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Getting Started
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Siemens ZTH, SINAMICS G120, CU250S-2 Getting Started

Converters with CU250S-2 Control Units
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SINAMICS G120 Converters with CU250S-2 Control Units
Safety information
1
Design of the frequency converter
2
Installing
3
Commissioning
4
More information
5
Siemens AG Industry Sector Postfach 48 48 90026 NÜRNBERG GERMANY
A5E32899990B AA
Ⓟ
09/2013 Technical data subject to change
Copyright © Siemens AG 2013. 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.
Converters with CU250S-2 Control Units Getting Started, 10/2013, FW V4.6, A5E32899990B AA
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Table of contents
1 Safety information ................................................................................................................................... 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 Residual risks of power drive systems ......................................................................................... 12
2 Design of the frequency converter ......................................................................................................... 15
2.1 Identifying the converter ............................................................................................................... 15
2.2 Overview of Control Units ............................................................................................................ 16
2.3 Power Module .............................................................................................................................. 16
2.4 Assembling frequency converter components ............................................................................. 18
3 Installing ............................................................................................................................................... 19
3.1 Installing the Power Module ......................................................................................................... 19
3.1.1 Connecting up the Motor and Power Module .............................................................................. 20
3.2 Installing Control Unit ................................................................................................................... 22
3.2.1 Overview of the interfaces ........................................................................................................... 22
3.2.2 Terminal blocks ............................................................................................................................ 24
3.2.3 Finding a suitable setting for the interfaces ................................................................................. 25
3.2.4 Wiring the terminal strip ............................................................................................................... 29
3.3 Installing encoders ....................................................................................................................... 31
3.3.1 Permissible encoders ................................................................................................................... 31
3.3.2 Sensor Module ............................................................................................................................. 32
3.4 Description files for fieldbuses ..................................................................................................... 32
4 Commissioning ..................................................................................................................................... 33
4.1 Tools to commission the converter .............................................................................................. 33
4.2 Commissioning with STARTER ................................................................................................... 34
4.2.1 Generating a STARTER project ................................................................................................... 34
4.2.2 Transfer inverters connected via USB into the project ................................................................ 34
4.2.3 Configuring a drive ....................................................................................................................... 36
4.2.4 Adapting the encoder data ........................................................................................................... 39
4.2.5 Loading the configured data into the drive ................................................................................... 40
4.2.6 Identifying motor data .................................................................................................................. 40
5 More information ................................................................................................................................... 43
5.1 Manuals for your inverter ............................................................................................................. 43
5.2 Product support ............................................................................................................................ 44
Safety information
Converters with CU250S-2 Control Units
6 Getting Started, 10/2013, FW V4.6, A5E32899990B AA
This manual describes how you install a SINAMICS G120 converter with CU250S-2 Control Unit and commission it.
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
The inverter contains open-source software (OSS). The OSS license terms are saved in the inverter.
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. See also the sections:
– Tools to commission the converter (Page 33)
– 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.
Converters with CU250S-2 Control Units Getting Started, 10/2013, FW V4.6, A5E32899990B AA
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1
Use for the intended purpose
The inverter described in this manual is a device for controlling an induction motor or a synchronous motor. The inverter is designed for installation in electrical installations or machines.
It has been approved for industrial and commercial use on industrial networks. Additional measures have to be taken when connected to public grids.
The technical specifications and information about connection conditions are indicated on the rating plate and in the operating instructions.
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 hazardous energy sources, e.g. compressed air, hydraulic systems, water.
4. Isolate or neutralize all hazardous energy sources, e.g. by closing switches, grounding or short-circuiting or closing valves.
5. Secure the energy sources against switching on again.
6. Make sure that the machine is completely locked ... and that you have the right machine.
After you have completed the work, restore the operational readiness in the inverse sequence.
Safety information
1.1 General safety instructions
Converters with CU250S-2 Control Units
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WARNING
Danger to life through a hazardous voltage when connecting an unsuitable power supply
Death or serious injury can result when live parts are touched in the event of a fault.
• 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.
WARNING
Danger to life when live parts are touched on damaged devices
Improper handling of devices can cause damage.
Hazardous voltages can be present at the housing or exposed components on damaged devices.
• 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.
• Connect cable shields and unused conductors of power cables (e.g., brake conductors) at least on one side to 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.
Safety information
1.1 General safety instructions
Converters with CU250S-2 Control Units Getting Started, 10/2013, FW V4.6, A5E32899990B AA
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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 inside and outside the device is prevented.
• Additionally, select the installation site so that an uncontrolled spreading of smoke can
be avoided in the case of a fire.
• Ensure that smoke can escape via designated paths.
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 transmitter power > 1 W closer than approx. 2 m to the components may cause the devices to malfunction and 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 a greater load on the motor insulation through a ground fault in an IT system. A possible result is the failure of the insulation with a risk for personnel through smoke development 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.
Safety information
1.1 General safety instructions
Converters with CU250S-2 Control Units
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WARNING
Danger to life due to fire if overheating occurs because of insufficient ventilation clearances
Inadequate ventilation clearances can cause overheating with a risk for personnel through smoke development and fire. 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. They can be found in the dimension drawings or in the "Product-specific safety instructions" at the start of the respective section.
WARNING
Danger of an accident occuring due to missing or illegible warning labels
Missing or illegible warning labels can result in death or serious injury.
• Check 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.
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.
• Run 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 functions
If you want to use safety functions, you must observe the safety notices in the safety manuals.
Safety information
1.2 Safety instructions for electromagnetic fields (EMF)
Converters with CU250S-2 Control Units Getting Started, 10/2013, FW V4.6, A5E32899990B AA
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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, inverters or motors.
People with pacemakers or implants are at a special risk in the immediate vicinity of these devices/systems.
• Keep a distance of at least 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).
Safety information
1.4 Residual risks of power drive systems
Converters with CU250S-2 Control Units
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1.4
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 defects and/or software errors in the sensors, controllers, actuators, and
connection technology
– Response times of the controller and drive
– Operating and/or ambient conditions outside of the specification
– Condensation / conductive contamination
– Parameterization, programming, cabling, and installation errors
– Use of radio devices / cellular phones in the immediate vicinity of the controller
– 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 malfunctions
– Software errors
– Operating and/or ambient conditions outside of 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 the contact with fire inside and outside the inverter is not possible.
Safety information
1.4 Residual risks of power drive systems
Converters with CU250S-2 Control Units Getting Started, 10/2013, FW V4.6, A5E32899990B AA
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3. Hazardous shock voltages caused by, for example:
– Component malfunctions
– Influence of electrostatic charging
– Induction of voltages in moving motors
– Operating and/or ambient conditions outside of 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 degree 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.
Safety information
1.4 Residual risks of power drive systems
Converters with CU250S-2 Control Units
14 Getting Started, 10/2013, FW V4.6, A5E32899990B AA
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