal fan defective

Check the internal fan and if required replace.

F30074 Communications fault between

Control Unit and Power Module

The 24V voltage supply of the converter (terminals 31 and 32) was
interrupted briefly.

Please check the voltage supply and the wiring.

A30502 DC link overvoltage

• Check the device supply voltage (p0210).

• Check the line reactor dimensioning

A30920

Temperature sensor fault

Check that the sensor is connected correctly.

A50001 PROFINET configuration error A PROFINET controller is attempting to establish a connection with a faulty

configuration telegram. Check to see whether "Shared Device" is activated

(p8929 = 2).

A50010 PROFINET name of station

invalid

Correct name of station (p8920) and activate (p8925 = 2).

A50020 PROFINET: Second controller

missing

"Shared Device" is activated (p8929 = 2). However, only the connection to a
PROFINET controller is present.

For further information, please refer to the List Manual.

Troubleshooting

5.2 Status LED overview

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
Getting Started, 04/12014, FW V4.7, A5E34262374B AA

61

5.2

Status LED overview

LED status indicators

The Control Unit has number of dual-colour LEDs which are designed to indicate the
operational state of the Inverter. The LEDs are used to indicate the status of the following
states:

● General fault conditions

● Communication status

● Input and Output status

● Safety-Integrated status

The location of the various LEDs on the Control Unit are shown in the figure below.

Figure 5-1 Status LED locations

Explanation of status LEDs

An explanation of the various states indicated by the LEDs are given in the tables below.

Troubleshooting

5.2 Status LED overview

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

62 Getting Started, 04/12014, FW V4.7, A5E34262374B AA

Table 5- 3 Description of general status LEDS

RDY

BF

Description of function

GREEN - On

-

Ready for operation (no active fault)

GREEN - flashing slowly

-

Commissioning or reset of factory settings

RED - on

Off

Firmware update in progress

RED - flashing slowly

RED - flashing slowly

Firmware updated is complete - power ON reset required

RED - flashing quickly

-

General fault condition

RED - flashing quickly

RED - On

Fault occurred during firmware update

RED - flashing quickly

RED - flashing quickly

Incompatible firmware or incorrect memory card

Table 5- 4 Description of PROFIBUS communications LED

BF

Description of function

Off

Cyclic data exchange (or PROFIBUS not in use - p2030 = 0)

RED - flashing slowly

Bus fault - configuration fault

RED - flashing quickly Bus fault:

- no data exchange

- baud rate search - cannot detect the correct baud rate

- no connection - the connection between the Inverter and PLC has been lost

Table 5- 5 Description of SAFE LED

SAFE

Description of function

YELLOW - On

One or more safety functions are enabled - but not active

YELLOW - flashing slowly

One or more safety functions are active - no safety function faults have occurred.

YELLOW - flashing quickly The Inverter has detected a safety function fault and initiated a stop response.

Table 5- 6 Description of PROFINET communications LEDS

ACT

LNK

Description of function

On/flashing

On

Link active and data transfer active if flashing

Off Off Link inactive with no data transfer

Table 5- 7 Description of Digital Input and Output LEDs

DI / DO

Description of function

On

Input/Output connected and working

Off Input/Output not connected or has stopped working

Troubleshooting

5.3 Further information

SINAMICS G120D converter with control units CU240D-2 and CU250D-2
Getting Started, 04/12014, FW V4.7, A5E34262374B AA

63

5.3

Further information

Table 5- 8 Technical Support

France

Germany

Italy

Spain

United Kingdom

[phone]

[phone]

[phone]

[phone]

[phone]

Further service contact information: Support contacts (http://support.automation.siemens.com/WW/view/en/16604999)

Table 5- 9 Manuals with further information

Information
level

Manual

Content

Available
languages

Download or order number
+

Getting Started

(this manual)

English,
German,
Italian,
French,
Spanish,
Chinese

Manuals

Manuals can be download using the
following link:

Document download
(http://support.automation.siemens.c

om/WW/view/en/25021636/133300)

SINAMICS Manual Collection (DVD)

The manual collection can be order
using the following order number:

• 6SL3298-0CA00-0MG0

++ Operating instructions -

inverter

Installing, commissioning and
operating the inverter.
Description of inverter
functions.

Technical data.

+++

Function Manual Safety

Integrated

Configuring PROFIsafe.
Installing, commissioning and
operating the integrated fail-

safe functions.

English,
German,
Chinese

+++ Function Manual Field

Busses

Configuring the field busses.

+++ List manual Complete list of parameters,

alarms and faults.
Graphic function block

diagrams.

+++ Operating instructions -

IOP

Description of operator panel

Troubleshooting

5.3 Further information

SINAMICS G120D converter with control units CU240D-2 and CU250D-2

64 Getting Started, 04/12014, FW V4.7, A5E34262374B AA