SINAMICS G120 Control Units CU240S Warnings and Cautions 1 Installation 2 Check List 3 Commissioning 4 Diagnostics A Getting Started FW 3.0: CU240S / CU240S DP / CU240S DP-F FW 3.
Safety Guidelines This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used.
Warnings and Cautions Table of contents 1 Warnings and Cautions ............................................................................................. 4 2 Installation ................................................................................................................ 6 2.1 Installing the Control Unit (all variants) .................................................................. 6 2.2 Terminals ........................................................................................
Warnings and Cautions 1 Warnings and Cautions General WARNING This equipment contains dangerous voltages and controls potentially dangerous rotating mechanical parts. Non-compliance with the Warnings or failure to follow the instructions contained in this manual can result in loss of life, severe personal injury or serious damage to property.
Warnings and Cautions CAUTION Children and the general public must be prevented from accessing or approaching the equipment! This equipment may only be used for the purpose specified by the manufacturer. Unauthorized modifications and the use of spare parts and accessories that are not sold or recommended by the manufacturer of the equipment can cause fires, electric shocks and injuries. NOTICE Keep these instructions within easy reach of the equipment and make them available to all users.
Installation 2 Installation Command and setpoint sources Control Unit CU240S The inverter is controlled and monitored per default via terminals. Control Unit CU240S DP / CU240S DP-F The inverter is controlled and monitored per default via the PROFIBUS DP interface. Control Unit CU240S PN / CU240S PN-F The inverter is controlled and monitored per default via the PROFINET interface. Note The command and setpoint sources can be changed in the commissioning procedure or via Parameters P0700 and P1000. 2.
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Installation Interfaces of the CU240S Control Units. The interfaces are shown in the figure below. Common Interfaces The CU240S Control Units have a number of interfaces such as terminals, general I/O DIP switches or MMC interface and Option Port in common.
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Installation Fitting the Control Unit to the Power Module The Control Unit is snapped onto the Power Module as shown in the figure below. To disconnect the CU push the release button on top of the PM. The process of fitting the Control Unit to the Power Module is the same technique independent from the type of G120 control unit or G120 power module.
Installation 2.2 Terminals Overview of CU240S Terminals Control Unit CU240S / CU240S DP CU240S DP-F CU240S PN CU240S PN-F 9 -3 2 2 6 2 3 2 2 Digital Inputs (DI) Fail-safe digital Inputs (FDI) Digital Outputs (DO) Analog Inputs (AI) Analog Outputs (AO) PTC/KTY84 interface Encoder interface Ext. 24 V Yes 1, TTL or HTL Yes Terminal tightening torque The maximum tightening torque of the control terminals is 0.25 Nm (2.2 lbf.in). The nominal length of cable cross-section is 1.5 mm2.
Installation Note If the CU is externally powered with 24 V DC but the power module is disconnected from the mains supply, the faults F0001 … F0028 are not generated. Cable length for 24 V DC supply and I/O cables The maximum cable length on the 24 V DC supply and I/O cables connected to the CU must not exceed 10 m (32.8 ft).
Installation Connector A standard 9 pin sub-D connector can be used for USS connection via RS485. Standard 9 pin sub D connector PG socket Max. baud rate Outgoing cable unit No 115200 baud 180° Bus termination The RS485 termination can be activated via switches on the housing of the SINAMICS G120. The bus termination switch is illustrated in figure "Control Units CU 240S" in section "Layout and Block Diagram".
Installation 2.4 Connecting the PROFIBUS DP Connecting the Inverter to the PROFIBUS DP network The inverter is to be connected to the PROFIBUS DP network via a sub-D socket on the CU240S DP or CU240S DP-F. The pins of the socket are short-circuit-proof and isolated.
Installation Baud rate Max. cable lengths for one segment 9.6 kbaud … 187.5 kbaud 1000 m (3280 ft)* 500 kbaud 400 m (1312 ft)* 1.5 Mbaud 200 m (656 ft)* 3 Mbaud … 12 Mbaud 100 m (328 ft)* ∗ Repeaters can be installed to increase the length of a segment. Cable installation rules During installation the bus cable must not be twisted, stretched or compressed. Supplementary constraints as regards electromagnetic compatibility must also be observed.
Installation PROFIBUS terminator Each bus segment must have a resistor network at both ends as shown in the figure below.
Installation Removing a bus connector You can remove the bus connector with looped-through bus cable from the PROFIBUS DP interface at any time without interrupting the data exchange on the bus. Only the final node must be terminated. R on off A1 B1 A2 B2 2.5 R on off A1 B1 A2 B2 Connecting a CU240S PN / CU240S PN-F via PROFINET Socket The Control Units CU240S PN and CU240S PN-F are equipped with a two port ethernet switch, carried out as RJ45 female sockets.
Installation Pin Designation Meaning Core color 1 2 3 4 5 6 TX+ TX RX+ RX- Transmission data + Transmission data Receiver data + Yellow Orange White Receiver data - blue Connector Order Number 6GK1901-1BB10-2Ax0 Label Max. baud rate Outgoing cable unit Degree of protection Operating temperature Industrial Ethernet FC RJ45 Plug 180 100 Mbit/s; Cat5e 180° IP20 -20 °C … +70 °C Industrial Ethernet Cables and cable length The CU240S PN provides all Ethernet-cables.
Installation Cable installation rules Screening The screen of the PROFINET cable must be connected with the protective earth, using a screen clamp on the PROFINET cable which must make 360° contact earth. The solid copper core must not be scored when the insulation is removed from the core ends.
Check List Note Pay attention to the following restrictions: • A ring-type topology is not permissible. • SINAMICS does not support routing from PROFIBUS to PROFINET and vice versa.
4 Commissioning Description When shipped from the factory the G120 inverter (control unit and power module) must not be operated before a commissioning of the inverter has been performed.
Commissioning What do you need? The following items are required to commission the Inverter with STARTER: ● STARTER software is installed on your PC ● The inverter is connected to the PC via the PC connection cable - order number: 6SL3255-0AA00-2AA0 Note For commissioning the inverter you can use the STARTER software, delivered with the PC Connection Kit or download the latest STARTER software version from the internet under the following link: http://support.automation.siemens.
Commissioning 4.1 Create a STARTER Project Commissioning procedure ● Switch the supply voltage to the inverter ● Start Commissioning Software STARTER and use the project wizard as described in the following steps ● In the next screen (not shown here), enter a significant project name (in the example "Basic Commissioning)" and if you want a comment then press the "Continue" button. The following dialog box will appear. Press "Change and test ..." button to set the PG/PC interface.
Commissioning box "PG/PC interface", press the "properties" button. – If not press the "Select ..." button to install the "PC COM-Port (USS)" interface as shown in the dialog box "Install/Remove Interfaces". If it is installed close the dialog box and press now the "properties" button.
Commissioning ● Setting properties of the COM port Via this dialog box, you set the com interface (COM1, COM2, COM3) and the Baud rate (default 38400). To find out the right values, select e.g. COM1 and press the "Read" button. If "???" is displayed in the Baud rate test area select another com interface. In case of the right interface a value will be displayed, that must be chosen via the "Baud rate" select box. In addition, select "Automatic mode" under the tab "RS485".
Commissioning 4.2 Going Online with the Inverter Description With the above described procedure the project is created and the following STARTER dialog appears, but there is still no online connection established so far. . The following dialog box shows in the left To go online with this inverter press column the online and in the right column the offline saved data. To load the online data to your PC, press "Load HW configuration to PG" and end the dialog with close.
Commissioning 4.3 Start Commissioning Description With closing the last dialog from the "Going Online Section" the "Offline mode" at the very down in the dialog box changes to "Online mode" and in case of first commissioning the message F00395 appears.
Commissioning It states that no commissioning has been performed so far with the inverter. To confirm, select the message and press the "Acknowledge" button. WARNING Message F0395 With acknowledging F00395 you overtake the responsibility to perform a commissioning. Commissioning of inverters with fail-safe functions is not described in this manual.
Commissioning Note Information about the symbols used in STARTER can be found in the online help. Press and then click at the requested symbol. E.g. If you have confirmed F0395, open the drive unit ( ), double-click the drive object ( ) and start the wizard for basic commissioning from the following STARTER dialog.
Commissioning Now you can select the basic commissioning settings for your application via pull-down menus. With pressing "Continue" button you jump to the next item.
Commissioning For calculation of the motor data we recommend to select "Restore factory setting and calculate motor data only" as shown in the dialog box.
Commissioning The basic commissioning wizard ends with the following dialog: To complete basic commissioning, the motor data identification, selected during basic commissioning must be performed via switching on the inverter. This can be done via the chosen command source (e.g. terminals, BOP or communication) or via STARTER as shown in the dialog box below.
Commissioning will be displayed. Once Motor data identification has finished, the alarm disappears and the inverter switches OFF ( becomes colored again).
Commissioning To set the command source back press "Give up control priority!" in the following dialog box. Take care of the warnings displayed. Now the basic commissioning is finished. To save the settings in the EEPROM of your inverter, select the SINAMICS project and press the "Copy RAM to ROM" button .
Commissioning Commissioning the application Now you can commission your application via the dialog boxes of the drive navigator or via the functions in the navigation area. If you have performed the application commissioning, disconnect your PC from the inverter via . In the following dialog select "save changes to drive unit (EEPROM), to current offline project and to PG/PC hard disk".
Commissioning This selection performs in addition to disconnecting the PC form the inverter the following steps: : saves project on your PC : saves drive settings on your PC (Upload) : Saves data from inverter RAM to EEPROM 4.4 Factory reset Description With a factory reset a defined initial state of all of the inverter parameters can be reestablished. To perform a factory reset with STARTER, the inverter must be in the online mode.
A Diagnostics Fault s and alarms A fault indicates a severe unfavorable state of the inverter. If a fault occurs, the inverter is powered down with an OFF2 command and the LED "SF" on the Control Unit is active. Faults must be acknowledged before the inverter can be switched on again. An alarm states that the inverter is ● in a critical state that can lead to a fault (e.g. A0501 current limit) ● in an extraordinary temporarily state e.g.
Diagnostics Fault Cause Remedy F00072 F00090 USS setpoint fault Encoder feedback loss Check USS master Check that the encoder is installed and commissioned correctly. F0395 The fault occurs after a CU/PM swap or startup clone. It can also be cause by a faulty read from the EEPROM. Alarm Meaning A0700 Correct the PROFIBUS configuration A0702 Check connector, cable and PROFIBUS master. Check setpoints from the PROFIBUS master. Switch SIMATIC CPU to "RUN".
Diagnostics Status display via LEDs The SINAMICS G120 inverters provide multiple functions and operating states which are indicated via LEDs. The LED for fail-safe inverters are not described in this manual. Colors The colors of the LEDs are self explanatory.
Diagnostics LED description ● System-Fault LED (SF) The system-fault LED indicates a general system error either software or hardware related. ● Ready LED (RDY) The ready LED indicates whether the inverter is ready to run. This LED does not indicate whether the drive is running or not. ● Bus-Failure LED (BF) The Bus-failure LED indicates if any bus failure occurred. A bus failure can be characterized as corrupted communication (e.g. a frame of the PROFIBUS) due to signaling problems on the bus itself.
